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High Voltage Degradation High Voltage Systems HIRF History Hot Stamping Humidity Variation HV connector HV system ICAs IEC 60851 IEC60172 IEEE immersion impedance 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 6722 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-22992 MIL-DTL-23053E MIL-DTL-3885G MIL-DTL-38999 MIL-E-25499 MIL-F-5372 MIL-HDBK MIL-HDBK-1646 MIL-HDBK-217 MIL-HDBK-454 MIL-HDBK-516 MIL-HDBK-522 MIL-HDBK-525 MIL-HDBK-683 MIL-HDBK-863 MIL-M-24041 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 polyurethane Potting Power over Ethernet power system Power systems predictive maintenance Presentation Preventative Maintenance Program Probability of Failure Product Quality PTFE pull through quadrax Radiation Red Plague Corrosion Reduction of Hazardous Substances (RoHS) regulations relays Reliability removable contact Research Resistance Revision C Rewiring Project Risk Assessment S&T Meeting SAE SAE Committee SAE J1127 SAE J1128 Sanitizing Fluids schematic Scrape Abrasion 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 signal reflection 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 WAIC 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 Wireless wiring components wiring diagram work unit code

Our Testing Services

Attenuation (Insertion loss)
$2,460
Spec
EN3475 Method 806 AS85485 Section 4.7.2 ASTM D4566 Method 24 AS6070 Method 5.2.1 MIL-DTL-24643C Method 4.9.1 MIL-DTL-17 Method 4.8.8 MIL-PRF-39012 Method 4.6.24 MIL-T-81490 Method 4.7.3 MIL-DTL-24643D Method 4.9.01 USB 2.0 Method 7.1.17
Type
Electrical
For
Conductor

The purpose of the attenuation test is to measure the energy lost by transmitting a signal through a cable. The energy loss measurement quantifies the cable's resistance to electrical signal transmission.

Bend Test
$1,170
Spec
AS22759 Method 5.7.6 AS4373 Method 712 AS6070 Method 5.4.4 AS85485 Method 4.7.3 EN3475 Method 405 MIL-DTL-25038J Method 4.6.5 NEMA 27500 Method 4.3.11 ASTM B187 Method 11.1 EN6059 Method 402
Type
Physical
For
Insulation

This test is used to determine the insulation elasticity and propagation of damage through the wire/cable insulation.

Blocking
$1,350
Spec
ANSI/NEMA WC 27500 Section 4.3.15 AS22759 Paragraph 5.3.11 AS4373 Method 808 AS5382 Method 5.4.9 AS6070 Method 5.3.4 AS81044 Method 4.7.5.11 AS85485 Method 4.7.4 BSS7324 Method 7.7 BSS7324 Method 7.07
Type
Thermal
For
Insulation

This test determines if a finished wire specimen will block (stick to itself) when subjected to the rated temperature of the specimen. While on an aircraft, wires may be exposed to high temperatures and it important to check if the finished wire specimens are prone to blocking. At the end of the test, we will inspect the wire and examine for adhesion (blocking) of adjacent turns.

Cable Weight
$630
Spec
ANSI/ NEMA WC27500 Method 4.5 AS6070 Method 5.1.4
Type
Physical
For
Cable

Knowing the weight of every component on an aircraft, down to the last wire, is vital to good design. This test is to be used to evaluate the weight of a finished cable specimen.

Characteristic Impedance 
$1,570
Spec
AS6070 Method 5.2.2 ASTM D4566 Method 47 EN3475 Method 805 MIL-DTL-17 Method 4.8.7 MIL-DTL-24643C Method 4.9.3 MIL-T-81490 Method 4.7.5 MIL-DTL-17 Method 4.8.07 MIL-DTL-24643D Method 4.9.03 MIL-DTL-915 Method 4.6.3
Type
Electrical
For
Cable

This test measures the characteristic impedance of a cable defined as the resistance of a transmission line.

