A Resistor Primer

What Causes Thick Film Resistor Failure

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Thick movie resistor failure is hardly ever caused by a failing of the resisting aspect yet is generally because of outside environmental elements such as mechanical as well as electric tensions and also taking care of problems. Failures can be either classed as a deterioration of efficiency or full failure (typically as an open as opposed to a short circuit).

Six usual causes of thick film resistor failing are:

Thermal problems
Mechanical stress
Constant overload
Environmental – metal migration


In addition to taking care of harm resulting in substrate cracks and also chips most mechanical damage is dued to either resonance or unsuitable mounting of the tool. Micro breaking of the resistor product caused by resonance or compression/ expansion of the resistor because of inappropriate installing could cause change in the resistance worth, harm to the resistive component or component failing. In all instances the risk of failure is raised by presence of several of the anxieties below.


Although a thick film resistor is typically covered to protect it from dampness and also hostile chemical aspects environmental aspects such as wetness and also contamination still need mindful factor to consider. Both can induce steel migration in between the terminals of the resistor resulting in potential short circuit or an adjustment in resistance worth.


A lot of mechanical failing modes of thick movie resistors are propagated by heat. It is for that reason vital to comprehend the heat dissipation commercial properties of the resistor as well as substratum material. A reduced power resistor dissipates heat using conduction through its element leads or links, while a high power resistor dissipates warmth with radiation.

When existing travel through a resistor it creates warmth and the differential thermal growths of the various product used in the resistor production procedure generates stresses in the resistor. Temperature level Coefficient of Resistance (TCR) is the best recognized parameter used to specify a thick film resistor security, as well as specifies the repellent component’s level of sensitivity to temperature level change. Power Coefficient of Resistance (PCR) measures the resistance adjustment because of self-heating when power is applied and also is especially essential for resistors utilized in power applications.


A continuous over-load of a resistor device degrades the insulation resistance and transforms the resistor criteria over time. Voltage tension could cause transmission from normally non-conductive materials in the resistor movie bring about deterioration and also periodically failing because of warm places. It is therefore essential to observe the resistor optimum defined voltage.


The crucial element in figuring out the surge survivability of a thick movie resistor is the mass of a resistor component, which is directly proportional to its density multiplied by its surface area. The geometry of a resistor likewise affects its rise stand up to ability. A bigger area leads to a higher film mass, and also inevitably a boosted surge efficiency. The increased surface enables even more warmth dissipation which is essential in power resistor applications.

The final element contributing factor to a resistor surge capacity is exactly how the element is resistor cut to develop the final resistance value. The technique utilized for cutting can create vulnerable points that induce failure under rise problems.


Damage via ESD is an unrealized defect that could be difficult to detect. The resistor might be partially broken down by ESD yet continuously do its designated feature. However, the possibilities of early or tragic failing of the resistor gadget are enhanced, especially if the gadget is subjected to several of the anxieties provided above.


A resistor might be the lowest price component in a system yet failing could be equally as tragic as failure of any other system aspect. It is therefore important to understand potential failing modes as well as how they may be attended to. A collaboration with an expert supplier with long term experience of thick film resistor technology and also its manufacture can lessen the dangers of failing.