Metal Oxide Film Resistor : Construction, Working and Its ...

What is the difference between metal film and metal oxide resistors?

The difference between metal film and metal oxide resistor include the following.

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Metal Film Resistor

Metal Oxide Resistor Metal films are the most common type of resistor. Metal oxide resistors are also popular and often used for high-power applications. Metal films typically have a smaller tolerance. Metal films typically have a higher tolerance but they handle higher power ratings. These are cylindrical axial resistors. These are axial & fixed value resistors. These resistors are applicable where a more precise value and high tolerance value are necessary within a circuit. These resistors are used for high endurance applications. The frequency response of these resistors is about 100 MHz. The frequency response of metal oxide resistors is about 100 MHz. These resistors have good characteristics for stability, TCR & tolerance. In addition, these resistors feature high linearity & low noise properties due to a low voltage coefficient. These resistors will exceed both the resistor&#;s performance like carbon film & metal film for different properties like voltage rating, power rating, surge capacity, high-temperature operation & overload capabilities. The maximum temperature of the metal film resistor operates up to 150°C & with platinum sensors, they work up to 600°C. The temperature coefficient of the metal oxide resistor is approximately 300 ppm/°C.

Advantages

Metal Film Resistors have the following advantages:

High Precision: Film thickness is easy to control, the manufacturing process is mature, with stable performance.

Low Noise: The temperature coefficient of resistance is small, it is not easy to produce a microphonic effect.

High Stability: High purity ceramic core, film-coated on the surface, no oxygen in the air will not oxidize the surface of the resistor, it has good anti-vibration and anti-shock performance.

High Power Rating: Metal film resistors also have a high power-rating, which means they can be used in high-power applications. They tend to have a lower temperature coefficient than carbon film resistors, which makes them ideal for use in precision circuits where a low-temperature coefficient is essential.

Disadvantages

The disadvantages of metal film resistors include the following.

Metal film resistors are more expensive than carbon composition and carbon film resistors because there&#;s a higher cost to precision.

Metal film resistors have a limited power rating of 3 watts or less. If you require more power, you&#;ll need to use a wire wound resistor instead.

They are sensitive to temperature changes, both within their environment and in the current they conduct.

They need to be regularly maintained, cleaned, and checked to make sure they work correctly.

The resistor will fail before it reaches its maximum power rating if there is a sudden surge in current or voltage.

The metal film will erode over time due to high temperatures caused by prolonged use at higher power levels than those specified on the resistor itself

Metal film resistors can only operate up until temperatures around 200°C (392°F).

They are not suitable for use in high-frequency circuits because their parasitic capacitance limits them from being able to handle frequencies above about 100 MHz (Megahertz).

Where are Metal Film Resistors Used/ Applications?

The applications of metal film resistors include the following.

Metal-film resistors are used in almost every circuit where resistance is required, including power supplies and other circuits.

They are also used to protect sensitive electronic components from dangerous voltages.

Metal-film resistors have been around for a long time, but only in recent years has their popularity begun to increase. The reason for this is because they are less expensive than other types of resistors and they are very reliable. This means that they can be used in a wide variety of applications including automotive electronics and computer circuitry.

Its resistance to currents makes it useful in a variety of situations, from industrial equipment to consumer electronics.

These resistors are used in different types of equipment in different fields like Industrial, military Automotive, Professional audio & video.

Industrial Applications: Metal film resistors are commonly used in industrial equipment. They help regulate the flow of current and prevent damage by overheating. Metal film resistors are also frequently employed in appliances, as they help to protect motors and other components of the machines.

Consumer Electronics Applications: Metal film resistors are used in a wide range of consumer electronics, including cell phones, laptops, and televisions. They help regulate the current flow in these devices and prevent them from overheating when they are used for extended periods at high power levels.

What is the Difference Between Metal Film Resistor and Other Types of Resistors?

Metal film resistors are more precise than carbon composition or wire-wound resistors, but they are not as precise as thin-film resistors. There is a wider tolerance range for metal film resistors than most other types of resistors, but the tolerance can be adjusted by adjusting the process used to make them.

What should I know before selecting a metal film resistor?

There are many factors to consider when choosing a metal film resistor. Here are some considerations:

How much power will the resistor dissipate?

Is there an issue with temperature rise?

How accurately does the value need to be?

