What was found
COMPONENTS ARE FAILING DUE TO OVERHEATING, CAUSING THE CONNECTOR’S SOLDER JOINTS TO MELT AND CAUSE THERMAL DAMAGE TO THE PITOT PROBE ELECTRICAL CONTACTS. 50 INSTANCES OF THE PITOT PROBE FAILURES BETWEEN 2022-08 AND 2025-11 OF THIS CRITICAL SAFETY ITEM ACROSS MULTIPLE AIRCRAFT SERIAL NUMBERS. PITOT-STATIC PROBE HEATER PINS (MALE CONTACTS) ARE DAMAGED DUE TO SANDBLASTING. IMAGES TAKEN BY A DIGITAL MICROSCOPE CONFIRMED THE DAMAGE OF THE SANDBLASTING AND THE CRATERED SURFACE LEFT BEHIND. CONNECTOR IS EXTREMELY LOOSE; LOW SURFACE AREA CONTACT BETWEEN CONNECTOR AND HEATER PINS ISSUE IS EXACERBATED BY VIBRATION. SOLDER ALLOY (SN60PB40) USED IN PRODUCTION FOR THIS APPLICATION MELTING RANGE IS (183-190°C); ARCING IS OCCURRING BETWEEN THE SOCKET AND PIN AT THE INTERFACE INCREASING THE TEMPERATURE. POOR SURFACE AREA CONTACT AT THE INTERFACE IS INCREASING RESISTANCE ALSO INCREASING THE TEMPERATURE AT THE INTERFACE. ROOT CAUSE IS SANDBLASTED HEATER PINS AND POOR ELECTRICAL CONTACT AT THE CONNECTOR INTERFACE TO THE PITOT PROBE. AIRCRAFT SERIAL 15842 IS BUNO 170179. CONNECTOR MANUFACTURER IS DCS-CHOL ELECSYS DIVISION CAGE CODE: 30463.