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  • Failure Analysis: Christmas Lights. Case Description & Hypotheses Fracture of the bent brass contact piece in various light bulb sockets The unbent contact
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Failure Analysis: Christmas Lights

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Page 1: Failure Analysis: Christmas Lights. Case Description & Hypotheses Fracture of the bent brass contact piece in various light bulb sockets The unbent contact

Failure Analysis:Christmas Lights

Page 2: Failure Analysis: Christmas Lights. Case Description & Hypotheses Fracture of the bent brass contact piece in various light bulb sockets The unbent contact

Case Description & Hypotheses

• Fracture of the bent brass contact piece in various light bulb sockets

• The unbent contact never failed

• Brass composition from EDS:– Copper – 70%– Zinc – 30%

• Possible causes:– Overload– Fatigue– Corrosion

Page 3: Failure Analysis: Christmas Lights. Case Description & Hypotheses Fracture of the bent brass contact piece in various light bulb sockets The unbent contact

Visual Examination

Contact removed by force

Contact easily removedOriginal failed contact

Corroded Contact

Page 4: Failure Analysis: Christmas Lights. Case Description & Hypotheses Fracture of the bent brass contact piece in various light bulb sockets The unbent contact

Metallography(Longitudinal Sections)

Section of original broken part at fracture surface

Close-up of crack

Slip lines on unfractured

sample at bend

Slip lines on original

fractured sample

Page 5: Failure Analysis: Christmas Lights. Case Description & Hypotheses Fracture of the bent brass contact piece in various light bulb sockets The unbent contact

Fractography

Fracture surface of original failed contact

(600x)

Fracture surface of brass exemplar broken with overload (600x)

Page 6: Failure Analysis: Christmas Lights. Case Description & Hypotheses Fracture of the bent brass contact piece in various light bulb sockets The unbent contact

Conclusion• Stress Corrosion

Cracking (SCC)– Stress: bend– Corrosive

environment: Sulfur and Chlorine

• Solutions:- Coating/Electroplating- Socket design change- Annealing


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