A resistor is a passive two-terminal electrical component that implements electrical resistance as a circuit element. In electronic circuits, resistors are used to reduce current flow, adjust signal levels, to divide voltages, bias active elements, and terminate transmission lines, among other uses. High-power resistors that can dissipate many watts of electrical power as heat may be used as part of motor controls, in power distribution systems, or as test loads for generators. Fixed resistors have resistances that only change slightly with temperature, time or operating voltage. Variable resistors can be used to adjust circuit elements (such as a volume control or a lamp dimmer), or as sensing devices for heat, light, humidity, force, or chemical activity. Resistors are common elements of electrical networks and electronic circuits and are ubiquitous in electronic equipment. Practical resistors as discrete components can be composed of various compounds and forms. Resistors are also implemented within integrated circuits.
Lead arrangements
Through-hole components typically have "leads" (pronounced ) leaving the body "axially", that is, on a line parallel with the part's longest axis. Others have leads coming off their body "radially" instead. Other components may be SMT (surface mount technology), while high power resistors may have one of their leads designed into the heat sink.
Fixed resistors
Carbon composition
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. The resistive element in carbon composition resistors is made from a mixture of finely powdered carbon and an insulating material, usually ceramic. A resin holds the mixture together. The resistance is determined by the ratio of the fill material (the powdered ceramic) to the carbon. Higher concentrations of carbon, which is a good conductor, result in lower resistances. Carbon composition resistors were commonly used in the 1960s and earlier, but are not popular for general use now as other types have better specifications, such as tolerance, voltage dependence, and stress. Carbon composition resistors change value when stressed with over-voltages. Moreover, if internal moisture content, such as from exposure for some length of time to a humid environment, is significant, soldering heat creates a non-reversible change in resistance value. Carbon composition resistors have poor stability with time and were consequently factory sorted to, at best, only 5% tolerance. These resistors are non-inductive, which provides benefits when used in voltage pulse reduction and surge protection applications. Carbon composition resistors have higher capability to withstand overload relative to the component's size. Carbon composition resistors are still available, but relatively expensive. Values ranged from fractions of an ohm to 22 megohms. Due to their high price, these resistors are no longer used in most applications. However, they are used in power supplies and welding controls. They are also in demand for repair of vintage electronic equipment where authenticity is a factor.
Carbon pile A carbon pile resistor is made of a stack of carbon disks compressed between two metal contact plates. Adjusting the clamping pressure changes the resistance between the plates. These resistors are used when an adjustable load is required, such as in testing automotive batteries or radio transmitters. A carbon pile resistor can also be used as a speed control for small motors in household appliances (sewing machines, hand-held mixers) with ratings up to a few hundred watts. A carbon pile resistor can be incorporated in automatic voltage regulators for generators, where the carbon pile controls the field current to maintain relatively constant voltage. This principle is also applied in the carbon microphone.
Carbon film
In manufacturing carbon film resistors, a carbon film is deposited on an insulating substrate, and a helix is cut in it to create a long, narrow resistive path. Varying shapes, coupled with the resistivity of amorphous carbon (ranging from 500 to 800 μΩ m), can provide a wide range of resistance values. Carbon film resistors feature lower noise compared to carbon composition resistors because of the precise distribution of the pure graphite without binding. Carbon film resistors feature a power rating range of 0.125 W to 5 W at 70 °C. Resistances available range from 1 ohm to 10 megaohm. The carbon film resistor has an operating temperature range of −55 °C to 155 °C. It has 200 to 600 volts maximum working voltage range. Special carbon film resistors are used in applications requiring high pulse stability.
Printed carbon resistors
Carbon composition resistors can be printed directly onto printed circuit board (PCB) substrates as part of the PCB manufacturing process. Although this technique is more common on hybrid PCB modules, it can also be used on standard fibreglass PCBs. Tolerances are typically quite large and can be in the order of 30%. A typical application would be non-critical pull-up resistors.
Thick and thin film
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