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Failure analysis and recommendation to improve the yields of a high temperature cartridge heater

The life of high temperature cartridge heaters was lower than expected, resulting in higher then acceptable field returns.  

A number of aspects of the design and quality were analyzed and recommendations were made, including weld quality, selection of materials, electrical connection techniques and others.  

The picture on the right is a cross-section of the end of a heater cartridge.

Several recommendations were implemented which significantly improved the reliability of the heater cartridges.