System Reliability Center

201 Mill Street

Rome, NY 13440-6916
888.722.8737
or 315.337.0900
Fax: 315.337.9932

Part Failure Mode Distributions

The following table summarizes a sampling of failure mode information collected by RAC.
Device Type
Accumulator, Tank

Actuator

Alarm, Annunciator

Battery,
Rechargeable,
Ni-Cd
Bearing

Belt

Blower Assembly

Brake

Bushing

Cable

Capacitor,
Aluminum,
Electrolytic, Foil

Failure Mode

Leaking
Seized
Worn
Contaminated
Spurious Position
Change
Binding
Leaking
Seized
False Indication
Failure to Operate
on Demand
Spurious Operation
Degraded Alarm
Degraded Output
No Output

0.47
0.23
0.20
0.10
0.36

Binding/Sticking
Excessive Play
Contaminated
Excessive Wear
Broken

0.50
0.43
0.07
0.75
0.25

Bearing Failure
Sensor Failure
Blade Erosion
Out of Balance
Short Circuit
Switch Failure
Excessive Wear
Leaking
Scored
Corroded
Loose
Excessive Wear
Loose
Cracked
Short
Excessive Wear
Open

0.45
0.16
0.15
0.10
0.07
0.07
0.56
0.23
0.11
0.05
0.05
0.85
0.11
0.04
0.45
0.36
0.19

Short
Open
Electrolyte Leak
Decrease in
Capacitance
Capacitor, Ceramic Short
Change in Value
Open
= Failure Mode Probability

Device Type
Antenna

Battery, Lithium

0.27
0.22
0.15
0.48
0.29

Battery, Lead Acid

0.18
0.05
0.72
0.28

Failure Mode
No Transmission
Signal Leakage
Spurious
Transmission
Degraded Output
Startup Delay
Short
Open

0.54
0.21
0.25

Degraded Output
Short
Intermittent Output

0.70
0.20
0.10

Capacitor,
Tantalum

0.78
0.14
0.06
0.02

Short
Open
Change in Value
Capacitor,
Short
Tantalum,
Open
Electrolytic
Change in Value
Capacitor, Variable, Change in Value
Piston
Short
Open
Circuit Breaker
Opens Without
Stimuli
Does Not Open

0.57
0.32
0.11
0.69
0.17
0.14
0.60
0.30
0.10
0.51

Clutch

Binding/Sticking
Slippage
No Movement

0.56
0.24
0.20

Coil

Short
Open
Change in Value
Open
Poor Contact/
Intermittent
Short
Open
No Oscillation

0.42
0.42
0.16
0.61
0.23

Short
Open
Parameter Change

0.49
0.36
0.15

Connector/
Connection

0.53
0.35
0.10
0.02

Crystal, Quartz

0.49
0.29
0.22

Diode, General

0.49

0.16
0.89
0.11

System Reliability Center

201 Mill Street
Rome, NY 13440-6916
888.722.8737
or 315.337.0900
Fax: 315.337.9932

Part Failure Mode Distributions (Cont'd)

Device Type
Capacitor,
Mica/Glass

Failure Mode

Device Type

Short
Change in Value
Open
Short
Open

0.72
0.15
0.13
0.63
0.37

Open
Short
Change in Value
Failed Off
Short
Open
Failed On
Failed Off
Failed On

0.42
0.40
0.18
0.45
0.40
0.10
0.05
0.90
0.10

Diode, Zener,
Voltage
Reference
Diode, Zener,
Voltage Regulator

Parameter Change
Open
Short
Open
Parameter Change
Short

0.69
0.18
0.13
0.45
0.35
0.20

Mechanical Filter

Electric Motor, AC

Winding Failure
Bearing Failure
Fails to Run, After
Start
Fails to Start
Leaking
Contaminated
Scored

0.31
0.28
0.23

Microwave, Diode

Fuse

Fails to Open
Slow to Open
Premature Open

0.49
0.43
0.08

Microcircuit,
Digital, MOS

Gasket/Seal

Leaking

1.00

Microcircuit,
Interface

0.54
0.46
0.60
0.22
0.09

Microcircuit, Linear

Capacitor, Paper

Capacitor, Plastic

Diode, Thyristor

Diode, Triac

Fitting

Gear

Excessive Wear
Binding/Sticking
Generator
Degraded Output
No Output
Fails to Run, After
Start
Loss of Control
= Failure Mode Probability

Diode, Rectifier

Diode, Silicon
Control Rectifier
(SCR)
Diode, Small Signal

Lamp/Light

Liquid Crystal
Display

Meter

0.18
0.90
0.05
0.05

Microcircuit,
Digital, Bipolar

Microcircuit,
Memory, Bipolar

0.09

Failure Mode

Short
Open
Parameter Change
Short
Open

0.51
0.29
0.20
0.98
0.02

Parameter Change
Open
Short
No Illumination
Loss of Illumination

0.58
0.24
0.18
0.67
0.33

Dim Rows
Blank Display
Flickering Rows
Missing Elements
Leaking
Clogged

0.39
0.22
0.20
0.19
0.67
0.33

Faulty Indication
Unable to Adjust
Open
No Indication
Open
Parameter Change
Short

0.51
0.23
0.14
0.12
0.60
0.28
0.12

Output Stuck High

Output Stuck Low
Input Open
Output Open
Input Open
Output Open
Supply Open
Output Stuck Low
Output Stuck High
Output Stuck Low
Output Open
Input Open
Supply Open
Improper Output
No Output
Slow Transfer of
Data
Data Bit Loss

