Common Electrical Connector Problems & Root Causes

Electrical Opens

      Low normal force

      Corrosion

            Environmental

            Manufacturing related

      Mechanical wear

            Cycle life

             Fretting Corrosion

        Debris

Electrical Shorting

      Dielectric breakdown

            Physical spacing

            High voltage

            Tin Whiskers

            Debris

      Overheating

            Current overload

Mechanical Performance

      High mating force

            High normal force

            Stubbing / alignment

            High Coefficient of Friction

      Low retention force

Connector Cost

      Design

            Material selection

                    Base materials

                    Surface finish / plating

      Applied cost