Cold Bend Test
$3,060
Spec
ANSI-NEMA-WC27500 Method 4.3.6 AS4373 Method 702 AS6070 Method 5.4.1 AS22759 Paragraph 5.7.3 AS81044 Method 4.7.5.16 AS85485 Method 4.7.19 BSS7324 Method 7.10 EN3475 Method 406 FED-STD-228 Method 2021 JES292 Method 63 J1128 Method 6.6 MIL-DTL-17 Method 4.8.19 MIL-DTL-24643C Methods 4.8.8 and 4.8.9 MIL-DTL-25038J Method 4.6.8 MIL-DTL-915 Method 4.5.5 MIL-STD-2223 Method 2004 MIL-W-81822 Method 4.6.21 NEMA HP100.1-1991 Method 7.2.10 ISO 6722 Method 5.10 AS23053 Rev A Method 5.07.1 EN3745 Method 406 EN60811 Method 504 IS 10810 Method 20 J1127 Method 6.05 J1128 Method 6.07 J2394 Method 6.2.7 J2394 Method 6.4.5 MIL-C-82621 Method 4.4.4.1 MIL-DTL-24643D Method 4.8.07 MIL-DTL-24643D Method 4.8.08 MIL-M-24041 Method 4.7.3.10 NASM 3036 Method 4.4.10
Type
Thermal
For
Insulation

This test determines the resistance of wire insulation to cracking at low temperature while being bent around a mandrel. Using a special cold chamber, we can condition the specimen at the low temperatures that can be experienced during flight and study how it reacts to the extreme conditions. This is a very good way to determine if the wire sample would be able to survive at these typical temperatures. At the end of the test, we will examine for any visible cracks then perform a wet dielectric test for assurance.

Contrast Measurement 
$2,870
Spec
AS22759 Paragraph 5.6.4 AS4373 Method 815 AS4373 Method 1001 AS6070 Method 5.6.2 EN3475 Method 706 BAC5152 Method 12.3 SS7333 Method 4.6.5
Type
Physical
For
Insulation

Also referred to as Contrast of Jacket or Contrast Test. The readability of a wire/cable is of critical importance for the proper installation, maintenance, and repair of the wiring system, thus the reason why UV laser marking of wires has become a widely used technology through the aerospace industry and has several benefits over traditional ink marking of wires/cables. The contrast measurement test examination evaluates the contrast of the UV laser marked area with the unmarked parts of the wire.

Diameter
$630
Spec
ANSI-NEMA-WC2700 Method 4.4 AS4373 Method 401 AS4373 Method 901 AS6070 Method 5.1.3 AS6324 Method 5.1.1.1 AS22759 Method 5.2.4 AS22759 Method 5.5.1 AS29606 Method 5.2 AS85485 Method 4.7.12 ISO 19642-2 Method 5.1.2 ISO 19642-2 Method 5.1.4 J1128 Method 5.3 ISO 6722 Method 5.1 MIL-DTL-32630 Method 4.7.2
Type
Physical
For
Wire, cable, or conductor

This test is typically used as a process control test to ensure that the measured diameter of a manufactured wire is within the range provided in the wire/cable specification. The wire/cable is measured in several locations and the average diameter is reported. For non-uniform cables, such as with twisted pairs, measurements are made both for the minimum and maximum diameter.

Dielectric Withstand – Dry
$740
Spec
AS6070 Method 5.2.16.1
Type
Electrical
For
Insulation

Evaluates the dielectric withstand capability of insulation per AS6070.

Flammability
$2,970
Spec
AITM Method 2.0005 ANSI -NEMA WC27500 Method 4.3.19 AS22759 Method 5.7.10 AS23053 Rev A Method 4.14 AS4373 Method 801 AS5382 Method 5.6.1 AS6070 Method 5.5.1 AS654 Method 5.3.12 AS81044 Method 4.7.5.18 AS85485 Method 4.7.13 ASTM D2671 Method 68 ASTM D876 Method 17-21 ASTM D3032 Method 18 EN3475 Method 407 FAR 25.853 Appendix F, Part I, Section a.3 FED-STD-228 Method 5221 MIL-DTL-25038 Method 4.6.10 MIL-DTL-32554 Method 4.6.9 MIL-DTL-32630 Method 4.7.6 MIL-DTL-81381 4.6.4.16 MIL-W-81822 Method 4.6.26 AS4373 Method 812 BMS 1352 Method 8.6 EN3844 Method 1 ESLU5T-1A263-AA Method 6.06 FMVSS 302 Method TP-302-03 JES292 Method 25 MIL-DTL-49055G Method 4.7.9 UL224 Method 5.11
Type
Chemical
For
Insulation

Flammability is perhaps one of the most common and most important tests performed on aerospace wiring. In general, a length of the wire/cable under test is placed in a draft-free chamber and hung free over a high-temperature flame for 30seconds - 15 minutes (specification dependent). A piece of tissue paper is placed under the sample to catch falling debris.

