Failure Analysis of Resistors
Chip Resistor F/A
When doing resistor failure analysis the most common failure mechanism based on historical data seen at SEM Lab, Inc. is corrosion of the silver thick film conductor at the termination due to atmospheric corrosion by sulfur (e.g. H2S). This causes the resistance of the chip resistor to increase and ultimately results in an open circuit.
Chip resistor failures and a cross-sectional image of a resistor are shown below. More information about chip resistor corrosion can be found here.