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Military/Aerospace & High Reliability

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High-Reliability Ceramic Capacitors for Military, Aerospace and Defense Systems


Designing for Reliability in Harsh Environments

Military, aerospace and defense systems demand components that perform predictably under extreme conditions—temperature cycling, vibration, and high electrical stress—where failure can compromise the entire system.

High-reliability capacitors—qualified to MIL specifications and QPL (Qualified Products List) requirements—are engineered for these conditions. QPL-qualified components undergo extensive electrical, environmental, and life testing, along with strict process controls, to ensure repeatable performance and long-term stability in mission-critical applications.

Johanson supports mil/aero and defense designs with high-reliability MLCCs, combining proven QPL alignment with in-house screening and testing to help reduce risk, improve consistency, and meet stringent program requirements.

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What Makes a Capacitor High Reliability?

  • MIL-STD screening and qualification
  • Environmental and thermal stress testing
  • Lot traceability and controlled manufacturing
  • Stable performance across wide temperature ranges

Common Reliability Challenges in Aerospace Electronics

  • Capacitor failure due to thermal cycling
  • Mechanical stress from vibration and shock
  • Performance drift over long mission lifetimes
  • Electrical stress in high-power systems


Applications

Avionics Systems

Capacitors used in flight control, navigation, and communication systems must meet strict reliability and performance standards.

RF & Microwave Systems

Supports filters, matching networks, and RF front-end modules where signal integrity and stability are critical.

Power Supplies & Conversion

High-reliability MLCCs enable stable performance in high-voltage and high-power aerospace systems.

Satellite & Space Systems

Designed for long-duration missions where maintenance is not possible and component reliability is essential.


Johanson Advantages

  • U.S. Based Manufacturing
  • QPL Approved Supplier
  • In-house MIL-STD screening and testing
  • High-reliability MLCC portfolio for aerospace and defense
  • Specializes in custom solutions for application-specific requirements


FAQs

What are high-reliability capacitors?

High-reliability capacitors are components designed and tested to meet strict aerospace and defense standards, ensuring stable performance under extreme environmental and electrical conditions.

When are MIL-spec capacitors required?

MIL-spec capacitors are typically required in aerospace, defense, and other mission-critical systems where reliability, traceability, and environmental performance must meet defined standards.

What causes capacitor failure in aerospace applications?

Common causes include thermal cycling, vibration, electrical overstress, and long-term material degradation.


Resources:

Have unique design requirements or require additional information?

Contact our Applications Engineers at: Ask a Question.


Applications to Products Chart

Applications
RF Bypass/Decoupling
Connector/Cable Filters
Housing/Chassis Filters
Mains Filtering Certified
Power Conditioning/Rail Filtering
SwitchMode PowerSupply Filtering
EMI/RFI Filtering
DC Block/Coupling
Antenna & Impedance Matching
RF Filters (e.g. LC, Pi, BPF, LPF)
Microwave Circuits
Millimeterwave Circuits
Power Amplifier Matching
RF Circuit Matching
MMIC SubMount

Collaborative Design Products

Johanson Capstrates Embedded Capacitors, Variable Pitch Capacitors, Custom Substrates

Military Qualifications, Testing & Inspections

In-House Testing Capabilities

In addition to manufacturing, the Camarillo facility has a complete High Reliability department with in-house testing capabilities.

Comprehensive Mil-Standard Testing Groups A, B & C

Available as Necessary


Electrical & Mechanical Inspections

  • 100% Electrical Testing
  • Cap, DF, IR, DWV, Voltage Breakdown
  • 100% Visual Inspection (Mil 883 Class K or S Options)
  • Full Data on Serialized Units
  • Hot IR Testing
  • Temperature Capacitance Coefficient (TCC)
  • Temperature Voltage Coefficient (TVC)

Environmental Testing

Burn In / Voltage Conditioning

  • Life Testing
  • Class H, K or S Element Evaluation
  • HALT / HASS Testing
  • Humidity Testing
  • Moisture Resistance
  • Resistance to Solder Heat
  • Shear Test / Bond Pull Test
  • Bend Testing
  • Steam Age
  • Temperature Cycling
  • Thermal Shock Testing
  • Shock / Vibration Testing
  • Wire Bond Testing

Analytical Testing

  • Destructive Physical Analysis (DPA)
  • Radiographic Inspection
  • SEM Inspection
  • Solderability Testing
  • Acoustic Microscopy (Sonoscan) Inspection
  • XRF Analysis

RF & Microwave Testing Expertise

  • Vector Network Analyzer Measurements
  • Resonant Line Measurements for ESR at Frequency

Simulation software and designer libraries.


Available Termination Options

MLCC Termination Options (Replating of Commercial Products)

Termination Type Barrier to Prevent Solder Leaching RoHS Primary Applications
Ni/Sn Ni Yes All solder applications where RoHS is required. This is Johanson’s standard termination used by the largest number of customers. Most likely to be in stock at Johanson or at Johanson authorized distributors.
Ni/SnPb Ni No Military applications where the lead (Pb) mitigates Tin whisker growth.
Flexterm Ni/Sn Ni Yes Flexible terminations for high physical stress applications.
Flexterm Ni/SnPb Ni No Flexible terminations for high physical stress applications.
Ni/Au Gold Termination Ni Yes Parts are epoxied in place or a mix of solder and epoxy attachment is used. Controlled Au thickness to avoid Gold embrittlement issues when soldering. Premium price.
Cu/Sn (Copper barrier) Cu Yes This non-magnetic termination is best suited for application where very high inductance / magnetic fields are present. Use where RoHS is required. Most common non-magnetic termination.
Cu/SnPb (Copper barrier) Cu No This non-magnetic termination is best suited for application where very high inductance / magnetic fields are present.
PdAg None No No plating - solderable thick film PdAg alloy termination.
PtAg None Yes No plating - solderable thick film PtAg alloy termination. Premium price.

Single Layer Termination Options

Termination Barrier RoHS Notes
TiW/Ni/Au Ni Yes Chip & Au wire where capacitor is soldered in place or a mix of solder and epoxy attachment is used.
TiW/Au None Yes Chip & Au wire where capacitor is epoxy attached. Optimum termination for wirebonding. Cannot solder this chip as substantial leaching will occur.

Lead-Frame Termination Options

Material Nickel Underplate Solderable Notes
Ni None Yes Used in very high-temp applications
Cu/Ni/SnPb Ni No Typically used in military applications
CuSn6 Phosphor Bronze Ni No SnPb plate
Iron-Nickel Alloy Ni Yes Sn plate
Pure Silver Leads None Yes Used in very high power RF. Premium price.

Contact JOHANSON to quote your custom lead materials & types

If you have unique needs or require additional technical information, contact your Johanson Representative or submit a technical request on our website at: Ask a Question.