Diode Failures: Causes & Prevention Tips

Diodes are essential components in various electronic systems playing a crucial role in ensuring the proper flow of current. However, like all components, diodes are also prone to failure. Diode failures can have a significant impact on the performance and reliability of electronic systems leading to unexpected system shutdowns, reduced efficiency and increased maintenance costs. Understanding the causes of diode failures and taking proactive measures to prevent them is crucial in ensuring the proper functioning of electronic systems. In this article, we will discuss the various types of diode failures, their causes and measures that can be taken to prevent them.

Diode Failures

Diode failures can occur due to several reasons including:

1. Overheating

Overheating can cause thermal stress on the diode and damage its p-n junction. This can result in permanent damage or complete failure of the diode. It is important to ensure that diodes are operated within their specified temperature range to avoid this type of damage.

2. Reverse bias

When a diode is reverse-biased, the voltage across it increases, and the reverse current increases. This can cause the diode to overheat and eventually fail. The very low resistance of a diode to forward current makes it especially vulnerable to burnout if installed incorrectly.

3. Overload

When a diode is subjected to excessive current, it can result in damage to the p-n junction causing the diode to fail. If the maximum forward current is exceeded, the heat generated is likely to destroy the diode. If the diode is reverse-biased beyond its peak inverse voltage limit, the current will overwhelm the diode’s ability to block it and an avalanche breakdown will occur, once again probably destroying the component.

4. Electrostatic discharge (ESD)

A sudden and powerful flow of electricity from one electrical conductor to another can damage the p-n junction causing the diode to fail. This is why surge protection devices are commonly used to protect electronic equipment from voltage spikes or transient surges.

5. Aging

Over time, diodes can degrade due to a variety of reasons including exposure to high temperatures, vibration, and humidity. This can cause a gradual decline in the performance of the diode and eventually lead to failure. Therefore, it is essential to take proper precautions and ensure that diodes are used in suitable environments to prevent degradation and extend their lifespan.

6. Mechanical stress

Mechanical stress can cause deformation in the crystal lattice of the semiconductor material leading to the creation of defects and altering the electrical properties of the device. This can result in a decrease in performance or complete failure of the diode. Therefore, proper handling and mounting of diodes are essential to avoid mechanical stress and ensure their reliability.

7. Contamination

Diodes can be contaminated by foreign materials that can interfere with their performance such as dust, moisture or chemicals. This can cause a reduction in the efficiency of the diode and eventually lead to failure.

8. Over-voltage

Excessive voltage can cause the p-n junction to break down resulting in damage to the diode and eventual failure. This can cause excessive heat and damage to the diode leading to eventual failure. Therefore, it is important to ensure that the diode is not subjected to excessive voltage.

9. Manufacturing defects

Diodes can be defective during the manufacturing process which can result in reduced performance or complete failure. Improper doping or impurities in the material can affect the diode’s electrical properties and lead to malfunction. Quality control measures are in place to minimize the likelihood of defective diodes entering the market but some defects may still occur.

10. Thermal cycling

Repeated exposure to temperature changes can cause stress on the diode leading to failure over time. It is recommended to operate diodes within their specified temperature range and avoid extreme temperature changes. Additionally, proper heat dissipation measures should be taken to reduce the risk of thermal stress on the diode.

11. Using the wrong type

If a Zener diode is used accidentally where a signal or rectifier diode is appropriate, the circuit will malfunction, as the Zener will probably have a much lower breakdown voltage and therefore will not block reverse current. Conversely, if a signal or rectifier diode is used where the circuit calls for a Zener diode, the reverse voltage will be clamped (or regulated at the diode’s forward voltage value). Since diodes are often poorly marked, a sensible precaution is to store Zener diodes separately from all other types.