Does it need to work at high frequencies?

Is moisture resistance required?

How Much Power Can I Use With a Metal Film Resistor?

The amount of power that can be used with a metal film resistor depends on the size of the resistor and its temperature rating. A smaller resistor will have a lower power rating than a larger resistor because it will have less surface area over which to dissipate heat. As temperatures rise, power ratings drop because it becomes harder for heat to dissipate through the air or other means.

Thus, if you&#;re looking for a way to add resistance to your circuit without spending a lot of money, metal-film resistors may be just what you&#;re looking for. They are very durable and dependable, which means that you can use them for years without having to replace them or fix them often. Even though metal film resistors aren&#;t cheap, they do make up for their cost by being able to stand up to harsh conditions and still perform well. Here is a question for you, what is a metal oxide resistor?

Metal Film Resistor : Construction, Working & Its Applications

Metal film resistor is the most common type of resistor used in electronics. They have been widely used since their development in the s, and are very popular for their consistency and accuracy. This is a type of resistor that has a metal oxide film deposited on the surface of a ceramic core. This is different from carbon film resistors, which have a layer of carbon instead of metal.

Metal film resistors have better performance than carbon or wire wound resistors. They are also more dependable and reliable than other types of electronics parts. For these reasons, metal film resistor is often used as replacements for other types of electronic components.

Metal Film Resistor Definition:

A metal film resistor is a passive two-terminal electrical component. It is designed to provide a specific resistance. The metal film resistor is constructed by depositing an insulating layer of oxide or nitride, which is then covered with a resistive metal film and terminated with a second insulating layer, usually oxide. These components are used in active filters, precision circuits, and timing applications.

The metal film resistor symbol is similar to a normal resistor which includes two connecting terminals like anode and cathode shown below.

Metal Film Resistor Construction

Metal Film Resistors are made of a metal film on an insulating substrate, similar to a thin-film resistor. The metal is deposited by evaporation onto the substrate. The metal film is typically 0.1 µm or thicker and has a much higher resistance than the substrate.

The resistors are formed by screen printing carbon paste onto the substrate in a shape that cross-sections the metal film, creating two parallel conductors with a uniform gap between them. The resistor body is coated with an epoxy coating for environmental protection and insulation.

Metal film resistors are manufactured using a photolithography process that creates high-accuracy and low-tolerance resistors. Photolithography is a photographic process that transfers images to semiconductor wafers during integrated circuit development. Metal film resistors have resistance values ranging from 0.1 ohms to 100 MΩ, with tolerances of ±0.1% or less at operating temperature ranges from -55°C to 155°C.

Working

The working of a metal film resistor is similar to the normal resistor to restrict the flow of electric current through it. So, it functions as the resistive element for the flow of electric current. The ceramic substrate of this resistor does not let heat throughout it.

Specifications

The specifications of the metal film resistor include the following.

The availability of typical tolerance is ±0.1%, ±0.25%, ±0.5%, ±1% & ±2%,

Resistance value ranges from >1Ω < 10MΩ

Max resistor temperature is175 °C

Load life (% change over h) is 1

Voltage coefficient is 0.0 %/V

Max noise is 0.2 µV/V

Temperature coefficient ±50 to ±100 ppm/°C

Metal Film Resistor Tolerance

Metal Film Resistor tolerance is the highest level of deviation from the nominal value of a resistor. This tolerance represents an accuracy standard for resistors, and it determines how much the measured resistance will vary from the ideal resistance. The tighter the tolerance, the more accurate your measurement will be.

The tolerance of a metal film resistor is the amount the resistance of the resistor can vary from its nominal value. This is usually expressed as a percentage, and can be calculated using the formula:

(Measured Value &#; Nominal Value)/Nominal Value)×100

If you measure 10kΩ and it has a 5% tolerance, then you know that tolerance is 500Ω. The highest possible value would be 10.5kΩ and the lowest possible value would be 9.5kΩ.

Metal Film Resistor Power Rating

The maximum power a resistor can handle is known as the power rating for that resistor.

The power rating is determined by how much heat the resistor can take before it fails. Heat causes the resistance in the resistor to rise, which causes it to dissipate more power, which causes it to get hotter, and so on. If this process runs away, the resistor&#;s temperature rises quickly and it fails catastrophically.
The maximum power (Pm ) a Metal Film Resistor can handle is calculated by dividing the maximum working voltage (Um ) by the resistance value (R):

Pm = Um/R

Metal Film Resistor Size Calculation

The size of a metal film resistor can be calculated from its power rating.

