Additional Resources > Windchill Risk and Reliability Practitioner’s Guide > Data Tables > Discrete Electronic and Electro-mechanical Components
Discrete Electronic and Electro-mechanical Components
Table A-1. Discrete Electronic and Electro-mechanical Components
Component Description
Base Failure Rate
B
failures 106hrs
K Factors
Predominant Failure Modes
G.1
G.2
S.1
S.2
A.1
A.2
Mode
%
Factor
Part
Ground
Fixed
Ground
Mobile
Ship
Protected
Ship
Exposed
Air
Protected
Air
Exposed
Accelerometers
Accelerometer, General
22.00
3.00
1.70
3.00
5.00
6.00
Accelerometer, Linear
18.00
3.00
1.70
3.00
5.00
4.00
Accelerometer, Angular
Accelerometer, Pendulum
Accelerometer, Strain
Gauge
32.00
3.00
1.70
3.00
5.00
4.00
Accelerometer, Sintered- Ceramic, Piezo-Electric
Actuators
Table A-1. Discrete Electronic and Electro-mechanical Components
Actuator, Linear
(Electrical)
1.20
2.00
1.50
2.70
2.20
4.00
Actuator, Rotary (Electrical)
2.40
2.00
1.50
2.70
2.20
4.00
Aerial
1.00
6.00
2.30
6.00
5.00
10.00
No Transmis- sion
54
Signal Leakage
21
Spurious Transmission
25
Aerial Dish
3.00
4.00
1.70
4.00
3.00
6.00
Ditto
Alternator
3.00
3.00
1.30
3.00
2.00
3.00
Batteries
3.00
3.00
1.30
3.00
2.00
3.00
Battery, Secondary, General
1.50
10.00
8.00
10.00
24.00
50.00
Battery, Secondary, Lead Acid
0.50
2.50
1.80
4.00
1.80
7.60
Degraded Output
70
Short Circuit
20
Intermittent Output
10
Battery, Secondary, Nickel Cadmium
0.20
2.50
1.80
4.00
1.80
7.60
Degraded Output
72
No Output
28
Battery, Secondary, Silver Zinc
Battery, Lithium
Degraded Output
78
Startup Delay
14
Short Circuit
6
Open Circuit
2
Cable, Electric, Intercon- necting - per cable. (Semi- permanent Surface/
Air ground installation)
1.20
Not Applicable
Capacitors, Fixed
Aluminum Electrolytic
0.30
3.00
2.00
10.00
9.00
13.00
Short Circuit
50
Open Circuit
30
Tantalum, Electrolytic, Foil
0.13
3.00
1.50
3.00
2.30
3.50
Short Circuit
75
Open Circuit
25
Capacitors, Fixed (Continued)
Table A-1. Discrete Electronic and Electro-mechanical Components
Tantalum, Electrolytic,
Sintered |Anode, Wet Elec- trolyte
0.12
2.40
2.30
2.40
4.80
5.00
Short Circuit
80
Open Circuit
20
Tantalum, Electrolytic, Solid
0.08
2.30
2.00
2.30
4.00
6.00
Short Circuit
50
Open Circuit
30
Ceramic
0.04
2.00
1.20
2.40
4.00
5.00
Short Circuit
50
Open Circuit
30
Ceramic, Chip
0.10
2.00
1.20
1.80
1.50
2.50
Short Circuit
50
Open Circuit
30
Mica
0.06
2.00
3.00
4.30
2.40
6.00
Mica, Button
Mica, Silvered
Porcelain
Paper, Metallized
0.06
2.00
2.70
8.00
2.00
10.00
Paper, Foil
0.12
2.70
1.50
2.50
3.50
Short Circuit
90
Open Circuit
5
Plastic Film (Synthetic Film)
0.05
3.00
1.70
3.00
3.00
7.00
Short Circuit
55
Open Circuit
40
Capacitors, Variable
Air
0.10
5.00
3.20
5.00
12.00
16.00
Ceramic
0.14
12.00
3.00
12.00
9.00
15.00
Glass
0.26
2.20
2.50
11.00
4.50
20.00
Circuit Breakers
Circuit Breaker, Magnetic
1.00
5.00
1.70
5.00
3.00
5.00
Circuit Breaker, Thermal
2.00
2.70
1.40
2.70
2.20
7.00
Clutch, Electro-Magnetic
3.50
3.00
2.00
3.00
4.00
5.00
Bearing Wear
30
Coil Failure
20
Contamination
25
Lubrication failure
15
Connections
Crimped
0.01
Hand Soldered
0.00
Connection failure rates are greatly dependent on the level of process control employed. The quoted base failure rates are achiev- able in all environments provided the effect of vibration on lead connections is eliminated.
