Thermal runaway case studies

[Jaxen]

Watching a load resistor fry itself during a bench test really made me reconsider my design practices. When temperatures start to rise, do you play it safe and derate, or do you go for heat sinking?

I’m eager to hear your stories of close calls or valuable lessons learned.

 

[Tovaren]

There was this one time I let a resistor get too hot, and it started smoking like a little campfire. Now, I either choose a bigger resistor than I need or add a heat sink. Nothing teaches you to respect wattage like seeing a component fry.

 

[cap&resistor]

I usually go for heat sinks on tough loads, but I’ve realized that derating is both easier and less embarrassing.
Watching a resistor glow red is enough to make you appreciate power limits and rethink your entire design.

 

[voltagepathmaker]

Years back, a resistor puffed up during a test and totally freaked out my cat. Now, I always check the surrounding temperatures, derate, and sometimes even double the rating just for peace of mind. Those close calls definitely create better habits than any manual could.

 

[soldersoldier]

I tend to play it safe and derate right off the bat.
I once tried using a heat sink on a stubborn 5W resistor.
It worked, but I ended up creating a mini radiator setup.
I’ve figured out that keeping things simple with safety margins beats trying to engineer complicated solutions any day.