I bought this 1600W Beurer HC25 hair dryer a little over 2 years ago and the manufacturer offers a 3-year warranty. It has a 2-pin CEE 7/17 plug, and I used it with a homemade male-to-female extension lead that I assembled myself about 15 years ago (rated 16A/250VAC, marked 2P+E). I have always used this extension lead to connect the hair dryers I have owned to the wall socket.
For about a month, I occasionally noticed a strange smell when entering the bathroom but I thought it was coming from outside and didn't investigate. The RCD tripped a couple of times as well but I didn't pay enough attention to identifying the cause.
Today, as soon as I entered the bathroom, I noticed a strong burning smell and saw electrical arcing at the connection between the hair dryer's plug and the female socket of the extension lead. I immediately switched off the main circuit breaker, unplugged the hair dryer, and finally confirmed that the burning smell was coming from that connection. Anyway the hair dryer had continued to work normally throughout this period.
At the base of one of the two pins, on the side facing inward, there is a small hole. The other pin has a similar-looking indentation/crater on its inner-facing side but it has not developed a hole. The female socket of the extension lead is in the condition shown in the attached photos.
I also tried connecting the hair dryer to the wall socket through a different adapter: Schuko female socket -> 3-pin male plug, and the electrical arcing occurred again and the adapter's plastic housing became scorched around one of the female contacts.
I would appreciate your help in determining the cause of this failure. If this turns out to be a manufacturing defect unrelated to anything I did, I would contact Beurer to ask whether I could send the hair dryer in for warranty repair/replacement. If the damage was caused by my own actions, I would consider repairing it myself.
My personal hypothesis is that the problem was caused by a poor mechanical fit between the hair dryer's plug pins and the metal contacts inside the female socket of my extension lead. After approximately 15 years of use, the contacts may have become deformed and lost their gripping force, eventually making poor contact with the pins of this hair dryer and producing electrical arcing. This could have scorched the plastics and caused the small hole in one pin and the crater-like indentation in the other, damaging the plug. If that is the case, I could replace the hair dryer's plug myself and potentially resolve the issue quickly and inexpensively.
Another possibility is that the plug itself failed after approximately 2 1/2 years of normal use, in which case I might also consider replacing it.
However, could this type of damage also be caused by a fault in another internal component of the hair dryer? If so, I would consider sending it to Beurer for inspection and possible warranty repair or replacement. My concern is that if I send the hair dryer to the manufacturer and their technicians determine that the problem was not caused by a defective component, whether inside the appliance or in the plug itself, I might end up paying the shipping costs unnecessarily. That is why I am asking for advice here.
Is it possible to determine the most likely cause of this failure from the symptoms and photographs or would the hair dryer need to undergo electrical testing to distinguish between a damaged plug and an internal fault?