"On the side" I do a fair amount of repair work to guitar gear — Amplifiers, pedals, guitars, etc…
I've had a similar symptom occur on different repairs, and found the same root cause for each. But the physics behind how it's possible is baffling to me.
I hate that. I hate not understanding why.
Basically it goes like this….
"Customer" complains that amp sounds like cr*p. I will find that it's outputting a weak-ish signal. Not dead, but has no kick or punch to it like a proper guitar amp should. It'll sound muffled, sometimes buzzy, dead or lifeless.
I find it's a marginal connection, sometimes a cold solder joint, sometimes a weak jack, etc… but it's always a metal-to-metal connection in the signal chain. In other words, there's a series resistance added that shouldn't be there.
Here's what's puzzling. The cases I'm thinking of, the amp can be made to sound "right" by slamming it with an abnormally strong input signal. i.e. more voltage than usual. After that, it'll work for a while.
It's like the higher-than-normal voltage signal somehow punches through whatever is the 'bad' connection and makes it good. Nothing physically moves.
I know it sounds bizarre, but I've seen it too many times to not accept it as "real".
So what gives??? These are AC signals, so it's not like a thyristor type action. And we're talking about mV to a few volts amplitudes. Not the hundreds of volts found in tubes – These problems are in the signal chain. I've even found this to occur on foot pedals, which are (typically) 9V DC devices.
Best Answer
Congratulations, you've rediscovered the surprising electrical properties of a loose connection, which have historically played a major role in radio engineering.
In the 1900s, this phenomenon was used to make the first RF detectors, known as a coherer, and numerous variants have been made. The most basic coherer has a loose metal connection, and when an RF signal is received, the voltage across the marginal connection causes the connection to become good, and completes the circuit, thus detecting the signal. Simultaneously, it also means that the coherer is unable to detect a new RF pulse anymore, and it's needed to be "decohered" by mechanical shock, making the connection loose again.
TL;DR: Even after 100 years, there is no universally accepted mechanism on how a coherer works. What is generally known is that the marginal contact is a metal-oxide-metal connection, and applying a voltage, even less than 1 V, is effective to break this oxidation layer between the metal contacts. Proposed mechanisms include electrostatic force, mechanical force from localized heating, micro-welding, or semiconductor physics. The specific mechanism may vary from material to material.
The following selective quotes from the book Early Radio Wave Detectors by Vivian J. Phillips (1980) offered some explanation. The book is available at the Internet Archive. For more information, you may want to read the book. It's a fun read!
And on its principle of operation...
The Wikipedia article Coherer says the exact mechanism can involve deep physics.
And in the cited paper, it determined that, in the particular case of a metallic granular media, the micro-welding effect is responsible for the dramatic decrease in resistance.
I found another master thesis, Coherers, a review by Thomas Mark Cuff that speculates there may be some deep semiconductor physics going on here.