Success Stories and Solved Problems

Gideon Analytical Laboratories received several T491D475K050AT Kemet tantalum capacitors for electronic failure analysis. A capacitor is a passive two-terminal electronic component that stores electrical energy in an electric field. While some capacitance exists between any two electrical conductors in proximity in a circuit, a capacitor is a component designed to add capacitance to a circuit. The Kemet T491D475K050AT has a capacitance of 4.7 uF, a voltage rating of 50 VDC, and a tolerance of 10%, measures 7.3mm x 4.3mm x 3.1mm (LWH), has a minimum operating temperature of -55 degrees Celsius and a maximum operating temperature of 125 degrees Celsius. One of these capacitors had already been tested and found to be a dead short. The other capacitors were to be used to determine whether acid had affected the forming voltage oxide.

Gideon Analytical Laboratories received two 1N645 silicon rectifier diodes for failure analysis. One was bad and the other was a quality diode to be used for comparison. A rectifier is an electrical device that converts alternating current(AC), which periodically reverses direction, to direct current(DC), which flows in only one direction. Rectifiers are used inside the power supplies of virtually all electronic equipment. AC/DC power supplies may be broadly divided into linear power supplies ands witched-mode power supplies. The 1N645 silicon rectifier diode has 225V 400mA ratings. It can handle a maximum of 5 Amps surge current and at 25 Degrees Celsius has an average maximum rectified current of 0.4 Amps. The goal was to determine why these diodes were failing.

Gideon Analytical Laboratories received several Murata Electronics GCM21BR70J106KE22L Multi-Layered Ceramic Capacitors (MLCCs) for failure analysis. An MLCC consists of a number of individual capacitors stacked together in parallel and contacted via the terminal surfaces. The starting material for all MLCC chips is a mixture of finely ground granules of paraelectric or ferroelectric raw materials, modified by accurately determined additives. The Murata Electronics GCM21BR70J106KE22L has a capacitance of 10 uF, a DC voltage rating of 6.3 VDC, has an XR7 dielectric, and has an SMD/SMT termination style. It has a minimum operating temperature of -55 Celsius and a maximum operating temperature of 125 Celsius. The goal was to determine why these MLCCs were failing, and while we did discover why, that is not the only thing we uncovered.

Gideon Analytical Laboratories received two On Semiconductor SS16 rectifier for failure analysis. The On Semiconductor SS16 Schottky Rectifier features glass-passivated junctions and a high-current capacity. Their applications include low voltage, high-frequency inverters, freewheeling, and polarity protection. Their storage temperature range is between -65 and 150 Degrees Celsius and the operating junction temperature is between -65 and 125 Degrees Celsius. Along with the two failed rectifiers, several good devices were also supplied for comparison. The goal was to determine why the On Semiconductor SS16 Schottky rectifiers were failing.

Gideon Analytical Laboratories received two Sunon Maglev MC35101V2-000U-G99 12V fans which did not operate. Along with the nonoperational fans, two functional fans were also sent to us for comparison. The Sunon Maglev MC35101V2-000U-G99 12V fan is an axial DC fan, with a speed of 7500 RPM and airflow of 6.5 CFM. An axial fan is a type of fan that causes gas to flow through it in an axial direction, parallel to the shaft about which the blades rotate. The flow is axial at entry and exit. The fan is designed to produce a pressure difference, and hence force, to cause a flow through the fan. Our goal was to determine why the Sunon Maglev MC35101V2-000U-G99 12V fans were failing.

Gideon Analytical Laboratories received four Vishay CRCW2512220RJNEG thick film chip resistors to be analyzed. Thick film resistors are the most used resistors in electrical and electronic devices. The resistive material is a special paste with a mixture of a binder, a carrier, and the metal oxides to be deposited. These Vishay CRCW2512220RJNEG resistors thick film chip resistors feature stability at different environmental conditions and 2mm pitch packaging option for 0603 sizes. Typical applications for these chip resistors include automotive, telecommunications, and industrial. Its resistance range is 1 and 10 ohms. All of the Vishay CRCW2512220RJNEG thick film chip resistors tested open. The goal was to try to diagnose these failures.

Gideon Analytical Laboratories received two LUMEX SSL-LX093UWC/Gc LEDs for failure analysis. A LED (Light Emitting Diode), is a semiconductor light source that emits light when current flows through it. LEDs can be used in many different applications. Electrons in the semiconductor recombine with electron holes, releasing energy in the form of photons. Some of the more creative uses include creating an LED virtual sky, LED bionic contact lenses, and LED wallpaper. Both of the LUMEX SSL-LX093UWC/Gc LEDs were intermittent; one was mounted to a PCB and the other was loose. The goal was to determine the cause of these failing LEDs.

Gideon Analytical Laboratories received six pulse transformer. Three were good, three were failures. Transformers can be thought of as an electrical component rather than an electronic component. A transformer basically is very simple static (or stationary) electro-magnetic passive electrical device that works to convert electrical energy from one value to another. The transformer does this by linking together two or more electrical circuits using a common oscillating magnetic circuit which is produced by the transformer itself. A transformer operates on the principle of electromagnetic induction. Faraday’s Law, which states that a time-varying magnetic field can induce a time-varying voltage in a loop of wire, is how transformers work. Usually, this accomplished by wrapping multiple turns of wire around some type of ferromagnetic material. Usually, there are two sets of windings: a primary and a secondary. The primary winding is attached to the generator; the secondary side is attached to the load. For this job, the goal was to determine the cause of the failures and inspect the other unused transformers for possible workmanship, material, or process that may have contributed to the cause of the failures experienced. Gideon Analytical Laboratories conducted electronic failure analysis on the transformers. Several different types of tests were run, as indicated by the table below:

Gideon Analytical Laboratories received a programmable logic device (PLD) P18586P for failure analysis. A programmable logic device is an electronic component used to build reconfigurable digital circuits. Unlike a logic gate, which has a fixed function, a PLD has an undefined function at the time of manufacture. Before the PLD can be used in a circuit it must be programmed. A PLD is a combination of a logic device and a memory device. The memory is used to store the pattern that was given to the chip during programming. Most of the methods for storing data in an integrated circuit have been adapted for use in PLDs. Logic devices provide specific functions, including device-to-device interfacing, data communication, signal processing, data display, timing and control operations, and almost every other function a system must perform. The PLD P18586P supposedly had bad output. The goal was to determine the reason why.

Gideon Analytical Laboratories received two acrylic film capacitors for electronic failure analysis. Six good capacitors were also provided for comparison. A capacitor is a passive two-terminal electrical component that stores potential energy in an electric field. The effect of a capacitor is known as capacitance. While some capacitance exists between any two electrical conductors in proximity in a circuit, a capacitor is a component designed to add capacitance to a circuit. A film capacitor is electrical capacitors with an insulating plastic film as the dielectric, sometimes combined with paper as a carrier of the electrodes. The goal was to determine why the acrylic film capacitors were failing.