The reason for the NVIDIA RTX 4090 power connector fire: Cheap solder and double-layer cable?

La raison de l'incendie du connecteur d'alimentation de la RTX 4090 de NVIDIA : Soudure bon marché et câble double couche ?

Igor Wallossek from IL exposed the probable reason behind the burning and melting of the 12VHPWR adapter. The 16-pin power connector, part of the PCIe Gen 5 suite, can deliver up to 600W of power to a GPU using a single cable, making setup much simpler. Unfortunately for NVIDIA, several users have reported that the 12VHPWR connector needed to power the GeForce RTX 4090 has melted and/or burned. Additionally, partner card models appear to be more affected than their FE counterparts. It turns out that the reason behind all these mishaps is quite simple: Cheap welds.

NVIDIA partners used poor quality manual soldering to connect the twelve wires to the 12VHPWR socket. However, as Igor explains, a much better alternative would be to crimp them for a much cleaner layout, as shown below:

The crimp is more durable, keeping external factors such as oxygen and moisture…outside. Soldering leaves them open to rust, as well as bending and breaking. Welding uses alloys that tend to form rigid layers vulnerable to tension and tensile loading. In addition, the contact resistance is higher, which leads to an increase in thermal load, resulting in softening, embrittlement and breakage.

The other flaw comes down to the two-layer design, which causes the cable to bend at the intersection. A correct 90 degree bend wouldn't have caused the thermal or tension issues we saw all over Reddit.