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Our Testing Services

Our lab contains a wide range of electrical, mechanical, chemical, and environmental test capabilities that can be augmented, adjusted, or modified to meet the needs of your particular applications. The following are some of the services that Lectromec offers.

Abrasion Resistance
$1,570.00
Spec
MIL-DTL-24643C Method 4.8.1
Type
Mechanical
For
Insulation

The Abrasion Resistance test evaluates an insulation's ability to endure rotational abrasion.

AC Loss Characteristics and Permittivity of Solid Electrical Insulation
$1,600.00
Spec
ASTM D150 -11
Type
Electrical
For
Insulation

This test measures both permittivity and A/C loss of an insulation sample and uses these values to determine a variety of characteristics of said specimen.

Accelerated Ageing
$1,610.00
Spec
EN3475 Method 401
Type
Thermal
For
Insulation

Accelerated aging is a test to help predict the long term chemical and mechanical durability of wire/cable insulation materials. Subjected to temperatures in excess of their prescribed rating, insulating materials break down quickly so data that would take months and years to gather can be attained in mere weeks and days.

Accelerated Service
$2,770.00
Spec
MIL-DTL-24643C Method 4.8.2
Type
Electrical
For
Completed Cable

The accelerated service test evaluates the performance of a finished cable at electric overload conditions.

Accelerating Aging
$880.00
Spec
BSS7324 Method 7.1
Type
Thermal
For
Insulation

Accelerated aging is a test to help predict the long term chemical and mechanical durability of wire/cable insulation materials. Subjected to temperatures in excess of their prescribed rating, insulating materials break down quickly so data that would take months and years to gather can be attained in mere weeks and days.

Accessory Thread Strength
$560.00
Spec
MIL-DTL-38999 Method 4.5.22
Type
Mechanical
For
Connector
Adherence of Plating
$1,500.00
Spec
EN3475 Method 507
Type
Chemical
For
Conductor

The purpose of adherence of plating is to measures the effectiveness of adherence of the applied plating to conductor. Copper conductors are normally plated with pure metal coatings to improve the conductor performance and reduce resistivity.

Adhesion of Conductors
$490.00
Spec
MIL-DTL-17 Method 4.8.1.4
Type
Physical
For
Cable

The Adhesion of Conductors test measures adhesion of each conductor layer of a cable to the cable's dielectric core.

Adhesion of Nickel Coating
$570.00
Spec
AS4373 Method 405
Type
Chemical
For
Conductor

The adhesion of Nickel coating test evaluates the adherence of a nickel plating to an underlying copper/ copper alloy material.

Age Degradation
$1,200
Spec
MIL-W-81044
Type
Thermal
For
Insulation

Life cycling of polyalkene wire is a three step process that starts with placing the wire in a high temperature air circulated oven for a defined period of time. Sustained high temperature exposure is performed followed by mechanical and electrical tests.

Aging Stability
$1,110.00
Spec
MIL-DTL-17 4.8.16 MIL-DTL-2463C 4.8.35
Type
Thermal
For
Cable Jacket

The specimens are suspended in a heat chamber without touching one another or the walls for 7 days at the applicable test temperature. After the conditioning period, the specimens are removed from the heat chamber and conditioned at room ambient temperature for 4 hours minimum.

Altitude Immersion
$1,800.00
Spec
AS81824 Method 4.8.6.1 EIA-364-03 MIL-DTL-38999 Method 4.5.9
Type
Environmental
For
Connector

It is no surprise that aircraft components are expected to withstand rapid and extreme changes in altitude without loss of functionality. The altitude immersion test subjects a sample connector to such changes in altitude pressure and assesses its ability to maintain functionality.

Altitude-Low Temperature
$1,200.00
Spec
MIL-DTL-38999 Method 4.5.21 EIA-364 Method 105
Type
Thermal
For
Connector

Wired, mated, and assembled connectors are tested inside a pressurized chamber with the temperature reduced to simulate an altitude of 100,000 feet. The chamber's internal temperature is reduced to -65 °C and is maintained until the connector temperature stabilizes.

Attenuation, Attenuations (Insertion loss)
$1,400.00
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
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 lost measurement quantifies the cable's resistance to electrical signal transmission.