Connections (Continued)
Table A-1. Discrete Electronic and Electro-mechanical Components
Flow Soldered
0.00
Through-Plated, PCB
0.00
Welded
0.00
Wire Wrapped (Using tool)
0.00
Connectors
Connector, co-axial
0.17
2.00
1.40
2.30
2.00
3.40
Contamina- tion / Corro- sion
29
Distortion
29
Fracture
22
Low Insula- tion
17
Connector, edge
0.01
2.00
1.40
2.30
2.00
3.40
Ditto
Connector, non-hermetic
0.04
2.00
1.40
2.30
2.00
3.40
Ditto
Connector, hermetic
0.03
2.00
1.40
2.30
2.00
3.40
Ditto
Crystal Devices
Crystal, Quartz
0.20
5.00
2.00
5.00
4.00
6.00
Open Circuit
80
Crystal Oscillator
0.76
No Oscillation
10
Diodes
Germanium, general purpose
0.30
8.00
2.30
8.00
5.00
8.00
Short Circuit
75
Open Circuit
5
Intermittent
18
Rectifier, low power, <1W
0.12
2.50
1.80
2.50
2.00
4.00
Open Circuit
60
Short Circuit
40
Rectifier, medium power,
<20W
0.20
3.00
1.20
3.00
1.50
5.00
Ditto
Rectifier, high power,
20W
0.50
3.00
1.20
3.00
1.50
5.00
Ditto
Silicon, signal
0.05
4.00
3.00
4.00
3.00
6.00
Open Circuit
24
Short Circuit
16
Parameter Change
58
Silicon, Reference/Regula- tion (Zener, Avalanche)
0.07
2.50
2.00
3.50
2.00
5.50
Open Circuit
45
Short Circuit
20
Parameter Change
35
Diodes (Continued)
Table A-1. Discrete Electronic and Electro-mechanical Components
Microwave, Gunn Oscil-
lator
0.50
4.00
1.70
4.00
3.00
5.00
Microwave, Detector
1.20
7.00
7.50
10.20
7.50
15.00
Microwave, Mixer
1.80
5.00
5.70
7.50
5.00
11.00
Microwave, Schottky
0.50
5.00
4.00
6.00
4.00
9.00
Step Recovery
0.30
5.00
6.00
8.00
5.00
11.00
Tunnel
0.30
5.00
6.00
8.00
5.00
11.00
Varactor Tuning
0.30
5.00
6.00
8.00
5.00
11.00
P.I.N. (Intrinsic), Switching
0.50
2.00
1.30
2.00
2.00
3.00
P.I.N. (Attenuation)
4.00
2.00
1.30
2.00
2.00
3.00
Thyristor, Reverse blocking, 2 leads (Shockley)
0.40
2.25
2.50
3.50
3.00
5.00
Failed OFF
45
Short Circuit
40
Open Circuit
10
Failed ON
5
Thyristor, Reverse blocking, 3 leads (Silicon Controlled Rectifier)
0.40
2.25
2.50
3.50
3.00
5.00
Open Circuit
2
Short Circuit
Thyristor, Bi-Directional, 2 leads, DIAC
0.40
2.25
2.50
3.50
3.00
5.00
Thyristor, Bi-Directional, 3 leads, TRIAC
0.75
5.00
6.00
7.00
5.00
10.00
Failed OFF
90
Failed ON
10
Surge Suppressor, Sele- nium
0.25
2.00
1.50
2.00
2.50
3.00
Fuses
Fuse, General
0.20
4.00
2.30
4.00
5.00
6.00
Fails to Open
49
Slow to Open
43
Premature Open
8
Fuse Link, Cartridge
0.10
5.00
2.00
5.00
4.00
8.00
Ditto
Gyroscopes
Gyroscope, displacement
12.00
3.00
2.00
3.00
4.00
4.00
Gyroscope, free
14.00
3.00
2.00
3.00
4.00
4.00
Gyroscope, rate
20.00
4.00
3.50
4.00
6.00
8.00
Gyroscope, integrating
20.00
4.00
3.50
4.00
6.00
8.00
Gyroscope, Laser
Table A-1. Discrete Electronic and Electro-mechanical Components
Inductors (Coils and Chokes)
L.F. Signal
0.11
8.00
2.70
8.00
6.00
10.00
Short Circuit
42
