This paper presents a case study of an intermittent audio failure analysis of a remote speaker-microphone module for a two-way radio. A root cause analysis was undertaken to identify probable causes of the intermittent failure, followed by a series of experiments to determine the strength and the intermittent audio failure load of cable components and the fully assembled cable. The combined experimental and finite element results demonstrated that the main contributor of the intermittent audio failure was the micro surface cracks on the copper conductor strands. In addition, the combination of the component materials and design of the cable have also contributed to the non-uniform state of residual stress induced in the copper conductors which have reduced the ability of the copper conductors to withstand the normal handling load under the influence of micro surface cracks.
