To study the failure rate of electrical components under the limitation of physical material properties, a factor influence analysis and control method was established. The physical limitations of electrical component failures were first discussed. Then, an analytical expression for the failure rate distribution was established, and the influence of factors on the failure rate was discussed. Finally, a failure rate control scheme was constructed. Based on the failure types and influencing factors of electrical components, a 12-dimensional factor space and an analytical expression for the failure rate distribution were constructed. The characteristics of the failure rate of electrical components were obtained by deriving the analytical expression. Temperature has an exponential effect on the failure rate, current density has a square effect, and electric field strength may also have an exponential effect in dielectric breakdown. Factors such as substrate current and humidity also have corresponding effects. Accordingly, a three-level failure rate control scheme was established, with the cost increasing and the effect decreasing in turn. Case studies obtained the influence of factors on components, and determined key failure rate change thresholds such as temperature 340 K and activation energy 0.6 eV. It provides a method for analyzing the failure characteristics of electrical components considering physical limitations.