After the power rating (power = voltage x current) and the maximum possible temperature rise are known, the resistor size can be calculated by adding the thermal resistance RTH of the resistor to the thermal resistance RθJA of the mounting surface.

Rth = (TJ &#; TA)/Pd

Here, Rth is thermal resistance

&#;Tj&#; is Junction temperature

&#;TA&#; is ambient temperature

&#;Pd&#; is power dissipation

Size limitation is given by:

RTHmax = (TJmax &#; TA)/Pd

Resistor size = Rthmax + RθJA

Metal Film Resistor Color Code

The color code for metal film resistors consists of three bands and a fourth band indicating tolerance.
The first two bands indicate the first two digits of the value.

The third band indicates the number of zeros following those first digits. For example, if the third band is red, there are two zeros following the first two digits. If it is gold, there are five zeros following those first two digits.

The fourth band indicates tolerance in percent. A brown or red band represents a 1% tolerance, while a gold or silver band represents a 10% tolerance.

If additional bands are present, they typically indicate temperature coefficient, but this varies based on the manufacturer and part number.

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Carbon Film Resistors Vs Metal Film Resistors

Invented in the year by Boykin, Resistors are widely used in almost all electronic circuits today. Resistors can be defined as a device that resists the flow of current flowing through itself, back when it was introduced the size of the resistors was very huge and the tolerance value reached as high as 10%. Furthermore, they were usually made of compressed carbon. Cut to the present time, resistors are often made with metal films and is available in small SMD packages with a tolerance value as low as 2% or even less in case of precision resistors. Some of the leading manufacturers of resistors in India are Carmet, KWK, Epcos India Pvt Ltd. and more. If you didn&#;t know, India makes up for some 34% of the demand for passive components like resistors by manufacturing them the rest are imported.

 

If you are interested to know more about Resistors Working and Characteristics then you can try reading this article. In this article, we will discuss the difference between Carbon Film Resistors and Metal Film Resistors.

 

Brief Intro to Resistors

The word Resistor is born out of the word &#;resist&#;, which means to withstand the effect. A resistor resists, directs, or regulates the flow of electrons that pass through it. This is done with the help of the conductive material that it is made out of. The name makes sense now, doesn&#;t it?  Resistors are connected in parallel and series as per the current and voltage requirements.

 

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These little devices regulate, attenuate, or reduce voltage and current, but do not have a source of power on their own. The current flows through them in a regulated manner leading to a loss of energy in the form of heat. Two resistors connect and pass on a current between them only when there is a potential difference. Yes, they follow ohm&#;s law. We&#;re sure, you must have heard of this law. Well, it is something to swear by in the world of electronics and electrics.

 

Moving on, there is an endless list of different types of resistors like composition type, film type, and wire-wound type of resistors depending on their characteristics. To name a few of these characteristics - physical size, reliability, temperature rating, noise, temperature coefficient, and voltage coefficient.

Well, you know the drill. However, we are here to talk about two very important kinds of resistors that are capable of transforming your electronic circuits.

 

Carbon Film Resistor

Before we begin talking this, let us first contemplate what film resistors are. Well, these are simply those resistors that are formed after depositing oxide film or pure metals on a substrate or some insulating ceramic. The layer is extremely thin and the whole process is known as sputtering.

 

Carbon Film Resistor is prepared by depositing carbon film on the ceramic substrate which is an insulator. The electric current is blocked to a certain extent by the carbon film. On the contrary, the insulating ceramic doesn&#;t let heat through it, which in turn makes the carbon film resistor capable of withstanding massive temperature without being damaged. Available between 1ohm to 1 Mega ohm, Carbon film resistors have a decent tolerance value.

Talking about the negative temperature coefficient of resistance - the property of observing a decrease in resistance in reaction to an increase in temperature, these have a high negative temperature coefficient making them susceptible to decreasing resistance as the temperature rises.

 

Also, these resistors are available at low cost and have a very low tolerance. They operate in a wide range. Applications of Carbon film resistors are widely in X-Rays, power supplies, and RADAR.

