Five Early Indicators That a Failure Is Process-Induced, Not Design-Related

When a component fails, the first instinct is often to question the design. While design flaws do occur, many failures originate earlier or later in the lifecycle—during manufacturing, assembly, handling, or test. Identifying process-induced failures early helps teams avoid misdirected redesign efforts and focus corrective action where it will be most effective. Recognizing these indicators …

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Cross-Sectioning for Failure Analysis

Cross-sectioning is a fundamental technique in electronic failure analysis used to expose and evaluate the internal construction of devices and assemblies. By physically sectioning a sample and examining its internal features, engineers can directly observe materials, interfaces, and structures that are otherwise inaccessible. Cross-sectioning plays a critical role in identifying manufacturing defects, material degradation, and …

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Using Time Domain Reflectometry for Electrical Fault Localization

Time Domain Reflectometry (TDR) is a diagnostic technique widely used in electronic failure analysis to evaluate the integrity of conductive paths within devices and assemblies. It is particularly effective for localizing continuity-related defects such as opens, shorts, and impedance discontinuities that are difficult or impossible to detect through visual inspection alone. Because TDR is non-destructive …

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Scanning Acoustic Microscopy in Electronic Failure Analysis

Scanning Acoustic Microscopy (SAM) is a non-destructive inspection technique used extensively in electronic failure analysis to detect internal structural defects that are not visible using optical methods. By utilizing high-frequency ultrasonic waves, SAM enables engineers to image subsurface features and interfaces within electronic devices and assemblies, making it particularly valuable for identifying delamination, voids, cracking, …

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