Elevated Temperature Aging

This test determines if the wire insulation can withstand a temperature aging test for a time period at a temperature greater than the insulation temperature rating. The wire must then withstand the bend and wet dielectric tests after the thermal exposure for the specimen to pass the test. This test is sometimes included as part […] Read more

Continuity of Conductors

AKA: Continuity of Conductor, Conductor Continuity A delivered wire spool is anticipated to include a single, continuous length of wire. While this may not be a single continuous conductor, any conductor discontinuities (where two conductor lengths are joined), should not have an impact on performance. The continuity of conductors test examines the conductor for flaws […] Read more

Thermal Endurance

The thermal endurance (or high temperature endurance) test determines the ability of the insulation of a firezone or similar wire to resist degradation due to exposure to high temperature. Degradation is judged by change in conductor resistance, cracking during bending, insulation dielectric breakdown, or decreased resistance to fluids. All of these points shall be tested […] Read more

Insulation Resistance – Connectors

This test examines the insulation resistance between connectors pins and the resistance between pins and the connector shell. This test is necessary to identify any manufacturing defects or specimen contamination. The pass/fail criteria conditions for this tests are connector specification specific and have a pin-to-pin and pin-to-shell resistance over 1MOhm. Read more

Continuity of Coating – Conductor

The conductor coating continuity test objective is to examine the conductor plating quality before it is subject to stranding or the insulation application process. As part of the test, the durability of the conductor coating is stressed with both mechanical and thermal stresses. General Procedures: For this test, a length of nickel plated conductor is […] Read more

Smoke Resistance

The smoke resistance test places a high current through the wire/cable to determines if the insulation/jacket will produce smoke. The current is increase on the specimen until the conductor temperature reaches the rated insulation temperature. This test can be adjusted to examine the impact of wires/cables or secondary protection in the same harness. This of […] Read more

Marking Durability

This test may also be referred to as Durability of Identification, Durability of Marking, or Durability of Wire Manufacturer’s Color and/or Identification. The long-term readability of wire/cable identification is important for supporting EWIS maintenance operations. A wire/cable with an easily identifiable circuit identification will make it easier to identify the correct circuit in need of […] Read more

Wicking

The wicking test focuses on the wire insulation’s propensity for drawing fluids into the wire. This can be a concern particularly for applications in which a wire/cable may be regularly exposed to fluids (e.g. wheel well of an aircraft). This test is not common on most wire types, but is found within the MIL-W-81044 (Polyalkene […] Read more

Seamless Verification

When wire harnesses are installed into aircraft, they may be pulled through structure, against electrical equipment, and other wire harnesses. In these scenarios, wire/cable constructions with an extruded surface will experience less damage than those wire/cable constructions with a non-uniform (non-smooth) surface. The non-uniform surface is common for tape-wrapped insulation constructions. The Seamless or Smooth […] Read more

Insulation Shrinkage

When wire/cable insulation shrinks, the insulation can pull back from a wire termination location. If the wire/cable termination is intended to be environmentally sealed, the insulation shrinkage can create the potential for exposed conductor which may lead to shorting or arcing. In operational environments, insulation shrinkage may also create splits in the wire/cable insulation caused […] Read more

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