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How to identify counterfeit electronics

15 January 2025
False cell phone battery bloat. Source: Adobe Stock

Falsely representing one's goods or services as another in order to defraud buyers or perpetrate other unlawful activities is known as counterfeiting. In the context of electrical components, "counterfeit" means any of the following: a product that is not authentic, a product whose materials or performance have been altered without prior notification, or a supplier provides a subpar component. Concerns about the prevalence of counterfeit electronics began when it was discovered that few counterfeit devices were used in systems critical to the military, aerospace, medicine, radiation detection, airport landing light systems and high-speed trains, all of which posed serious risks to the safety of the individuals involved.

Unauthorized copies of legitimate devices can be cloned, commented, repackaged, recycled or otherwise altered. Providing parts that are not up to grade or have defects is also considered counterfeiting. This includes reintroducing and selling "as is" through broker chains devices that were either rejected or produced in excess. Due to possibly diminished quality, unclear reliability and diminished performances, the counterfeit electronics display materials and traits that may cause serious hazards. This article will discuss how to identify such electronic components.

Identifying counterfeit electronic components

1. Visual inspection

During visual inspection, it is necessary to confirm all measurements, including actual body dimensions, lead spacing, component markings and mold cavities, to ensure that electronic components sizing measurements (height, length and width) match the product specifications documented on the output control module datasheet. Look for scratches, inconsistencies or irregularities on the component's surface. Counterfeiters may sand off original markings and re-mark components. Inspect leads or pins for signs of rework, such as scratches, corrosion or inconsistent plating.

2. X-ray inspection

Electronic component X-ray inspection enables vendors to view die frame and wire bond integrity as well as the part's inner workings. Contrary to popular belief, the inside of an electronic component is far more difficult to forge. In order to find inconsistencies, X-ray inspection compares the item in question to manufacturer standards using a reference part. X-rays can reveal discrepancies in internal structures, such as die size, wire bonding or voids that don’t match the original manufacturer’s specifications. You can also examine the integrity of lead connections. Counterfeit parts might have poor or irregular lead bonding.

3. Decapsulation and die inspection

To conduct decapsulation testing, a range of solvents, acids and bases are used to dissolve the mold material that covers the die. This enables suppliers to visually verify the electronic part for manufacturing errors by viewing its inner workings with a high-powered microscope. This involves removing the component's package to expose the die for inspection. The die can then be compared to known authentic parts to verify manufacturer logos, die markings and design patterns.

4. Electrical testing

Measure electrical characteristics like voltage, current, capacitance and resistance. If the values are inconsistent with the manufacturer’s specifications, the part may be counterfeit. Test the part in actual circuit conditions. Counterfeit components often fail to perform as intended under full load or stress conditions.

5. Scanning electron microscopy (SEM)

SEM provides highly detailed images of the surface and allows for the comparison of material quality, such as lead plating or die markings.

6. Comparing documentation and supplier validation

Cross-check the component’s physical and electrical characteristics against the manufacturer’s datasheet. Inconsistencies between the actual part and its datasheet can signal counterfeit components. Authentic components should have traceability paperwork, like certificates of conformance, batch numbers and purchase history.

7. Supplier validation

Buy components only from authorized or trusted distributors. Avoid sourcing from unknown or suspicious channels as they may be prone to selling counterfeit parts. Verify the component’s supply chain using secure and traceable documentation. Many manufacturers use barcodes or serial numbers to track and verify components. You can verify these numbers against the manufacturer's database to check authenticity.

8. Thermal and mechanical testing

Counterfeit components often use substandard materials that may fail under extreme temperatures or mechanical stress. Conducting these tests can reveal if the part meets the original specifications.

Cons of using counterfeit electronics

  1. System failures: Counterfeit components are typically manufactured using substandard materials or flawed designs, leading to premature failures. These failures can disrupt the normal functioning of devices or systems, causing costly downtime or even irreparable damage.
  2. Safety hazards: In critical systems such as medical devices, transportation and defense, counterfeit components can result in life-threatening malfunctions. For example, a counterfeit component in an aircraft’s avionics system could cause a system crash, jeopardizing passenger safety.
  3. Security breaches: Counterfeit electronics may also introduce security vulnerabilities. Malicious actors could embed malware or design flaws into counterfeit components, enabling cyberattacks, espionage or system sabotage.
  4. Increased repair and replacement costs: When counterfeit components fail, manufacturers must bear the costs of repairs, replacements and warranty claims. These costs can far exceed the savings initially gained from purchasing cheaper counterfeit parts, making it a financially unwise decision in the long run.
  5. Damage to brand reputation: Using counterfeit components can tarnish a company’s reputation. When systems fail, customers may lose trust in the reliability of the brand. This can result in lost business, legal action and long-term reputational harm.

Conclusion

The sale of counterfeit electronic components causes worry within the electronic manufacturing industry about real economic and innovative growth, as well as product performance issues for buyers (which can lead to increased maintenance costs and reduced revenue due to damage). Despite efforts by governments and companies to prevent counterfeit electronic parts from entering the market, many manage to get through.



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Discussion – 1 comment

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Re: Identification of counterfeit electronics
#1
2025-Jan-28 8:07 AM

'Battery bloat', as shown in the illustration, is a normal thing for lithium ion batteries.

I've had it happen to a Samsung phone purchased new from a Verizon store, as well as a Microsoft Surface Pro 4 computer purchased new from Best Buy. In fact, I've got the computer apart right now and I'm in the process of replacing the battery in it.

While I'm not a fan of either Verizon nor Best Buy, I don't think they would stoop to selling counterfeit products.

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