Date:         Wed, 6 Feb 2013 04:34:39 -0500
Reply-To:     David Beierl <dbeierl@ATTGLOBAL.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         David Beierl <dbeierl@ATTGLOBAL.NET>
Subject:      Re: No Start Cause: Relay Failure. PICS, Thoughts.
Comments: To: neil n <musomuso@GMAIL.COM>
In-Reply-To:  <CAB2RwfjO6aDKaodFewkYPuZXyn_ViGRK_amo6w3JvmFOL5oVbA@mail.g
              mail.com>
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At 01:42 AM 2/6/2013, neil n wrote:
>https://lh4.googleusercontent.com/-h3JODsFUDHM/URHsPfqBbZI/AAAAAAAAGy4/5DkyKweHpnc/s576/Jetta%2520Power%2520Supply%2520Relay%2520Solder%2520Crack.jpg
>
>https://lh3.googleusercontent.com/-vmq-vUhQT4s/URHsPue73gI/AAAAAAAAGzA/cNsoAUx6cJw/s640/Jetta%2520Power%2520Supply%2520Relay%2520Solder%2520Crack%25202.jpg

Fascinating.  As Dick says, the flux suggests prior rework.  The
first image clearly shows a large melt zone caused by arcing around
the terminal (delimited by the curved line midway between the
terminal and lead), and in the second there appears to be a fracture
zone around the righthand lead as well, not surprising under the
circumstances.  Since 63/37 solder (which solidifies abruptly) is
expensive, the solder used in the wave tank will have had a mushy
zone between solidus and liquidus.

This relay clearly was not designed to be used without a socket to
mechanically support the terminals, and/or the mechanical staking of
the terminal into the relay baseplate has failed.  I'd suggest
getting a socket under it or its replacement if at all possible.

Yours,
d