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Whisker Failures

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"Publicly" Reported Failure References

Tin (and Other Metal) Whisker Induced Failures
The following section provides a sample of publicly available references describing electronic system failures attributed to metal whiskers (tin, zinc, silver, etc.).  This list is NOT ALL ENCOMPASSING. A Whisker Anecdotes section has also been established to document whisker induced problems where more "formal" publicity is either unavailable or unwanted by the individuals/organizations contributing the information

Commercial Satellite Failures Military Failures Medical Failures
Industrial/Power Computers Anecdotes

On-Orbit COMMERCIAL (non-NASA) Satellite Failures 
The following commercial (non-NASA) satellites have reportedly suffered on-orbit failures of their satellite control processors due to tin whisker induced short circuits where the whiskers grew on pure tin plated electromagnetic relays

Name Launch Date First Satellite Control Processor Failure Redundant Satellite Control Processor Failure
Complete Losses
GALAXY VII [PanAmSat] 27 October 1992  13 June 1998 22 November 2000
GALAXY IV [PanAmSat] 24 June 1993  (not caused by 'tin whiskers')  19 May 1998
SOLIDARIDAD 1 [SatMex] 19 November 1993  28 April 1999  27 August 2000
GALAXY IIIR [PanAmSat] 15 December 1995  21 April 2001 15 January 2006
Partial Losses
OPTUS B1 13 August 1992 21 May 2005 Still Operational
DBS-1 [DirecTV] 17 December 1993  4 July 1998 Still Operational
PAS-4 [PanAmSat] 3 August 1995  3rd quarter 1998 Still Operational
DirecTV 3 (DirecTV) 9 June 1995 4 May 2002 Still Operational

(Table Information Obtained from: Satellite News Digest)

Articles about Commecial (non-NASA) Satellite Failures:

LAUNCHES OF HUGHES HS 601 SATELLITES READY TO RESUME - (Hughes/Boeing Press Release August 1998)

DirecTV 3:
 
Boeing BSS 601 DirecTV 3 Experiences SCP Glitch (Space and Tech.com - May 2002)
Anomaly on DirecTV 3 (Microcom's Space NewsFeed - May 2002)
Anomaly Noted On DIRECTV 3 Satellite (DirecTV Press Release - May 14, 2002)
Processor Problem Continues To Dog Boeing Satellites (e-inSITE.com - May 2002)
Anomaly Noted on DIRECTV 3 Satellite
(Hughes Press Release May 2002)

GALAXY VII:
PANAMSAT's GALAXY VII Satellite Ceases Operations: Full-Time Services are Not Affected (PanamSat Nov. 2000)
Galaxy VII Lost (Microcom's Space Newsfeed Nov. 2000)

SOLIDARIDAD 1:
Satmex’s Solidaridad HS 601 Fails (Space and Tech.com September 4, 2000)
Mexican Satellite Failure May Be Linked to Past Problem (SpaceViews Aug 2000)
$250 million Mexican satellite goes silent
(Florida Today Space Online - Aug. 29, 2000)

Satellite failure causes communications blackout
GALAXY IV
Pager Messages Lost in Space -Crucial Satellite Causes Widespread Trouble - (CNN.com  May 20, 1998)
National Public Radio Story - Satellite (NPR.org May 1998)

S. Silverstein, "Reasons for Failure Lost with Galaxy 4", Space News, Aug. 17-23, 1998, pp. 19-20
B. Nordwall, Aviation Week & Space Technology, Aug. 17, 1998, pp. 47


GALAXY III-R
Design flaw surfaces on PanAmSat's Galaxy 3R (Spaceflight Now.com - April 24, 2001)
Galaxy IIIR Shifts to Backup Control After Failure (Space and Tech.com - April 23, 2001)

Military Failures

  1. Military Airplane:  G. Davy, "Relay Failure Caused by Tin Whiskers", Northrop Grumman Electronic Systems Technical Article, October 2002

  2. Patriot Missile:  Anoplate WWW Site:  Suspected tin whisker related problems (Fall 2000)

  3. Phoenix Air to Air Missile:  L. Corbid, "Constraints on the Use of Tin Plate in Miniature Electronic Circuits", Proceedings 3rd International SAMPE Electronics Conference, pp. 773-779, June 20-22, 1989.

  4. F-15 Radar:  B. Nordwall, "Air Force Links Radar Problems to Growth of Tin Whiskers", Aviation Week and Space Technology, June, 20, 1986, pp. 65-70

  5. U.S. Missile Program:  J. Richardson, and B. Lasley, "Tin Whisker Initiated Vacuum Metal Arcing in Spacecraft Electronics," Proceedings 1992 Government Microcircuit Applications Conference, Vol. XVIII, pp. 119 - 122, November 10 - 12, 1992.

  6. U.S. Missile Program:  K Heutel and R. Vetter, "Problem Notification: Tin Whisker growth in electronic assemblies", Feb. 19, 1988, memorandum

Medical Equipment Failures

  1. Heart Pacemaker Recall Food and Drug Administration March 1986

  2.  Apnea Monitor Failures:  J. Downs, "The Phenomenon of Zinc Whisker Growth and the Rotary Switch (or, How the Switch Industry Captured the Abominable Snowman)", Metal Finishing, August 1994, pp. 23-25  NOTE:  This issue is a ZINC Whisker failure!

Industrial/Power

  1. Westinghouse Nuclear Tech Bulletin TB-05-4, "Potential Tin Whiskers on Printed Circuit Board Components", June 8, 2005

  2. Westinghouse Nuclear Tech Bulletin TB-02-5, "(Tin Whiskers on Potentiometers used in) Basler Power Supplies", July 12, 2002

  3. P. Daddona, "Reactor Shutdown: Dominion Learns Big Lesson from a Tiny Tin Whisker", The Day (New London, CT), July 4, 2005

  4. C. Stevens, "Relay Failures Induced by the Growth of Tin Whiskers:  A Case Study", IEEE Boston Reliability Chapter 38th Annual Spring Reliability Symposium, May 16, 2001
  5. GE Power Management, "Technical Service Bulletin:  Tin Whiskers in MOD10 Relays", March 27, 2000
  6. Dr. B. Chudnovsky, "Degradation of Power Contacts in Industrial Atmosphere: Silver Corrosion and Whiskers", 48th IEEE Holm Conference on Electrical Contacts 2002
    NOTE:  This is a SILVER Whisker Issue!
  7. 2-Way Radio Receiver Sensitivity Issue Due to Metal Whiskers, HAM Radio Forum, Kevin Custer (W3KKC)

Computer Servers / Routers / Power Supplies / etc

  1. "What Nasty Little Things are Lurking Inside Your Data Center?" (Source:  Unisys World Monthly--November 2002) 
    NOTE:  This issue is a ZINC Whisker failure!
  2. See the ZINC WHISKER section of this www site for LOTS of articles attributing system failures to ZINC WHISKERS from Raised Access Floor Tiles
 
Responsible NASA Officials:

   Michael Sampson/NASA GSFC Code 306
   Dr. Henning Leidecker/NASA GSFC Code 562
Additional Researchers: 

   Jong Kadesch/Orbital Sciences Corp.
   Jay Brusse/Perot Systems

Last Updated:

December 10, 2007

DISCLAIMER:
This website provides information about tin whiskers and related research. The independent research performed during the past 50+ years is so vast that it is impractical to cover all aspects of tin whiskers in this one resource. Therefore, the absence of information in this website about a particular aspect of tin whiskers should NOT be construed as evidence of absence.

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