0.28
0.28
0.22
0.22
0.36
0.36
0.12
0.09
0.08
0.58
0.16
0.16
0.10
0.77
0.23
0.79
0.21

System Reliability Center

201 Mill Street
Rome, NY 13440-6916
888.722.8737
or 315.337.0900
Fax: 315.337.9932

Part Failure Mode Distributions (Cont'd)

Device Type
Hybrid Device

Failure Mode

Device Type

0.51
0.26
0.17
0.06

Microcircuit,
Memory, MOS

Keyboard Assembly Spring Failure

Contact Failure
Connection Failure
Lock-up
Microwave Antenna No Transmission

0.32
0.30
0.30
0.08
1.00

Microwave
Amplifier

Microwave
Attenuator

Attenuation
Increase
Insertion Loss
High Insertion Loss
Open
Power Loss
No Output

0.90

Printed Wiring
Assembly

Center Frequency
Drift
No Output

0.80

Power Decrease
Loss of Intermediate
Frequency
Power Loss
No Output

0.90
0.10

Relay

0.90
0.10

Resistor,
Composition

No Output
Untuned Frequency
Reduced Power
Microwave Voltage- No Output
Controlled
Untuned Frequency
Oscillator (VCO)
Reduced Power
Microwave Yttrium No Output
from Garnet
Untuned Frequency
(YIG) Resonator
Reduced Power
Microwave Phase
Incorrect Output
Shifter
No Output
Microwave
Change in
Polarizer
Polarization

0.80
0.10
0.10
0.80
0.15
0.05
0.80
0.15
0.05
0.90
0.10
1.00

Resistor, Fixed

Optoelectronic LED

0.70
0.30

Resistor, Variable

0.50
0.50
0.54
0.46

Rotary Switch

Microwave
Connector
Microwave
Detector
Microwave Filter

Microwave Mixer

Microwave
Modulator

Open Circuit
Degraded Output
Short Circuit
No Output

Microwave
Oscillator

Open
Short

Optoelectronic
Short
Sensor
Open
Pneumatic Actuator Spurious Closing
Spurious Opening
= Failure Mode Probability

Power Supply

0.10
0.80
0.20
0.90
0.10

Pump, Centrifugal
Pump, Hydraulic

Regulator

0.20

Resistor, Fixed,
Film
Resistor, Fixed,
Wirewound
Resistor, Network
Resistor,
Thermistor

Screw

Failure Mode

Data Bit Loss

Short
Open
Slow Transfer of
Data
No Output
Limited Voltage
Gain

0.34
0.26
0.23
0.17

No Output
Incorrect Output
Open
Short

0.52
0.48
0.76
0.24

No Output
Degraded Output
Leaking
Improper Flow
No Flow
Stuck Closed
Stuck Open
No Output
Leaking
Insufficient Output
Fails to Trip
Spurious Trip
Short
Parameter Change
Open
Short
Open
Parameter Change
Short
Open
Parameter Change
Short
Open
Parameter Change
Short
Open
Short
Open
Parameter Change
Short
Open
Erratic Output
Short
Improper Output
Contact Failure
Loose
Excessive Wear

0.67
0.33
0.82
0.12
0.06
0.23
0.23
0.22
0.22
0.10
0.55
0.26
0.19
0.66
0.31
0.03
0.84
0.11
0.05
0.59
0.36
0.05
0.65
0.26
0.09
0.92
0.08
0.63
0.22
0.15
0.53
0.40
0.07
0.53
0.47
0.67
0.33

0.90
0.10

System Reliability Center

201 Mill Street
Rome, NY 13440-6916
888.722.8737
or 315.337.0900
Fax: 315.337.9932

Part Failure Mode Distributions (Cont'd)

Device Type
Sensor

Software

Switch, Thermal

Switch, Toggle

Synchro

Transducer, Sensor

Failure Mode

Device Type

Failure Mode

Erratic Output
Short
Open
No Output
Design Changes
Design Errors
User Error
Documentation
Error
Parameter Change
Open
No Control
Short

0.59
0.20
0.12
0.10
0.46
0.41
0.07
0.06

Transistor, Bipolar

Short
Open

0.73
0.27

Transistor, FET

0.63
0.27
0.08
0.02

Tube, Electron

0.51
0.22
0.17
0.05
0.05
0.53

Open
Sticking
Short

0.65
0.19
0.16

Tube, Traveling
Wave

Winding Failure
Bearing Failure
Brush Failure
Out of Tolerance
False Response
Open
Short

0.45
0.33
0.22
0.68
0.15
0.12
0.05

Valve, Hydraulic

0.42
0.42
0.16

Valve, Relief

Short
Output Low
Parameter Change
Open
Output High
Change in
Parameter
Open
Unstable Output
Short
Reduced Output
Power
High Helix Current
Gun Failure
Open Helix
Leaking
Stuck Closed
Stuck Open
Leaking
Stuck Open
Stuck Closed
Spurious Opening
Spurious Closing
Premature Open
Leaking

Transformer

Open
Short
Parameter Change
= Failure Mode Probability

Valve, Pneumatic

0.25
0.15
0.07
0.71
0.11
0.09
0.09
0.77
0.12
0.11
0.28
0.20
0.20
0.16
0.16
0.77
0.23

Copyright 2001 Alion Science and Technology. All rights reserved.

Source:

RAC Publication, CPE, Reliability Toolkit: Commercial Practices Edition.

For More Information:

RAC Publication, Chandler, G., W. Denson, M. Rossi, and R. Wanner, 1991, FMD, Failure
Mode Distributions.

RAC Product, MIL338CD, Electronic Design Reliability Handbook, CD-ROM Version.