Open Circuit
42
Change in Value
16
L.F. Power
0.25
8.00
2.70
8.00
6.00
10.00
Ditto
R.F. Signal
0.08
6.00
2.30
6.00
5.00
8.00
Ditto
R.F. Power
0.15
6.00
2.30
6.00
5.00
8.00
Ditto
R.F. Variable
0.20
Ditto
Saturated
0.24
Ditto
Inductors (Coils and Chokes) (Continued)
Solenoid, Electrical
1.50
3.00
1.70
3.00
3.00
4.00
Fails to Operate
57
Slow Move- ment
43
Solenoid, Rotary
1.50
3.00
1.50
3.00
2.50
4.00
Ditto
Solenoid, Valve, General
6.40
3.00
1.70
3.00
3.00
4.00
Ditto
Transformers
High Power, Pulse and Power (>1kV)
0.16
0.34
0.13
0.45
0.27
0.45
Low Power /Signal
0.02
0.05
0.02
0.07
0.04
0.05
Audio
0.05
0.10
0.04
0.13
0.07
0.10
Transistors
Germanium
0.13
6.60
5.50
8.00
6.60
8.30
High
Collector-Base Leakage current
59
Low
Collector-Emit ter Break- down Voltage
37
NPN/PNP (f<200MHz)
0.05
4.40
4.70
6.30
6.80
8.80
Power NPN/PNP (f<200MHz)
0.09
5.00
5.00
6.00
5.00
8.00
Table A-1. Discrete Electronic and Electro-mechanical Components
Si FET (f £ 400MHz)
Short Circuit
51
Output Low
22
Parameter Change
17
Open Circuit
5
Output High
5
Si FET (f > 400MHz)
Ditto
GaAs FET (P<100mW)
Open Circuit
61
Short Circuit
26
Parameter Change
13
GaAs FET (P³100mW)
Ditto
Unijunction
0.10
5.50
5.90
8.80
5.50
12.00
RF, Low Noise (f>200MHz, P<1W)
Parameter Change
50
Short Circuit
40
Open Circuit
10
RF, Power (P³1W)
Ditto
Electrical Components
Meter, Electrical, General
2.30
40.00
1.70
4.00
3.00
Contamination
71
Mechanical Damage
23
Meter, Electrical, Moving Coil
3.00
2.70
1.40
2.70
2.20
Meter, Electrical, Moving Iron
Magneto
11.00
4.00
1.70
4.00
3.00
4.00
Motors
Motor, Electrical, AC
1.20
3.00
1.30
3.00
2.00
3.00
Bearing Failure
28
Winding Failure
31
Fails to Run After Start
23
Fails to Start
18
Motor, Electrical, Stepper
0.50
4.00
1.70
4.00
3.00
4.00
Motor, Fractional HP
3.30
2.30
1.20
2.00
1.50
5.50
Motor, Full HP
0.90
4.50
1.80
4.00
35.00
13.00
Motor, Servo (Servomotor)
1.50
3.00
1.70
3.00
3.00
4.00
Bearing Failure
45
Table A-1. Discrete Electronic and Electro-mechanical Components
Motor, Servo (Servomotor) Integrating
6.00
Winding failure
50
Motor, Servo (Servomotor) Position
1.00
Slip Ring and Brush (per pair)
3.20
5.00
2.60
5.00
6.00
Contamination
37
Shorted Contact
26
High Resis- tance
15
Open Circuit
9
Motor, Synchro
3.00
2.00
1.30
2.00
2.00
3.00
Bearing Failure
33
Winding failure
45
Brush Failure
22
Dynamotor, (AC/DC Rotary Converter)
9.00
4.00
1.70
4.00
3.00
4.00
Brush, Contact (per contact)
0.50
7.00
2.30
7.00
5.00
10.00
Generators
Generator, Electrical, AC
3.00
3.00
1.30
3.00
2.00
3.00
Degraded Output
60
No Output
22
Fails to Run After Start
9
Loss of Control
9
Generator, Electrical, DC
7.00
4.00
1.70
4.00
3.00
4.00
Ditto
Blower / Fan
4.00
3.60
6.25
22.00
10.00
25.00
Winding Failure
35
Bearing Fail- ures
50
