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 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 resistance. 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, 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.[6] These resistors are non-inductive, which provides benefits when used in voltage pulse reduction and surge protection applications.[7] Carbon composition resistors have higher capability to withstand overload relative to the component's size.[8]
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.[8] They are also in demand for repair of vintage electronic equipment where authenticity is a factor.
