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Lead Fracture from Inadequate Support

8. Components:  Lead fracture due to inadequate mechanical support

Leads fractured during vibration testing due to no mechanical support. Engineering drawing did not call out to specify additional mechanical support with staking material.

Additional parts were damaged by broken part bouncing around inside the enclosure.

Reference :
NASA-STD-8739.3 paragraph 8.1
Unusual environmental applications require special design measures to provide necessary environmental survival capability. Such measures shall be detailed on the appropriate engineering documentation. Engineering documentation shall prescribe which alternative approach is selected, as well as staking compounds and conformal coating requirements.


J-lead part at 10X magnification

close up view of lead crack (100X)