 

Metal Oxide Film Resistor

In contrast to carbon film resistors, metal oxide film resistors use thin metal oxide films to coat an insulating ceramic rod. The compound made out of oxygen atoms and other atoms works wonders in forming a coating film.  However, metal oxide film resistors are made using tin oxide.  Also, antimony oxide is added to yield better resistance.

 

Moving on, these resistors are capable of withstanding high temperatures due to the presence of an insulating ceramic rod that doesn&#;t let heat pass through itself. At the same time, metal oxide resists the current. The more the antimony, the more is the resistance. But that doesn&#;t even end here, metal oxide film resistors heavily depend on the thickness of the metal oxide and the width of the helical metal oxide film cut for good resistance. The width of the helical metal oxide film cut and the thickness of the metal oxide are inversely proportional to the resistance.

 

Wondering what makes them special? As a matter of fact, resistors come at a very low cost and withstand high temperatures while making very less sound. Also, they are small in size along with high reliability and stability. Win-Win!

 

Carbon Film Resistor Vs Metal Oxide Film Resistor

Well, engineers are always in a dilemma about which one to use. Whether to use the carbon film resistor or the metal oxide film resistor. Alright, let us break it down for you, bit by bit. After all, you want your experiments to go spot on, now don&#;t you?

 

According to our comparison between Metal Film and Carbon Film Resistors, we feel Metal-oxide film resistors triumph over carbon film resistors due to certain properties that they possess which are discussed below.

 

Voltage and Temperature Coefficient

Metal Oxide film resistors have a better voltage coefficient and temperature coefficient than carbon film resistors. The voltage coefficient is the change in resistance with respect to the change in the voltage. In short, it is the ratio of the change in resistance to the change in the voltage. As a matter of fact, metal oxide film resistors work in a wide resistance range and can withstand a higher temperature than the carbon film resistors.

 

Noise Design Metal Oxide film resistors have low noise design as compared to the carbon film resistors. They keep current to the minimum. Thus, ensuring less noise.

 

If you didn&#;t know, metal oxide film resistors make up for better resistors for radio frequency or high-frequency application in comparison to the carbon film resistors.

 

Tolerance The minimum tolerance level of carbon film resistors of 2% doesn&#;t stand a chance against that of metal oxide film resistors which can go as low as 0.1%.

 

Size

Finally, the size of the metal oxide film resistors is smaller as compared to the carbon film resistors making them a better option to go for.

Now that we have done our bit in making you see the nuances of both the kinds of resistors, you can take your pick, folks. Happy nerding it out.

Resistors: Types And Applications

By H. Ward Silver    View In Digital Edition  

An ohm is an ohm, right? Not so fast &#; there are many different types of resistors. To insure that your circuit works and stays working, use the right type of resistor. In this article, you'll learn about the common types of resistors and their special characteristics.

Resistor Fundamentals

 

George Ohm.

Every conductor exhibits some resistance to the flow of electrical charge (except for superconductors). George Ohm discovered the exact relationship between voltage (V), current (I), and resistance (R), formulating the law that bears his name and is learned by every electronics student:

V = I x R or I = V / R or R = V / I

As electrons flow through a material in response to an electric field, they collide with the atoms that make up the material. The collision transfers some of the electron&#;s energy to the atoms, which vibrate in response. These vibrations result in an increased temperature of the material. The energy that heats the material is the power dissipated, calculated as:

Power (P) = I2 x R or P = V2 / R

A perfect resistor does not care whether the current flowing through it is AC or DC. The electrons collide with atoms going in either direction.

 

FIGURE 1. Resistors can be constructed in a number of ways to optimize power handling, stability, or size.

Nevertheless, practical construction details, as shown in Figure 1, create some parasitic effects, making an actual resistor act like the circuit model shown in Figure 2. The model describes how the actual resistor&#;s characteristics make its electrical behavior depend on frequency and on how voltage and current are applied to it.

 

FIGURE 2. This is a model of how a resistor actually behaves in a circuit. The type of resistor determines the importance of each component.

The series inductance, LS, is primarily created by the leads attached to the resistor. Notice that for the surface-mount resistor, there are no leads, which greatly reduces LS. The electrodes also form a very small capacitor, CP, that affects the resistor&#;s behavior at very high frequencies. Although the resistor&#;s coating is a very good insulator, current can still flow in very small amounts across the surface of the resistor as a leakage current, represented by RP. This becomes important when the resistor has a very high value or is used in a high voltage circuit.

