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Printed Wiring Assemblies (PWAs)
Vibration-induced failure of electric component leads

The
above design was reported to have experienced catastrophic
component failure during vibration testing, resulting
in fractured and broken component leads of heatsink-mounted
powered devices. The above photograph of the failed
assembly clearly shows a pattern of damage consistent
with repeated movement and flexure of the components.
The primary cause of the unwanted movement was attributed
to a design decision, in which the heatsink was allowed
to "float" with respect to the printed wiring
assembly.
A design change, which mechanically bonded the heatsink
and printed wiring assembly together, significantly
reduced the incidence of component lead failures during
vibration test.
Reference
:
NASA-STD-8739.3,
4.3. Reliable Soldered Connections
1. Reliable soldered connections result from proper
design; control of tools, materials, processes, and
work environments; use of properly trained and skilled
personnel; and careful workmanship.
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