Slip- rings/Brushes
5
Table A-1. Discrete Electronic and Electro-mechanical Components
Opto-Electronics
Light Emitting (LED) Single Point
0.10
2.00
1.30
2.00
2.00
Open Circuit
100
Light Emitting Array
0.10 per element
2.00
1.30
2.00
2.00
Open Circuit
100
Photodiode (light sensors & counters)
2.00
2.00
1.30
2.00
2.00
Open Circuit
100
Opto-Isolator
0.27
4.00
1.70
4.00
3.00
Open Circuit
100
Laser Diode, GaAs/Al GaAs
16.00
5.00
2.40
7.50
5.00
7.00
Open Circuit
100
Laser Diode, In GaAs/In GaAsP
28.00
5.00
2.40
7.50
5.00
7.00
Open Circuit
100
Lamp, Filament
1.00
2.50
1.30
2.50
2.00
6.00
Open Circuit
90
Breakage
10
Lamp, Neon
0.20
3.00
1.30
3.00
2.00
4.00
Lens, Optical
0.40
3.00
2.00
3.00
4.00
6.00
Breakage
100
Fibre Optics
Cable, Plastic coated, Silica Fibre
Link, Single Fibre, Digital
Link, Single Fibre, Analogue
Transmitter, Digital
Transmitter, Analogue
Receiver, Digital
Receiver, Analogue
Printed Circuit Boards
Double Sided
0.01
2.00
2.00
5.00
3.00
10.00
Open Circuit
76
Short Circuit
24
Multi-Layer
0.13
2.00
2.00
5.00
3.00
10.00
Ditto
Surface Mount Tech. Circuit Boards
0.37
4.80
4.80
114.00
17.00
95.00
Ditto
Relays
Relay, Armature (Electro-mechanical)
0.35
3.50
2.60
8.00
9.00
10.00
Coil faults
5
Contact faults
75
Mechanical faults
10
Relay, Crystal can
0.16
10.00
5.00
8.00
10.00
12.00
Relay, Dry Reed (per contact pair)
0.15
7.00
8.00
13.00
9.00
11.00
Table A-1. Discrete Electronic and Electro-mechanical Components
Relays (Continued)
Relay, Electro-Mechanical, Flat-Pack
Relay, Electro-Mechanical, PCB
Relay, Hybrid (Mechanical switch with Solid State circuitry)
Relay, Mercury-wetted contact
1.00
7.00
4.00
7.00
9.50
11.00
Relay, Mercury-wetted contact (per contact pair)
0.30
Relay, Resonant Reed
0.35
Relay, Time Delay
0.34
7.00
4.50
7.00
8.50
10.00
Relay, Solid State (SSR)
Relay, T05 Encapsulated
Relay, Co-Axial
Relay, Latching, Mechan- ical
0.45
3.00
3.00
6.00
3.50
5.00
Relay, Latching, Magnetic
Relay, Power
1.00
7.00
4.50
7.00
9.50
14.00
Relay, Stepping
Relay, Thermal
0.35
3.00
2.20
3.00
5.00
6.00
Resistors - Fixed
Fixed, Carbon Composition
0.015
6.00
2.00
6.00
3.00
6.00
Open Circuit
75
Change of Value
20
Fixed, Carbon Film
0.02
7.00
2.00
10.00
9.00
12.00
Ditto
Fixed, Cermet, Single Unit (thick film)
Fixed, Carbon Film (High Stability)
Fixed, Metal Film
0.016
2.50
1.50
3.50
1.50
3.60
Ditto
Fixed, Oxide Film
0.02
4.00
1.70
4.00
3.00
4.00
Open Circuit
95
Fixed, Temperature Sensi- tive (Thermistor) Rod, Bead or Disc Type
0.18
3.00
1.50
2.00
1.40
2.00
Open Circuit
95
Change in Value
5
Fixed, Voltage Sensitive (Varistor)
Open Circuit
95
Change in Value
5
Table A-1. Discrete Electronic and Electro-mechanical Components
Resistors - Fixed (Continued)
Fixed, Wirewound, Preci- sion
0.05
4.00
3.50
5.00
4.00
6.40
