Aluminum alloy resistors are current-limiting components that are typically connected in series within a circuit. Their effectiveness depends on the current flowing through them, especially when multiple branches are involved. If a resistor has a near-zero ohm value, it cannot limit the current effectively, leading to a short circuit where the current becomes theoretically infinite. This can cause damage to other components in the circuit.
Wirewound resistors are commonly used for high-current applications and are generally not available in standard configurations. When these resistors overheat, the cylindrical wire may show signs of burning, such as blackened areas, cracks, or even melting. In some cases, the resistance wire inside may crack or break without leaving visible traces. Cement-based wirewound resistors may also crack when burned, but they often appear intact otherwise. In extreme cases, the outer casing may rupture without showing any burn marks, though the internal resistance might still be damaged.
Resistors are among the most common components in electrical equipment, but they are not necessarily the most failure-prone. The most typical form of damage is an open circuit, where the resistance increases significantly. It is rare for a resistor to decrease in value, but this can happen under certain conditions. Carbon film, metal film, and wirewound resistors are generally considered safe. However, the second most commonly used type—often high-power resistors—can be more prone to damage. When damaged, low-resistance resistors may char and turn black, making the issue easy to spot. High-resistance resistors, on the other hand, may show less obvious signs of damage, but evidence of overheating or breakdown is usually present.
If a resistor has a very high or infinite resistance value, it acts like an open circuit, stopping all current flow. In industrial applications, resistors used between two extremes often allow a small but measurable current to pass, though not as much as during a short circuit. This behavior is similar to water flowing through pipes: a large-diameter pipe allows more flow, while a smaller one restricts it. Resistors function in a similar way, controlling current based on their resistance value.
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