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Not a poor solder job - a design issue
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Posted by Ari [Email] (#2847) [Profile/Gallery] (more from Ari) on Tue, 18 Jan 2005 09:47:13 Share Post by Email
In Reply to: no magnification needed, Wingerr, Tue, 18 Jan 2005 09:34:16
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There are formula for determining the life of a solder joint, and in addition to thermal cycles, there is also vibration and the mass/moment arm of what's connected to it.

Even with a perfect solder joint, the metallic structure of the solder can fracture. The location of the relay is inhospitable - underhood temperatures and vibration are killers. The large mass of the relay bounces around, creating micro-cracks in the crystaline structure of the solder. These only get bigger with time. I'm sure the solder joints didn't look that way when the relay came from the factory.

The proper solution is to not use solder as a mechanical connector. Ideally, the relay (or any massive component) should be mechanically connected to the board - glue, screws, etc., and the solder only for electrical connection, and unstressed. However, this adds cost to the relay in added parts and build operations. Doesn't seem like it would add much to a relay they ask $100 for, but that $100 is based on a build price of around $6. (a guess).
The relays, in general, make it through the warranty period. We're talking about extending the life of a component from 7 years out to 20 - it's tough to make a cost benefit analysis pay off for making the part more expensive.

That's a long way around to say that I don't think they ever did a recall, or even a service campaign. Fractured solder joints on headlight relays have been going on since the first 9000 rolled off the line.

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