Bayonet Coupling Pin Strength
$640.00
Spec
MIL-DTL-38999 Method 4.5.17
Type
Mechanical
For
Connector

Coupling components have the potential to undergo high mechanical stress as a result of poor clamping, heavy wire harnesses, and maintenance operations. The intention of the bayonet coupling pin strength test is to assess the strength of the pins in each of the couplings. For this test, a static 50-pound load is applied to the coupling pins to determine if the coupling is structurally sound. The pass/fail conditions are based off of consistent electrical connection and no disengagement of the contact.

Bend Test
$660.00
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
Type
Physical
For
Insulation

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

Blocking
$960.00
Spec
ANSI/NEMA WC 27500 Section 4.3.15 AS4373 Method 808 AS85485 Method 4.7.4 AS22759 Paragraph 5.3.11 BSS7324 Method 7.7
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.

Bondability of Insulation to Potting Compounds
$960.00
Spec
ASTM3032 Method 19 AS4373 Method 102
Type
Chemical
For
Insulation

Bonding compounds are often used as a means of protecting electrical terminations from the moisture and other contaminates. Furthermore, proper adhesion of potting compounds can have a positive impact on component durability to vibration and mechanical shocks. The bondability of insulation to potting compounds test evaluates the adhesion to the wire/cable insulation.

Cable to Cable Abrasion
$1,040.00
Spec
EN3475 Method 511
Type
Physical
For
Insulation

This test is used to determine the ability of the insulation to withstand the rubbing of one insulation on another in a vibratory environment. Wire's in close contact with other wires can rub on each other on aircraft causing deterioration to the insulation. Different insulation materials have different damage effects to the insulation. The test analyzes the effects of different materials on the test sample.

Capacitance per Unit Length 
$660.00
Spec
EN3475 Method 801
Type
Electrical
For
Insulation

This test measures the capacitance of a cable per unit length. Capacitance is defined as the ratio of voltage between two surfaces divided by their difference in charge.

Characteristic Impedance 
$1,110.00
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
Type
Electrical
For
Cable

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

Circumferential Elongation (PTFE only)
$400.00
Spec
AS22759 Method 5.3.1.3
Type
Physical
For
Insulation

This test determines the elongation of insulation of a wire in a circumferential direction. This test was developed to measure the resistance of polytetrafluoroethylene (PTFE) insulation to rupture when under a radial stress. Using a power driven apparatus built by Lectromec technicians, a cone shall be driven through the insulation. At the end of the test, the average percent circumferential elongation shall be calculated.

Cold Bend Test
$1,400.00
Spec
ANSI-NEMA-WC27500 Method 4.3.6 AS4373 Method 702 AS6070 Method 5.4.1 AS22759 Paragraph 5.7.3 AS85485 Method 4.7.19 BSS7324 Method 7.10 EN3475 Method 406 FED-STD-228 Method 2021 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-STD-2223 Method 2004 NEMA HP100.1-1991 Method 7.2.10
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.

Comparative Tracking Index of Electrical Insulating Materials
$2,100.00
Spec
ASTM D3638 EN60112 UL 510 Method 14
Type
Electrical
For
Insulation

In this test, a contaminate liquid is slowly dripped between two electrodes on the surface of the material. By adding this contamination, electrical conduction between the two electrodes is started and carbonization of the polymer slowly occurs. Once the carbonization occurs and the electrical current exceeds the threshold set on the test, the test is halted, and the voltage is decreased. This continues until sufficient amount of data is gathered to interpolate the number of contaminate drops necessary to achieve the electrical current threshold.

Conductor Elongation and Tensile Breaking Strength
$1,100.00
Spec
AS22759 Method 5.2.6 AS4373 Method 402 AS6324 Method 5.14 AS85485 Method 3.4.3 MIL-STD-2223 Method 5002 AS29606 Method 5.4
Type
Physical
For
Conductor

This test determines the percentage elongation at break for soft or annealed copper conductors and the break strength and the percent elongation for high strength copper alloy conductors. Using a special machine built by Lectromec technicians, the conductor shall be stretched until breakage. This test may be used on conductors either before application of insulation or after insulation with the insulation removed. The insulation process may affect the elongation and break strength of the conductor. At the end of the test, we will know the tensile breaking strength of the wire sample and the length of the elongation due to the test.