Open Circuit
65
Change in Value
26
Short Circuit
9
Fixed, Voltage Sensitive (Varistor)
Open Circuit
95
Fixed, Wirewound, Power
0.06
3.00
2.50
4.00
4.00
6.00
Ditto
Resistors - Variable
Variable, Carbon Composi- tion
2.00
3.75
2.00
17.00
4.50
17.00
Erratic Opera- tion
95
Insulation Failure
5
Variable, Cermet
0.40
3.00
2.30
3.00
5.00
7.00
Variable, Conductive Plastic
0.60
2.50
1.80
2.50
3.50
6.00
Excessive Contact Resis- tance
30
Open Circuit track
60
Variable, Non-Wirewound
2.00
3.30
1.20
4.20
2.00
5.00
Erratic Opera- tion
95
Insulation Failure
5
Variable, Wirewound, Precision
1.00
5.80
2.30
9.00
5.70
11.00
Excessive Contact Resis- tance
30
Open Circuit
40
Variable, Wirewound, Semi-Precision
2.00
8.50
8.60
10.00
6.40
10.00
Erratic Opera- tion
55
Variable, Wirewound
0.75
11.00
3.30
11.00
8.00
11.00
Erratic Opera- tion
55
Open Circuit
40
Variable, Plastic Film Precision
Excessive Contact Resis- tance
30
Open Circuit track
60
Resistors - Pre-Set
Pre-Set, Carbon Composi- tion
0.20
5.00
2.30
5.50
5.00
6.00
Pre-Set, Cermet
0.15
6.50
2.70
7.00
6.00
8.00
Table A-1. Discrete Electronic and Electro-mechanical Components
Resistors - Pre-Set (Continued)
Pre-Set, Wirewound
0.15
2.60
2.40
4.30
4.00
5.00
Pre-Set, Thick/Thin Film Network DIL
0.10
5.00
4.00
5.00
9.60
13.00
Open Circuit
92
Short Circuit
8
Synchros
Synchro-Generator (Transmitter)
2.00
3.00
1.70
3.00
3.00
4.00
Windings Shorted
50
Windings Open
43
Synchromotor (Receiver)
2.00
3.00
1.70
3.00
3.00
4.00
Windings Shorted
50
Windings Open
43
Switches
Switch, Centrifugal
1.80
Switch, Co-Axial
0.25
Switch, Float (Liquid Level)
5.00
N/A
Switch, Inertia
0.40
N/A
N/A
N/A
1.50
1.50
Switch, Limit (Heavy Duty)
10.00
5.00
2.00
5.00
3.00
6.00
Switch, Micro (Light Duty)
0.60
5.00
2.30
5.00
5.00
7.00
Contact Resis- tance High
60
Open Circuit
27
Switch, Mercury
Switch, Pressure
5.60
4.00
1.30
5.00
10.00
16.00
Switch, Push Button
0.32
6.00
1.50
8.50
8.00
17.00
Open Circuit
60
Short Circuit
7
Sticking
33
Switch, Reed
0.10
1.50
Switch, RF
Switch, Rotary Wafer (per active contact)
0.12
3.00
1.70
3.00
3.00
4.00
Intermittent Contact (Spring frac- ture and contamina- tion)
90
Switch, Sensitive
(Non-Manually Operated
0.53
8.50
2.10
12.00
18.00
24.00
Contact Resis- tance High
60
Open Circuit
27
Table A-1. Discrete Electronic and Electro-mechanical Components
Switch, Stepping
0.22
2.50
2.00
3.00
3.00
N/A
Switch, Thermostatic
2.00
3.00
1.30
3.00
2.60
3.00
Parameter Change
63
Open Circuit
27
No Control
8
Short Circuit
2
Switch, Thermal Delay
0.50
3.00
2.20
3.00
5.00
6.00
Parameter Change
63
Open Circuit
27
No Control
8
Short Circuit
2
Switch, Toggle
0.40
5.70
1.10
8.00
11.00
17.00
Open Circuit
65
Short Circuit
16
Sticking
19
Switch, Waveguide, General
2.00
3.00
1.70
3.00
3.00
4.00