Plating Adhesion

Composite connectors (Class J and M) provide the benefit of a lightweight construction with limited drawbacks. To verify the connector plating in high temperature operation conditions, the plating adhesion test is performed. For this test, the connector under evaluation is immersed in oil at its operational temperature. It is then quickly cooled to room temperature […] Read more

Post Test Examination

The post test examination is a visual assessment commonly used after stressing the sample connector. This is an encompassing visual examination of physical nonconformities and possible effects of previously applied testing. This test is typically performed without the aid of magnification. Read more

Temperature Cycling

Connectors are cycled between a low temperature and high temperature environment, and the plating is examined. This is an examination to ensure that after temperature changes connectors do not display signs of peeling, blistering, flaking, and separation of plating or other damage detrimental to the operation of the connector. Read more

Ice Resistance

Through the service life of an aircraft there are thousands of electrical thermal cycles. Those connectors subjected to external conditions maybe become icy during flight. This ice resistance test examines a connector’s performance in icy conditions. In the test, mated connectors are immersed in water and then frozen to -65C for three cycles. At the […] Read more

Contact Engagement and Separating Force

The engagement force of a connector contact is an indicator of whether a good electrical connection is made. This test examines the contact engagement forces. For female type connectors, each socket is tested individually by using a male connector with only one pin installed in the appropriate position to mate with the socket under test. […] Read more

High Temperature Exposure with Contact Loading

For this test, contacts are removed and crimped to a wire and then reinstalled. An initial measurement of the axial location is made with a 2-pound axial load, a specified weight is suspended freely from the contact, and a monitoring circuit connected that senses discontinuities. The connectors are then placed within an oven at elevated […] Read more

Contact Walkout

For this test, a pin installed in the connector is crimped to a wire, and the wire is hung over a mandrel with a weight. The connector position relative to the mandrel then undergoes one hundred cycles, effectively stressing the installed pin. Two pins are tested per connector, and the pins in question must not […] Read more

Thermal Shock – Hermetically Sealed Connectors

The thermal shock test is applicable to hermetically sealed connectors. The connector undergoes successive cycles consisting of times submersed in hot and cold water baths. After cycling is complete the connectors are dried in a forced air oven, and to pass the examination, the connector must have sustained no damage detrimental to the operation of […] Read more

Shell Spring Finger Forces

Aerospace connectors are expected to withstand regular mating and unmating during maintenance, component replacement, etc. It is important that a connector be adequately secured when in use, but not so tightly mated as to hinder the ability to unmate for maintenance. The shell spring finger force test evaluates the force required to engage and separate […] Read more

Humidity Test

There are several locations in aircraft where electrical connectors are regularly subject to high humidity conditions. Even without high humidity conditions, thermal cycling can wear down connector seals and create paths for fluid ingress. The system level impact can vary from signal degradation to shorting and electrical arcing. This test examines a connector’s resistance to […] Read more

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