Case 1042 ยท Public preview
Melted Gold and Welded Contacts Can Distinguish Electrical Arcing from Relay Defects
Two relays failed after operating for a period during environmental stress screening, while a stock relay served as a control.
Failed-to-control comparisonSEMContact-surface examinationEDSInternal construction review
What the evidence preview establishes
Both failed relays exhibited high-voltage arcing between the pin 7 and pin 8 contacts. No construction anomaly or manufacturing-quality issue was found that explained the failures.
Why this case matters
Use damage symmetry and control contacts to distinguish an internal relay defect from an external electrical event. Localized melted plating and contact welding identify the failed interface, but circuit records are still required to locate the transient source.
Full evidence reserved for MEMBER and STOREThe complete case includes the evidence sequence, four interpreted figures, alternative explanations, limitations, and practical application guidance.