Sherlock Investigates: Switch Failures

Have you ever had a switch fail for no apparent reason? Or start to melt when you try to solder on a wire? “Sherlock,” our intrepid failure detective, rounds up some likely suspects…

“SHERLOCK”

Switches are all very different for various applications but some common generic defects have been around for a long time and still persist. The number one failure that shows up in my scrapbook of failures is ROSIN FLUX. Flux is still used on most solder terminal switches and if the flux penetrates the contact area, failure is certain. When flux is very hot during soldering, it flows very easily into the switch if it is not sealed. Even switches that looked sealed have failed because of the melting of the case material. Switches made of polycarbonate can melt during soldering and flux can seep into the switch and cover the contacts. Flux is an insulator and, when it is activated and hardens, it becomes a sheet of film that can…

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CQ Amateur Radio (Digital) - 1 Issue, February 2023

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