View Latest Blog Entries
Testing & Assessment Certification Standard & Regulation Aging Wires & Systems Maintenance & Sustainment Protection & Prevention Management Conference & Report Research Miscellaneous Arcing
Popular Tags
Visual Inspection High Voltage AS50881 MIL-HDBK MIL-HDBK-525 FAR Electromagnetic Interference (EMI) AS4373 Maintenance FAR 25.1707 Wire System Arcing Damage
All Tags in Alphabetical Order
2021 25.1701 25.1703 abrasion AC 33.4-3 AC 43 Accelerated Aging accessibility ADMT Aging Systems AIR6808 AIR7502 Aircraft Power System aircraft safety Aircraft Service Life Extension Program (SLEP) altitude arc damage Arc Damage Modeling Tool Arc Fault (AF) Arc Fault Circuit Breaker (AFCB) Arc Track Resistance Arcing Arcing Damage AS22759 AS22759/87 AS23053 AS29606 AS4373 AS4373 Method 704 AS50881 AS5692 AS6019 AS6324 AS81824 AS83519 AS85049 AS85485 AS85485 Wire Standard ASTM B355 ASTM B470 ASTM D150 ASTM D2671 ASTM D8355 ASTM D876 ASTM F2639 ASTM F2696 ASTM F2799 ASTM F3230 ASTM F3309 ATSRAC Attenuation Automated Wire Testing System (AWTS) Automotive Avionics backshell batteries bend radius Bent Pin Analysis Best of Lectromec Best Practice bonding Cable Cable Bend cable testing Carbon Nanotube (CNT) Certification cfr 25.1717 Chafing Chemical Testing Circuit Breaker circuit design Circuit Protection cleaning clearance Coaxial cable cold bend collision comparative analysis Compliance Component Selection Condition Based Maintenance Conductor Conductor Testing conductors conduit Connector connector installation Connector rating connector selection connector testing connectors contacts Corona Corrosion Corrosion Preventing Compound (CPC) corrosion prevention Cracking creepage D-sub data analysis data cables degradat Degradation Delamination Derating design safety development diagnostic Dielectric breakdown dielectric constant Dimensional Life disinfectant Distributed Power System DO-160 dry arc dynamic cut through E-CFR electric aircraft Electrical Aircraft Electrical Component Electrical Power Electrical Testing Electrified Vehicles Electromagnetic Interference (EMI) Electromagnetic Vulnerability (EMV) Electrostatic Discharge EMC EMF EMI EN2235 EN3197 EN3475 EN6059 End of Service Life End of Year Energy Storage engines Environmental Environmental Cycling environmental stress ethernet eVTOL EWIS certification EWIS Component EWIS Design EWIS Failure EWIS sustainment EWIS Thermal Management EZAP FAA FAA AC 25.27 FAA AC 25.981-1C FAA Meeting failure conditions Failure Database Failure Modes and Effects Analysis (FMEA) FAQs FAR FAR 25.1703 FAR 25.1707 FAR 25.1709 Fault fault tree Filter Line Cable Fixturing Flammability fleet reliability Flex Testing fluid exposure Fluid Immersion Forced Hydrolysis fuel system fuel tank ignition Functional Hazard Assessment functional testing Fundamental Articles Fuse Future Tech galvanic corrosion Glycol Gold Gold plating Green Taxiing Grounding hand sanitizer handbook Harness Design harness protection hazard Hazard Analysis health monitoring heat shrink heat shrink tubing high current high Frequency high speed data cable High Voltage High Voltage Degradation HIRF History Hot Stamping Humidity Variation HV connector HV system ICAs IEC 60851 IEC60172 IEEE immersion insertion loss Inspection installation installation safety Instructions for Continued Airworthiness insulating material insulating tape Insulation insulation breakdown insulation resistance insulation testing interchangeability IPC-D-620 ISO 17025 Certified Lab ISO 9000 J1673 Kapton Laser Marking life limit life limited parts Life prediction life projection Lightning lightning protection liquid nitrogen lithium battery lunar Magnet wire maintainability Maintenance Maintenance costs Mandrel mean free path measurement mechanical stress Mechanical Testing MECSIP MIL-C-38999 MIL-C-85485 MIL-DTL-17 MIL-DTL-23053E MIL-DTL-3885G MIL-DTL-38999 MIL-E-25499 MIL-HDBK MIL-HDBK-1646 MIL-HDBK-217 MIL-HDBK-454 MIL-HDBK-516 MIL-HDBK-522 MIL-HDBK-525 MIL-HDBK-683 MIL-STD-1353 MIL-STD-1560 MIL-STD-1798 MIL-STD-464 MIL-T-7928 MIL-T-7928/5 MIL-T-81490 MIL-W-22759/87 MIL-W-5088 MIL–STD–5088 Military 5088 modeling moon MS3320 NASA NEMA27500 Nickel nickel plating No Fault Found OEM off gassing Outgassing Over current Overheating of Wire Harness Parallel Arcing part selection Partial Discharge partial discharge at altitude Performance physical hazard assessment Physical Testing polyamide polyimdie Polyimide-PTFE Power over Ethernet power system Power systems predictive maintenance Presentation Preventative Maintenance Program Probability of Failure Product Quality PTFE pull through Radiation Red Plague Corrosion Reduction of Hazardous Substances (RoHS) regulations relays Reliability Research Resistance Revision C Rewiring Project Risk Assessment S&T Meeting SAE SAE Committee Sanitizing Fluids Secondary Harness Protection separation separation distance Separation Requirements Series Arcing Service Life Extension Severe Wind and Moisture-Prone (SWAMP) Severity of Failure shelf life Shield Shielding Shrinkage signal signal cable Silver silver plated wire silver-plating skin depth skin effect Small aircraft smoke Solid State Circuit Breaker Space Certified Wires Splice standards Storage stored energy superconductor supportability Sustainment System Voltage Temperature Rating Temperature Variation Test methods Test Pricing Testing testing standard Thermal Circuit Breaker Thermal Endurance Thermal Index Thermal Runaway Thermal Shock Thermal Testing tin Tin plated conductors tin plating tin solder tin whiskering tin whiskers top 5 Transient Troubleshooting TWA800 UAVs UL94 USAF validation verification video Visual Inspection voltage voltage differential Voltage Tolerance volume resistivity vw-1 wet arc white paper whitelisting Winding wire Wire Ampacity Wire Bend Wire Certification Wire Comparison wire damage wire failure wire performance wire properties Wire System wire testing Wire Verification wiring components work unit code