Humidity Resistance
$4,110
Spec
AS22759 Paragraph 5.7.8 AS4373 Method 603 AS6070 Method 5.3.3 AS81044 Method 4.7.5.22 AS85485 Method 5.15 EN3475 Method 412 MIL-DTL-81381 Method 4.6.4.19 ISO 6722 Method 5.21 BSS7324 Method 7.03 CHED-227A Method 4.2.2.2 SS7614 Method 3.4.25
Type
Environmental
For
Insulation

The humidity resistance test evaluates the impact of prolonged heat and humidity exposure to wire/cable insulation.

Insulation Stripping
$490
Spec
AS22759 Method 5.5.3 AS5768 Method 1 AS6070 Method 5.4.5
Type
Mechanical
For
Wire

The insulation stripping test evaluates the ability of insulation to be stripped from a wire sample without causing damage to the conductor.

Jacket Color
$940
Spec
AS6070 Method 5.1.2 MIL-W-81822 Method 5.6.15
Type
Physical
For
Insulation

Insulation color is often used to identify a wire or cable's system or function(s). The jacket color test evaluates the characteristics of an insulative jacket's color as compared to the limitations specified in the applicable standard.

Jacket Flaws (Spark Test)
$2,460
Spec
ANSI/ NEMA WC27500 Method 4.3.4 AS4373 Method 505 AS22759 Method 5.3.3 AS81044 Method 4.7.5.1 ASTM D3032 Method 13 FED-STD-228 Method 6211 J1128 Method 6.5 MIL-DTL-17 Method 4.8.3 MIL-DTL-24643C Method 4.9.9 MIL-DTL-25038 Method 4.6.13 MIL-DTL-49055G Method 4.7.3 MIL-STD-2223 Method 3002 SAE AS85485 §4.7.17.1 MIL-W-81822 Method 4.6.17 ISO 6722 Method 5.6 AS6070 Method 5.2.17 J1654 Method 5.2 MIL-DTL-17 Method 4.8.03 MIL-DTL-24643D Method 4.9.09
Type
Electrical
For
Insulation

The jacket flaws test (or spark test) aims to identify any defects in a wire/ cable's outer insulation that would allow an amount of leakage current.

Life Cycle
$22,140
Spec
AS22759 Method 5.7.5 AS23190 Method 4.7.4 AS4373 Method 807 AS6070 Method 5.3.1 AS654 Method 5.3.7 AS81044 Method 4.7.5.19 AS85485 Method 4.7.10 MIL-DTL-32554 Method 4.6.3 MIL-DTL-81381 Method 4.6.4.17 MIL-STD-2223 Method 4001 ISO 6722 Method 5.14 AS70991 Method 4.7.4 MIL-DTL-32630 Method 4.7.10 MIL-PRF-6106 Method 4.7.22
Type
Thermal
For
Insulation

The life cycle test (also referred to as the 'Multi-day heat aging test') seeks to assess short-term elevated temperature exposure to a wire/cable above the sample's temperature rating.

Marking Durability
$2,870
Spec
AS4373 Method 710 AS6070 Method 5.6.1 AS22759 Method 5.6.3 AS81044 Method 4.7.5.3 AS85485 Method 5.12 MIL-DTL-25038J Method 4.6.14 MIL-DTL-49055G Method 4.7.17 MIL-PRF-85045G Method 4.7.5.19 ISO 6722 Method 5.18 AS22759 Method 4.5.36 AS22759 Method 5.6.4 J2394 Method 6.4.12 NEMA HP-3 Method 6.1.6
Type
Mechanical
For
Insulation

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 evaluation/repair/replacement. If the identification has worn off, then debugging operations may require removing more equipment and/or demating more connectors.
The marking durability test seeks to evaluate the wire/cable identification after abrasion. The pass/fail criteria are based on the individual wire/cable specification but is primarily focused the readability of the wire/cable marks.

Mutual Capacitance
$1,040
Spec
AS6070 Method 5.2.4 ASTM D4566 Method 18
Type
Electrical
For
Cable

This test measures the funtional capacitance between a pair of insulated wires within an multi-pair cable.

Phase Delay
$1,040
Spec
AS6070 Method 5.2.13 ASTM D4566 Method 45
Type
Electrical
For
Cable

Phase delay is a measure of the delay in time a signal is emitted and when it is received at the other end. It is important that signal carrying cable adhere to a minimum phase delay to ensure timely and accurate function of the relevant system(s).

