Military/Aerospace & High Reliability
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.
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
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.