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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 Surface Verification test is a process control test used to ensure that smooth wrapped tape insulation has properly annealed without a visible outer edge or observable internal wrapping lines.
More information on the benefits of seamless wires/cables can be found here.
Our Process
Perform visual examination of the specimen. Record any anomalies or defects.
Place the specimen perpendicularly into the casting mount, and pour casting compound and allow it to harden.
Using increasingly finer grit sandpaper, polish the cross sectional surface of the specimen until completion with 600 grit sandpaper.
Under 200x magnification, investigate for signs of outer edges or visible spacing of insulation layers.
Record and report results.