Flex Endurance Test Basics

November 6, 2022 Chris Wollbrink

While most wire installed in an aircraft is placed in static conditions, there are still several harnesses that must support regular flexing. Applications such as landing gears, wiring attached to panels/doors, and flight control surfaces have regular flexing. What is the best approach to selecting and verifying wires/cables for these applications? It turns out that there are several options. Read more

IEC 60851-5 Winding Wires – Electrical Property Test Methods

October 18, 2022 Laura Wishart

Winding wires, or magnet wires, are the wires used to construct coils in electronic components (transformers, relays, etc.) that generate the component’s magnetic field. These wires are primarily composed of a copper or aluminum conductor with a very thin layer of insulation. The insulation layer is as thin as possible to keep the wire cross-section small making it possible to squeeze the highest number of windings in the motor. Whereas most electrical wires are cylindrical, winding wires often have a rectangular cross-section profile; this allows for maximum cross-section during winding, thus reducing potential losses. Read more

Heat Shrink Tubing Tests

September 30, 2022 Laura Wishart

Heat shrink tubing is a very commonly used component in Electrical Wiring Integration Systems (EWIS). Just as with any other component of an aircraft wiring system, heat shrink tubing must withstand extensive severe testing before being approved for use. This article reviews select standards and methods for heat shrink tubing testing. Read more

Glycol and Silver-Plated Conductors

September 14, 2022 Michael Traskos

In this article, we discuss silver’s susceptibility to corrosion when exposed to glycol, its impact on aircraft, and ways to mitigate potential degradation. Read more

Heat Shrink Tubing Flammability Tests

August 31, 2022 Laura Wishart

As is the case with many components in electrical wiring, one of the most important properties of heat shrink tubing is its resistance to fire. Take a look at several methods used to determine and categorize the flame-resistant properties of heat shrink insulation tubing. Read more

Which Red Plague Testing is Right for My Application?

August 18, 2022 Michael Traskos

In short, red plague is corrosive galvanic corrosion that occurs between the silver plating and copper core of silver-plated copper wire. This has been a known issue since at least the 1950s and has popped up dozens of times since then with issues identified during initial product inspection. This article dives into the practical applications of red plague testing and how to identify and potentially mitigate the risks thereof. Read more

SAE April 2022 Update

July 25, 2022 Michael Traskos

After two unsuccessful attempts to meet in person, the SAE AE-8A/D committee met to update standards whose progress has been slowed over the last two years. Read more

AIR7502 and Future Implications for Aviation

July 8, 2022 Laura Wishart

The AIR7502 defines voltage levels for HV aircraft and components. The extent to which AIR7502 is incorporated into the aerospace industry remains unsure, but the implications of the document are worth considering even before the document’s use is determined. Read more

High Voltage Arc Tracking Requirements (Part 2)

June 18, 2022 Michael Traskos

In part 2 of this article series, we continue to discuss how arc track resistance testing as we know it must be re-evaluated as more HV systems with unique testing requirements lead the aviation industry moving forward. Read more

High Voltage Arc Tracking Requirements (Part 1)

June 6, 2022 Michael Traskos

Arc track resistance testing has been a staple of the aerospace industry for nearly 40 years. This originated from the issues raised in the 1980s with polyimide insulated wire. Since that time, test methods have evolved to assess and quantify the susceptibility of wires to carbon arc tracking and the ability to withstand electrical arcing events. Read more

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