Corrosion of Electronic Components

The Materials Lab. Electronic Failure Analysis Group supports USAF electronic systems in the areas of materials and manufacturing processes. It has been established that a large majority of electronic failures are caused by materials and manufacturing process defects. We have found that corrosion of electronic components is the cause of failure in about 20 of the items submitted to us for investigation. It would be beneficial to the Air Force if corrosion prevention in electronic systems were well documented. Existing documents, such as T.O. 1-1-689 and NAVAIR 16-1-540, are a step in the right direction. However, compulsory MIL specifications should be applied to Air Force electronic corrosion prevention. This is essential because corrosion in Air Force electronic systems contributes significantly to system failure. Failure analysis investigations of aircraft circuit breakers, an antenna, printed wiring boards, a fuse, a linear steering position transducer, a stepper motor, an accelerometer, a disk recorder head, and electrical connectors are presented. The cause of failure is identified and possible means of preventing similar failures is presented.