Conductor Resistance
$540.00
Spec
AS4373 Method 403 AS6324 Method 5.1.3 AS22759 Paragraph 5.4.1 AS29606 Method 5.5 AS85485 Method 4.7.8 ASTM B298 Method 8.2 ASTM D4566 Method 13 FED-STD-228 Method 6021 ISO 19642-2 Method 5.2.1 MIL-DTL-24643C Method 4.9.4 MIL-DTL-25038J Method 4.6.9 MIL-STD-2223 Method 5003
Type
Electrical
For
Conductor

This test determines a conductor's direct current (DC) resistance at a specified reference temperature (typically set at ambient temperature). There are two methods used to conduct this test known as the Kelvin Bridge Method and the Wheatstone Bridge Method which are used to obtain the resistance of the specimen. Both methods will give similar results, however, the Kelvin Bridge Method is more accurate. At the end of the test, the reported results include the specimen's conductor resistance and the test parameters.

Conductor Solderability
$1,630.00
Spec
AS4373 Method 105 AS6324 Method 5.2.3 AS22759 Method 5.2.3 EN3475 Method 509 J1128 Method 6.2 MIL-STD-202 Method 208 MIL-STD-2223 Method 5004
Type
Chemical
For
Conductor

The purpose of this test is to assess the conductors ability to absorb solder. Soldering is a common method for wiring to connectors on aircraft. Certain conductors plates such as tin and silver are more solderable and thus used for these applications.

Conductor Strand Blocking
$280.00
Spec
AS4373 Method 404 AS6324 Method 5.1.7
Type
Mechanical
For
Wire
Conductor Stranding 
$250.00
Spec
AS22759 Method 4.5.1
Type
Physical
For
Conductor

Conductor stranding is a quality check method to determine the stranding value. The value is determined by the number of strands times the wire gauge of the strands.

Contact Engagement and Separating Force
$1,340.00
Spec
MIL-DTL-38999 Method 4.5.38 AS39029 Method 4.7.6 EIA-364 Method 05
Type
Mechanical
For
Connector

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.

Contact Resistance
$570.00
Spec
EIA-364 Method 06 MIL-DTL-26482 Method 4.6.5 MIL-DTL-22992H Method 4.6.4 MIL-DTL-38999 Method 4.5.14.2 MIL-DTL-83733 Method 4.7.9 MIL-PRF-55339 C Method 4.5.14 MIL-STD-202 Method 307 AS39029 Method 4.7.5
Type
Electrical
For
Contacts

MIL-DTL-26482 compliant connectors must have contact resistance for size 20 is less than30mΩ less than 20mΩ for size 14. Contact resistance is the contribution to the total resistance of a material that comes from the connector.

Contact Retention
$840.00
Spec
EIA-364 MIL-DTL-38999 Method 4.6.32
Type
Mechanical
For
Contacts

This test examines the axial force necessray to displace a contact from the proper location when inserted into a connector.

Contact Walkout
Contact for Pricing
Spec
MIL-C-38999 Method 4.5.32 MIL-DTL-83733 Method 4.7.25
Type
Mechanical
For
Connector

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 become dislodged to pass the test.

Contamination
$670.00
Spec
MIL-DTL-17 4.8.21
Type
Electrical
For
PVC Jacket

The contamination test measures the quality factor (Q) of a test sample. One end of the specimen is cut square, while the other end is prepared to provide the shortest possible connection to the high terminal of a Q-meter, with the shield connected to a ground terminal. After attaching the specimen, measurements are taken with the Q-meter.

Continuity of Coating – Conductor
$800
Spec
AS85485 Method 4.7.7.1 ASTM B355 J1128 Method 6.1
Type
Chemical
For
Conductor

The objective of the continuity of the conductor coating is to examine the quality of the conductor platting before it has been subject to stranding or the insulation application process. Further, this examines the durability of the conductor coating to both mechanical and thermal stresses.

Continuity of Conductors 
$440.00
Spec
ANSI-NEMA WC27500 Method 4.3.8 AS85485 Method 4.7.7.1 EN3475 Method 306
Type
Electrical
For
Conductor
Contrast Measurement 
$2,060.00
Spec
EN3475 Method 706 AS4373 Method 1001 AS22759 Paragraph 5.6.4 AS6070 Method 5.6.2
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.

