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Thanks Kontiki99, I will keep the idea in mind, but it is not practical in this case since the diode is about 3/8 inch square and sealed inside a metal hermetic housing. IR stuff, I know we shouldn't have to do this much sorting, however there are not many manufacturers that make big power...

With load and temperature cycling the cracks tend to grow leading to complete device failure.

We are having major problems with rectifier diodes (70 amp 200 volt DO5 devices). We are testing for solder voids by measureing heat retained in the diode after a power pulse, contamination and general construction by a biased temperature cycle. However we do not have a good test to detect...