View Latest Blog Entries
Testing & Assessment Certification Standard & Regulation Aging Wires & Systems Maintenance & Sustainment Management Conference & Report Protection & Prevention Research Miscellaneous Arcing
Popular Tags
Visual Inspection High Voltage AS50881 MIL-HDBK MIL-HDBK-525 FAR AS4373 Maintenance Electromagnetic Interference (EMI) 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 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 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

What does aircraft wire testing cost for AS22759/87?

Testing & Assessment

Aerospace wiring systems are often underappreciated by other aircraft system engineers for their complexity. Aerospace wires and cables, like all aerospace components, undergo a rigorous set of qualification tests before they can be placed on an aircraft. Many in the aerospace industry want to know what the cost of aerospace wire testing is. Wire tests vary depending on the particular type of wire and specification, but they all fall into one of four categories: electrical, thermal, chemical, or mechanical.

Here we discuss the testing that is involved in one of the more common modern wire constructions (AS22759/87) and the costs associated with it, as well as what is involved in a typical testing program. For information on the tests Lectromec performs and the price associated with those tests, we have added a test listing page.

Discussion of tests

Here are the 25 tests that make up the AS22759/87 (or for those old school engineers, MIL-W-22759/87).

# Test ID Test Type
1 Insulation Stripping Mechanical
2 Insulation Shrinkage Thermal
3 Thermal Index Thermal
4 UV Laser Marking Usability
5 Insulation Strip force Usability
6 Impulse Dielectric Electrical
7 Insulation Resistance Electrical
8 Spark Test Electrical
9 Dry Arc Propagation Resistance Electrical
10 Wet Arc Propagation Resistance Electrical
11 Fluid Immersion Chemical
12 Forced Hydrolysis Thermal/Chemical
13 Humidity Resistance Thermal/Chemical
14 Cold bend test Thermal/Mechanical
15 Dynamic cut-through at Temperature Mechanical/Thermal
16 Durability of Wire Manufacturer’s Color and/or Identification Mechanical
17 Flammability Chemical
18 Thermal Shock Resistance Thermal
19 Life Cycle Thermal
20 Blocking Thermal
21 Lamination Sealing Chemical
22 State of Sinter Chemical
23 Wrap Mechanical
24 Smoke Chemical
25 Tape Overlap Manufacturing

Sales Process

Typically, we start any process with a discussion with the client. This helps us better understand the client’s particular needs, and may help to identify tests that better represent the objectives sought. If the client already has a list of tests that needs to have performed, the request can be submitted to myself or; we are usually able to get a quote sent out within 24 hours.

After the quote is accepted and Lectromec receives a purchase order, the client ships the samples to Lectromec’s laboratory in Chantilly, Virginia. Once the samples are received, they are catalogued, assigned a unique internal tracking number, and stored in Lectromec’s climate controlled storage area.

The tests are then added to Lectromec’s testing schedule and the individual test samples are prepared.


Most AS22759/87 tests can be carried out in a couple of weeks. However, there are a couple of tests that can make a project run into several months, the main ones being the Thermal Index (#3) and the Forced Hydrolysis (#12) tests. Both of these tests require long-term elevated temperature exposure and subsequent evaluation. The Forced Hydrolysis testing requires at least 30 weeks of elevated temperature exposure. During this time, the samples are wrapped around a mandrel and submerged in a saline solution at an elevated temperature. Since the objective is to determine a wire’s long term survivability in a moist environment , it is necessary to ensure that a long duration test is performed.

The duration of the Temperature Index testing is longer than the forced hydrolysis test and dependent on the material performance. The samples are placed into an oven at a set elevated temperature and periodically assessed and mechanically stressed until failure occurs. The temperature is then reduced and the test is repeated, the goal being to determine the long-term temperature rating of the wire.


The completion of the 25 tests associated with the AS22759/87 comes to $28,000.00.

With each test, the client receives:

  • Testing performed by an ISO 17025 certified lab.
  • Technical assistance and engineering support from an experienced aerospace wire/cable test lab.
  • A complete report discussing the test results, pre-test and post-test photos, description of the test, equipment calibrations, and, if everything passes, Lectromec’s seal of approval.
  • If requested, a video of active parts of the tests (e.g. dry arc track resistance testing).
  • Regular updates on test results and project progress.

For those customers that have some internal testing capabilities and do not have a need for each of these tests, Lectromec’s test services are quite flexible and a test plan can be created to fill our client’s individual needs.

Looking for Customization?

Roughly half of the testing performed in Lectromec’s lab is customized for our customers’ particular needs. Often the standard tests don’t do justice to the aerospace wire performance characteristics. It is not uncommon to enhance the basic minimal requirements in order to prove better performance. This may be done when one manufacturer is comparing its product against that of another manufacturer. We have the range of equipment and technical expertise to address most custom needs, and if we do not, often we can recommend another lab that does.

Expectations of the Client

Once all of the tests are defined and Lectromec has received the purchase order, Lectromec will need a sufficient wire length for test performance. In the test listing above, roughly 500ft (~150m) of wire is needed.

All test samples are property of the customer. They can be returned if requested or Lectromec will maintain the test samples for at least two years.

Wrapping it up

The testing of any component that goes onto an aircraft is important and has its particular requirements. Lectromec has been working in aerospace wire and cable assessment for more than three decades and has the experience to address particular wire and cable testing needs. Please submit questions in the comment section below or contact Lectromec at

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. In September 2014, Michael was appointed as an FAA DER with a delegated authority covering EWIS certification.