Resistance to Fluids
$17,930
Spec
AS22759 Method 5.7.7 AS23053 Method 5.11 AS4373 Method 601 AS4373 Method 711-4.5 AS6070 Method 5.3.2 ASTM D3032 Section 23 AS81044 Method 4.7.5.21 EIA-364 Method 10 EN3475 Method 411 FED-STD-228 Method 7021 J1128 Method 6.8 EN6059 Method 303 MIL-DTL-25038J Method 4.6.6 MIL-DTL-26482 Method 4.6.27 MIL-DTL-32554 Method 4.6.6 MIL-DTL-32630 Method 4.7.16 MIL-DTL-38999 MIL-STD-2223 MIL-W-81822 Method 4.6.25 ISO 6722 Method 5.17 Method 7.30 AS23190 revD Method 4.7.5 AS5385 Method 5.4.1 AS85485 Method 5.16 BSS7324 Method 7.31 EIA/TIA-455-12A Method 12A EN3745 Method 411 ESLU5T-1A263-AA Method 6.07 J1127 Method 6.07 J1128 Method 6.09 J2394 Method 6.4.10 MIL-DTL-17 Method 4.8.28 MIL-DTL-24643D Method 4.8.26 MIL-DTL-3885 Method 4.5.5 MIL-DTL-49055G Method 4.7.16 MIL-DTL-81381 Method 4.6.4.18 MIL-PRF-85045G Method 4.7.6.9 MIL-STD-810 Method 512.2
Type
Chemical
For
Insulation

In this test, a sample is exposed to a variety of aerospace fluids. The duration and temperature of the exposure varies and is defined by the selected test standard.

Thermal Shock
$1,970
Spec
AS22759 Paragraph 5.7.4 AS4373 Method 805 AS39029 Method 4.7.7 AS6070 Method 5.5.2 AS81044 Method 4.7.5.17 AS85485 Method 5.25 ASTM D3032 Section 21 EN3475 Method 404 MIL-DTL-25038 Method 4.6.12 MIL-DTL-32554 Method 4.6.2 MIL-DTL-32630 Method 4.7.9 MIL-DTL-49055G Method 4.7.7 MIL-PRF-55514 Method 4.8.19.1 MIL-STD-202 Method 107 MIL-STD-2223 Method 4004 MIL-STD-810 Method 510 NEMA 27500 Method 4.3.9 BSS7324 Method 7.51 MIL-PRF-39018 Method 4.6.16 MIL-STD-810 Method 503.7 MIS-41167T Method TS-C
Type
Thermal
For
Insulation

Temperature cycling can cause rapid degradation of wire/cable insulation integrity. This can manifest and insulation splits, cracks, and/or delamination. Often an overlooked test method for assessment, the thermal shock test proves and excellent means of assessing the construction quality of a wire or cable.

Unbalanced Pair to Ground Capacitance
$1,040
Spec
AS6070 Method 5.2.4 ASTM D4566 Method 22
Type
Electrical
For
Multi-Pair Cable

A capacitance unbalance bridge is used to measure the pair-to-ground capacitance of a wire pair inside of a multi-pair cable.

Velocity of Propagation
$950
Spec
AS6070 Method 5.2.15 ASTM D4566 Method 46 EN3475 Method 804 MIL-T-81490 Method 4.7.7
Type
Electrical
For
Conductor

The velocity of propagation (also known as the Phase Velocity) test measures the speed of electrical signal transmission down a wire/cable. The velocity of signal propagation is typically represented as a fraction of the speed of light in a vacuum and is primarily impacted by the wire/cable dielectric.

VSWR/ Return Loss
$1,170
Spec
AS6070 Method 5.2.12 ASTM D4566 Method 50 EN 3475 Method 812 MIL-DTL-17 Method 4.8.9 MIL-PRF-39012 Method 4.6.11 MIL-PRF-55339 C Method 4.5.9 MIL-T-81490 Method 4.7.4 MIL-DTL-17 Method 4.8.09
Type
Electrical
For
Cable

Return Loss is a relative measurement of the reflected signal on a cable. In an ideal system, no signal would be reflected, all of the power on a signal would be received by the load, and the return loss would be infinite. In real-life applications, there will always be at least some amount of the input signal reflected back on the cable.

Wrinkle Test
$320
Spec
AS4373 Method 709 AS6070 Method 5.4.3
Type
Physical
For
Insulation

This test is used to evaluate the quality of insulation and its ability to withstand wrinkling. Wrinkles can occur to insulation when bent back and forth frequently, eventually causing the insulation to deteriorate.