Getting the Right Data


How important is it to have the right data on your wire and cable products? For those seeking qualification to a product standard, having test data that matches the requirements is important. Without this data, qualification cannot happen. But what about the products that fall outside of industry standards? How many tests are necessary to prove performance and product airworthiness?

Several past articles directly covered the physical, functional, and maintenance test factors that should be considered. Left out from these articles was how far a wire/cable assessment should go.

Wire and Cable Testing
Anyone can claim their wire/cable is aerospace ready, but without supporting data, the claims are hollow. Get the testing you need to prove product performance. Contact Lectromec.

Basic Wire

A good basis for any basic wire for aerospace applications is the AS22759. Wires based on this standard are among the most common wires use in aerospace (many OEMs have general airframe wire that closely mirror this standard). Because of its wide adoption, this standard and the slash sheets (the configurations of wire gauge, conductor plating, and insulation type) cover a wide range of applications in aircraft environments. The following table provides a summary of performance ranges for the more modern constructions in the AS22759.



Abrasion Resistance

N/A or specified across operational temperature spectrum

Arc Track Resistance

N/A or < 10 wires fail post test examination

Dielectric Strength


Dynamic Cut Through

Gauge Dependent (> 25lbs for 20AWG at 23C)


Self-Extinguish: < 3s
No dripping of motel material

Fluid Resistance

Subject to more than 20 aerospace fluids without swelling or cracking

Forced Hydrolysis

N/A or 2000 hours (or more) at 70C

Humidity Resistance

15-day humidity cycling without Insulation Resistance change

Insulation Adhesion


Insulation Resistance

24AWG – 10AWG: 5GOhm for 1000ft
8AWG – 00AWG: 3GOhm for 1000ft

Low temperature bending

Rated to -65C

Maximum Temperature Rating

150 – 260 C

Notch Propagation

N/A or no propagation of notch to conductor after bending.


< 1% after exposure to elevated temperatures


Conductor dependent


26AWG-20AWG: 0.25 – 6lbs
18AWG-14AWG: 0.50 – 7lbs


Gauge dependent

The aerospace industry is set up such that each generation of components is more reliable than the last. Because of this, it is very difficult to justify ignoring any of these tests or accept performance reduction in any of these categories. The latest generation of wires/cables have served the industry well and regressing in performance is difficult.

However, there are plenty of unique wiring applications on aircraft and, so long as the performance decrease can be justified, and it can be established that it will not have an impact on overall aircraft reliability, the component will be acceptable.


To go beyond a single wire ran into a cable construction, there are two standards which provide a robust framework: NEMA25700 and AS6070. Those seeking guidance on general cable parameters should review Lectromec’s articles on AS27500. While AS27500 does provide a robust framework in which more than 1 million combinations exist, the test outlined in AS27500 does not provide sufficient guidance for those looking to evaluate the performance of a high-speed data cable; this falls into the AS6070 framework.

The AS6070 is a relatively new standard and the range of performance criteria is much smaller than that of the AS22759 wires. As of today (April 2018), only a few specification sheets have been identified. However, this is an ongoing effort and additional cable varieties are anticipated in the coming years.

The important elements to identify is that the AS6070 specification does provide guidance and recommendations on which methods should be used when evaluating high-speed data cables. These methods include velocity of propagation, surface transfer impedance, cross talk etc.


With all of the production variables and must be controlled, building a reliable, high-quality wire for aerospace applications is a true achievement. But without supporting data the claims are unsubstantiated, and the wire cannot be placed on the certified aircraft. Nothing is worse than a great product that cannot get to market.

To get past these roadblocks, Lectromec helps wire/cable producers prove the quality and performance of their products. With the capacity to perform 98% of all aerospace wire and cable tests in-house, you get the test data you need.

Michael Traskos

Michael Traskos

President, Lectromec

Michael has been involved in wire degradation and failure assessments for more than a decade. He has worked on dozens of projects assessing the reliability and qualification of EWIS components. Michael is an FAA DER with a delegated authority covering EWIS certification and the chairman of the SAE AE-8A EWIS installation committee.