The total resistance of resistors connected in series is the sum of their individual resistance values.
Power resistors are required to dissipate substantial amounts of power and are typically used in power supplies, power conversion circuits, and power amplifiers; this designation is loosely applied to resistors with power ratings of 1 watt or greater. Power resistors are physically larger and may not use the preferred values, color codes, and external packages described below.
If the average power dissipated by a resistor is more than its power rating, damage to the resistor may occur, permanently altering its resistance; this is distinct from the reversible change in resistance due to its temperature coefficient when it warms. Excessive power dissipation may raise the temperature of the resistor to a point where it can burn the circuit board or adjacent components, or even cause a fire. There are flameproof resistors that fail (creat an open circuit) before they overheat dangerously.
Resistors may be specified with higher rated dissipation than is experienced in service to account for poor air circulation, high altitude, or high operating temperature.
In some precision applications, the temperature coefficient of the resistance may also be of concern.
Carbon composition resistors (CCR) consist of a solid cylindrical resistive element with embedded wire leads or metal end caps to which the lead wires are attached. The body of the resistor is protected with paint or plastic. Early 20th-century carbon composition resistors had uninsulated bodies; the lead wires were wrapped around the ends of the resistance element rod and soldered. The completed resistor was painted for color-coding of its value.
Thin film resistors are usually far more expensive than thick film resistors. For example, SMD thin film resistors, with 0.5% tolerances and with 25 ppm/K temperature coefficients, when bought in full size reel quantities, are about twice the cost of 1%, 250 ppm/K thick film resistors.
A common type of axial-leaded resistor today is the metal-film resistor. Metal Electrode Leadless Face (MELF) resistors often use the same technology.
Metal-oxide film resistors are made of metal oxides which results in a higher operating temperature and greater stability and reliability than metal film. They are used in applications with high endurance demands.
The following drawing is a very schematic representation of the components of the metal foil resistor, it is based on a study by Hero Faierstein , and regarding the metal used the Evanohm is based on a study by Mark Robinson, the study is called Strain Gage Materials Processing, Metallurgy and Manufacture Mark Robinson Hamilton Precision Metals1780 Rohrerstown Road Lancaster, PA 17601
A resistor may have one or more fixed tapping points so that the resistance can be changed by moving the connecting wires to different terminals. Some wirewound power resistors have a tapping point that can slide along the resistance element, allowing a larger or smaller part of the resistance to be used.
Where continuous adjustment of the resistance value during operation of equipment is required, the sliding resistance tap can be connected to a knob accessible to an operator. Such a device is called a rheostat and has two terminals.
High-resolution multiturn potentiometers are used in precision applications. These have wire-wound resistance elements typically wound on a helical mandrel, with the wiper moving on a helical track as the control is turned, making continuous contact with the wire. Some include a conductive-plastic resistance coating over the wire to improve resolution. These typically offer ten turns of their shafts to cover their full range. They are usually set with dials that include a simple turns counter and a graduated dial, and can typically achieve three-digit resolution. Electronic analog computers used them in quantity for setting coefficients and delayed-sweep oscilloscopes of recent decades included one on their panels.
There are various standards specifying properties of resistors for use in equipment:
Early 20th century resistors, essentially uninsulated, were dipped in paint to cover their entire body for color-coding. This base color represented the first digit. A second color of paint was applied to one end of the element to represent a second digit, and a color dot (or band) in the middle provided the third digit. The rule was "body, tip, dot", providing two significant digits for value and the decimal multiplier, in that sequence. Default tolerance was ±20%. Closer-tolerance resistors had silver (±10%) or gold-colored (±5%) paint on the other end.
A resistor of 100 ohms ±20% would be expected to have a value between 80 and 120 ohms; its E6 neighbors are 68 (54–82) and 150 (120–180) ohms. A sensible spacing, E6 is used for ±20% components; E12 for ±10%; E24 for ±5%; E48 for ±2%, E96 for ±1%; E192 for ±0.5% or better. Resistors are manufactured in values from a few milliohms to about a gigaohm in IEC60063 ranges appropriate for their tolerance. Manufacturers may sort resistors into tolerance-classes based on measurement. Accordingly, a selection of 100 ohms resistors with a tolerance of ±10%, might not lie just around 100 ohm (but no more than 10% off) as one would expect (a bell-curve), but rather be in two groups – either between 5 and 10% too high or 5 to 10% too low (but not closer to 100 ohm than that) because any resistors the factory had measured as being less than 5% off would have been marked and sold as resistors with only ±5% tolerance or better. When designing a circuit, this may become a consideration. This process of sorting parts based on post-production measurement is known as "binning", and can be applied to other components than resistors (such as speed grades for CPUs).
Resistances less than 100 Ω are written: 100, 220, 470. The final zero represents ten to the power zero, which is 1. For example:
Resistances less than 10 Ω have 'R' to indicate the position of the decimal point (radix point). For example:
000 and 0000 sometimes appear as values on surface-mount zero-ohm links, since these have (approximately) zero resistance.
More recent surface-mount resistors are too small, physically, to permit practical markings to be applied.
Many precision resistors, including surface mount and axial-lead types, are marked with a four-digit code. The first three digits are the significant figures and the fourth is the power of ten. For example:
Axial-lead precision resistors often use color code bands to represent this four-digit code.
The failure rate of resistors in a properly designed circuit is low compared to other electronic components such as semiconductors and electrolytic capacitors. Damage to resistors most often occurs due to overheating when the average power delivered to it greatly exceeds its ability to dissipate heat (specified by the resistor's power rating). This may be due to a fault external to the circuit but is frequently caused by the failure of another component (such as a transistor that shorts out) in the circuit connected to the resistor. Operating a resistor too close to its power rating can limit the resistor's lifespan or cause a significant change in its resistance. A safe design generally uses overrated resistors in power applications to avoid this danger.
There can also be failure of resistors due to mechanical stress and adverse environmental factors including humidity. If not enclosed, wirewound resistors can corrode.
Surface mount resistors have been known to fail due to the ingress of sulfur into the internal makeup of the resistor. This sulfur chemically reacts with the silver layer to produce non-conductive silver sulfide. The resistor's impedance goes to infinity. Sulfur resistant and anti-corrosive resistors are sold into automotive, industrial, and military applications. ASTM B809 is an industry standard that tests a part's susceptibility to sulfur.
An alternative failure mode can be encountered where large value resistors are used (hundreds of kilohms and higher). Resistors are not only specified with a maximum power dissipation, but also for a maximum voltage drop. Exceeding this voltage causes the resistor to degrade slowly reducing in resistance. The voltage dropped across large value resistors can be exceeded before the power dissipation reaches its limiting value. Since the maximum voltage specified for commonly encountered resistors is a few hundred volts, this is a problem only in applications where these voltages are encountered.