Resistor Types

For a piece of conducting material to be made into a practical resistor, a pair of electrodes and leads are attached so that current can flow. The resistor is coated with an insulating material to protect the conducting material from the surrounding environment and vice versa. There are several different resistor construction methods and body styles or packages that are designed for a certain range of applied voltage, power dissipation, or other considerations.

Carbon Composition
Composition means that the resistive material is a mix of carbon and stabilizing compounds. The amount of carbon in the mix determines the resistance of the material. A small cylinder, like a pencil lead, is held between the two electrodes and coated with resin or phenolic, making a non-inductive resistor with low LS that is often used in RF circuits.

Carbon comp resistors are available with power ratings of 1/4 to 2 watts. They can also handle temporary overloads much better than film resistors because the heat is distributed evenly throughout the cylinder of resistive material. That makes them a good choice for circuits that protect against and absorb pulses and transients, for example. Unfortunately, these resistors are also strongly influenced by temperature and humidity and so are not good for circuits that depend on precise, stable resistance values.

Film Resistors
In a film resistor, the resistive material is a very thin coating of carbon or metal on an insulating substrate, such as ceramic or glass. The value of the resistance is determined by the thickness of the film and the amount of carbon or metal in it. These resistors are available with very accurate and stable values.

A drawback of film resistors is that they are unable to handle large amounts of power because the film is so thin. Overloads can also damage the film by creating &#;hot spots&#; inside the resistor, changing its value permanently. The value of film resistors is sometimes adjusted before sealing by cutting away some of the film with a laser, a process called trimming.

If the film is deposited on the inside of a tube, the trimming process creates a coil-like current path that raises the LS of the resistor. If your circuit operates at high frequencies, be sure the resistors you select have a low value of LS.

Surface-mount resistors are almost always film resistors. These resistors have no leads at all, so LS is very low. The film is deposited on a ceramic sheet. Because of their extremely small size, surface-mount resistors have very low power ratings &#; from 1/10 to 1/4 watt.

Wirewound
Common in power supplies and other equipment where lots of power is dissipated, a wirewound resistor is made just as you might expect. A high-resistance wire is wound on an insulating form &#; usually a ceramic tube &#; and attached to electrodes at each end. These are made to dissipate a lot of power in sizes from one-watt to hundreds of watts! Wirewound resistors are usually intended to be air cooled, but some styles have a metal case that can be attached to a heatsink or metal chassis to get rid of undesired heat.

Because the resistive material in these resistors is wound on a form, they have very high LS. For this reason, wirewound resistors are not used in audio and RF circuits. Be careful when using a resistor from your junk box or a grab bag in such a circuit!

Small wirewound resistors look an awful lot like film or carbon comp resistors. There is usually a wide color band on wirewound resistors, but not always. If you&#;re in doubt, test the resistor at the frequencies you expect to encounter. There are special versions with windings that cancel most of the inductance, but have a much higher CP that also affects the resistor&#;s performance above 50 kHz.

Ceramic and Metal Oxide
If you need a high-power non-inductive resistor, you can use cermet (ceramic-metal mix) or metal oxide resistors. These are constructed much like a carbon comp resistor, substituting the cermet or metal oxide for the carbon composition material.

Adjustable Resistors
There are many different types of adjustable resistors. The simplest are wirewound resistors with some of the wire exposed so that a movable electrode can be attached. The most common are adjusted with a rotary shaft as shown in Figure 3. The element provides a fixed resistance between terminals 1 and 3. The wiper moves to contact the element at different positions, changing the resistance between either end of the element and terminal 2.

 

FIGURE 3. A potentiometer (or pot) acts as a variable voltage divider by moving a wiper across the surface of a fixed-resistance element.

If an adjustable resistor has only two terminals (1 and 2 in the figure), then it is called a rheostat and acts as an adjustable resistance. Most rheostats are intended for use in high-power circuits with power ratings from several watts to several tens of watts.

If the adjustable resistor has three terminals, it is called a potentiometer or &#;pot&#; for short. Most pots are intended to act as voltage dividers and can be made into a rheostat by leaving terminal 1 or 3 unconnected. Miniature versions called trimmers mount on a circuit board and are used to make small adjustments or calibrate a circuit. They are available in single-turn or multi-turn versions.

