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Metal Film Failures?

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I had 4 out of 30 brand new cathode load resistors fail. They are well under the limits for dissipation and voltage. They were 180K @ 2W purchased from Mouser. Three opened and one doubled in value.

Now here's the rub: The four that failed were soldered in a large solder pot on a PC board. A water based flux was used and washed off with tap water. Then after some touchups, the board was soaked in Isopropal alcohol for 10 nminutes and dried with compressed air. I have been using the technique on PC boards for over 20 years without incident.

The other 24 resistors were point to point wired and all are within tolerance.

Too much heat? Did the water or alcohol get ito the resistor body somehow.

Any ideas or similar expereinces? This has me stumped.


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Topic - Metal Film Failures? - Gusser 11:07:58 08/11/06 (9)


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