Corona Extinction Voltage
$810.00
Spec
AS4373 Method 502 EN3475 Method 307 MIL-DTL-17 Method 4.8.6
Type
Electrical
For
Insulation

High voltage spikes onto wires/cables can progressively degrade the insulation performance and lead to an insulation breach and/or create conductive paths through the insulation. In this test, the sample is exposed to a high voltage to determine the corona inception and corona extinction voltage.

Cross-talk
Contact for Pricing
Spec
EN3475 Method 808
Type
Electrical
For
Conductor

Cross-talk occurs when a signal traveling through one cable interferes with another generally in a twisted pair cable.

Crush Resistance
$1,270.00
Spec
ASTM D3032 Method 20(A) EN3475 Method 515
Type
Mechanical
For
Insulation

The crush resistance test method measures the capability of wire insulation to withstand an applied load, simulating the damage that may occur when insulated wire is crushed between two flat surfaces.

DC Leakage
$360.00
Spec
MIL-PRF-39018 Method 4.6.4
Type
Electrical
For
Capacitor

In practice, the energy stored in capacitors will dissipate and discharge through the dielectric. The leakage rate is based on a combination of factors that include: the dielectric material, component age, use, temperature, and applied voltage. The DC leakage test is a test that helps to identify the long-term power storage capacity of capacitors and is often included as part of capacitor qualification test plans.

DC Resistance
$400.00
Spec
MIL-STD-202 Method 303
Type
Electrical
For
Component

This test is to measure the direct-current (dc) resistance of resistors, electromagnetic windings of components, and conductors. It is not intended that this test apply to the measurement of contact resistance.

Deformation Resistance (Installation with Plastic Cable Ties)
$1,110.00
Spec
EN3475 Method 513
Type
Physical
For
Cable insulation

This purpose of this test is to evaluate the performance of a cable after installation of plastic cable ties. On aircraft, improper installation of cable ties can cause deterioration to the cable over time.

Delamination
$650
Spec
AS4373 Method 809 ANSI 27500 Section 4.3.14 AS22759 Paragraph 5.3.8
Type
Thermal
For
Insulation

This test evaluates tape wrapped insulation for sealing between wraps after thermal stress.

Delamination and Blocking
$1,110.00
Spec
EN3475 Method 403
Type
Thermal
For
Insulation

This test determines if a finished wire specimen will block (stick to itself) or flaring of layers 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 or delamination. At the end of the test, we will inspect the wire and examine for adhesion (blocking) and delamination (separation of layers) of adjacent turns.

DelTest
$1000
Spec
Lectromec custom test method
Type
Electrical
For
Determination of Temperature Coefficients
$600
Spec
ISO 19642-2 Method 5.2.2
Type
Electrical
For
Wire

A conductor's resistance changes with temperature and is dependent on the conductor's material properties. In this test, the wire is submerged in a oil bath with a temperature accuracy of 0.2C. The bath is progressively heated to the target temperature and the change is conductor resistance is captured at multiple temperature during the test.

Diameter
$440.00
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
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 Voltage
$590
Spec
ASTM D3032 Section 8 AS4373 Method 510 AS22759 Paragraph 5.4.4 EN3475 Method 302 ISO 19642-2 Method 5.2.3 J1128 Method 6.4 MIL-DTL-26482 Method 4.6.10 MIL-DTL-38999 Method 4.5.11 MIL-DTL-83733 Method 4.7.17.1 MIL-PRF-55339 C Method 4.5.13 MIL-STD-202 Method 301 MIL-STD-2223 Method 3005 NEMA 27500 Method 4.3.3 NEMA 27500 Method 4.3.7
Type
Electrical
For
Insulation

The dielectric is perhaps one of the most referenced tests when examining wires. The reason is that it tests the most important part of the wire insulation: determine if the wire insulation is free of breaches (or has been sufficiently degraded such that a high voltage would breach any weak points in the insulation). The basics of the test are that the entire wire, except for an inch at both ends, is placed in a water bath (with salt and wetting agent) and a high voltage potential is placed between the conductor and the return electrode in the water bath. If there is a failure in the insulation, then there will be a noticeable current flow. Dependent on the test method used, the pretest soak time, voltage amplitude and type (AC or DC) will vary.