Larger pots with 1/8&#; or 1/4&#; diameter shafts are intended for use as a user control. Pots are available with resistance values from a few ohms to several megohms and with power ratings up to five watts.

Like fixed-value resistors, the construction of the pot is important. Higher-power pots may have a wirewound element that has enough inductance to be unsuitable for audio or RF signals. Smaller pots, particularly trimpots, are not designed to be strong enough for use as a frequently-adjusted control. Most pots have relatively high values of CP, as well.

Pots are also available with elements that have a non-linear taper or change of resistance with wiper position. For example, a log taper pot has a resistance that changes logarithmically with shaft rotation. This is useful in attenuator circuits, for example. An audio taper pot is used to create a voltage divider that mimics the loudness response of the human ear so that volume appears to change linearly with control rotation.

Resistor Networks
In order to save space on printed circuit boards, resistor networks are often used. These are miniature printed circuits themselves, placing several resistors on one substrate. The resistors may be isolated from each other, share one common terminal, or be connected in series. There are a number of configurations that can be found in any component supplier&#;s catalog.

Power Dissipation and Voltage Ratings

After value, power dissipation is the next most important characteristic of a resistor. An overloaded resistor often changes in value over time and can often get hot enough to burn itself and surrounding components. Every circuit designer learns the smell of burnt resistor sooner or later!

The common rule of thumb is to calculate how much power the resistor will have to dissipate and then use the next largest size or a factor of two higher dissipation rating, whichever is larger. The power rating is based on unobstructed air circulation around the resistor. For resistors dissipating more than a watt, arrange nearby components so that air can circulate freely. If possible, mount power resistors horizontally so that convection cools all parts of the resistor equally.

Another important rating is maximum applied voltage. Voltages above this value may cause an arc between the resistor terminals! At high voltages, RP can also become significant, allowing current to leak around the internal resistance. High-voltage resistors must be kept clean. Fingerprints, oil, dirt, and dust all create unwanted current paths, lowering RP and increasing leakage or even arcing. This is why resistors for use in high-voltage circuits are long and thin with their terminals far apart &#; to minimize leakage and maximize the ability to withstand high voltage.  NV

HOW TO READ A RESISTOR

Learning the resistor color code (&#;Bad boys ravish ...&#;) is a rite of passage for electronics techs the world over. A handy Web guide is available at https://physics.ucsd.edu/neurophysics/courses/physics_120/resistorcharts.pdf or just type in &#;resistor color code&#; to an Internet search engine. Surface mount and power resistors may also have the value printed on their body as a three- or four-digit code with the final digit acting as an exponent. For example, &#;513&#; means 51 x 103 or 51KΩ.

TOLERANCE AND TEMPERATURE COEFFICIENT

Resistors have a nominal value and a tolerance (the amount of acceptable variation above or below the nominal value). Most resistors have a 1%, 5%, or 10% tolerance and you can find smaller or tighter tolerances. Which values of resistors are available is determined by the tolerance series. For example, in the 5% series, values are selected so that each is approximately twice the tolerance or 10% from the next highest or lowest value.

Resistors also change value with temperature. The relative change of resistance with temperature is called the temperature coefficient or tempco and it is specified as parts per million or ppm or as percentage change per degree Celcius of temperature change. A positive tempco means that resistor value increases with temperature. When designing and constructing sensitive circuits that use precision (1% or tighter tolerance) resistors, it is important to keep them at an even temperature.

CHOOSING RESISTORS

Here are some special applications that require special types of resistors. These aren&#;t hard and fast rules, but can guide your initial selection. For most circuits, plain old carbon film or carbon comp resistors will work just fine.

ESD and Transient Protection &#; Carbon composition, metal oxide (withstand short pulse overloads and low inductance)

Audio and Instrumentation circuits &#; metal film (low noise)

High Voltage &#; wirewound and metal oxide in high-voltage body styles

RF &#; carbon composition and metal oxide (low inductance)

Precision circuits &#; carbon or metal film (fixed value) and cermet (trimmers or controls)

Remember to consider what is important for your circuit &#; value, power or voltage, stability, cost &#; then look for the resistor type that meets those requirements.

 

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