Dielectric Withstand Voltage – Connectors
$710.00
Spec
MIL-DTL-26482 Method 4.6.9 MIL-DTL-38999 Method 4.5.11.1 MIL-DTL-83513 Method 3.5.4 EIA-364-20
Type
Electrical
For
Connector

In particular, this test method examines the performance at different pressures (altitudes). As the atmospheric pressure decreases, so too does the required maximum service voltage to be used in testing.

Dimensional Stability
$670.00
Spec
MIL-DTL-17 Method 4.8.20 MIL-DTL-24643C Method 4.8.36
Type
Thermal
For
Insulation

The dimensional stability test determines the protrusion or contraction of the insulation with respect to the outer conductor on both specimen ends.

Dimensions
$1,200
Spec
AS23053 Rev A Method 5.3 EN3475 Method 203 MIL-DTL-24643C Method 4.7.2 MIL-PRF-55339 C Method 4.5.1.2 ASTM B298 Method 8.3
Type
Physical
For
Cable

The purpose of this test is to measure the dimensions such as gauge and diameter of a cable. The dimensions of a cable determine the amount of electric current or wire rating a wire can carry.

Dry Arc Propagation Resistance
$5,050.00
Spec
AS4373 Method 508 AS22759 Paragraph 5.7.12 BSS7324 Method 7.4.3 EN3475 Method 604 MIL-STD-2223 Method 3007
Type
Electrical
For
Insulation

The test evaluates a wire's ability to prevent arc-propagation to other wires in the sample harness.

Durability
$600.00
Spec
AS39029 Method 4.7.10 MIL-DTL-38999 Method 4.5.8 MIL-DTL-26482 Method 4.6.17 MIL-DTL-26482 Method 4.6.18
Type
Mechanical
For
Connector

Electrical connectors are expected to connect and disconnect regularly without degradation for routine activities such as maintenance, replacement, and troubleshooting. The durability test evaluates the ability of an electrical connector to withstand mating and de-mating for a large number of repetitions.

Dynamic Cut Through
$1,160
Spec
AS4373 Method 703 AS22759 Paragraph 5.7.13 ASTM 3032 Method 22 BSS7324 Method 7.23 EN3475 Method 501 EN6059 Method 405
Type
Physical
For
Insulation

The dynamic cut-through test is designed to assess the cut-through force of a wire/cable specimen. The wire/cable specimen is compressed under a the fine edge of a jig until contact is made between the wire/cable conductor and the test jig. The pass/fail criteria for this test is based on the wire/cable's specification.

Electrical Engagement
$680.00
Spec
MIL-DTL-38999 Method 4.5.15
Type
Mechanical
For
Connector

When using connectors in wire system design, the regular and consistent contact between contacts on both sides of the connector is crucial. To determine this, the electrical engagement test examines the mating length of the connector contacts.

Electrolytic Erosion
$1,060.00
Spec
MIL.DTL-38999 Method 4.5.35
Type
Electrical
For
Connector

Whether through contamination during maintenance actions, ingress from degraded seals, or other degradation, the fluid ingress into a connector can cause degradation and impact reliability. To assess this, the electrolytic erosion test measures the propensity of connectors to erode when contaminants are present and the connector is in use.

The test consists of introducing a salt-water contaminant to a connector, mating the connector, then energizing the pins for 40 hours at 60 volts. Upon completion, the contacts are examined under magnification for erosion to the base metal.

Elevated Temperature Aging
$500.00
Spec
MIL-STD-2223 Method 4001 MIL-DTL25038J
Type
Thermal
For
Insulation

This test determines if the wire insulation can withstand a temperature aging test for a time period at a temperature greater than the temperature rating of the insulation. The wire must then withstand the bend (LINK) and wet dielectric (LINK) tests after the thermal exposure in order to pass. The purpose of the test is to ensure that the insulation will not fail if exposed to extreme heat which may occur while during flight. At the end of this test, we will know which specimens passed or failed by reporting the results of the bend and wet dielectric tests.

External Bending Moment
$760.00
Spec
MIL-DTL-38999 Method 4.5.16
Type
Mechanical
For
Connector

In this test, the receptacle connector is mounted as in normal service to a rigid panel. Before mating the plug connector to the receptacle, an adapter is attached to the connector. A defined load at a specified rate is applied to the adapter arm then held for one minute. During test test, any circuit discontinuity greater than 1 microsecond will be considered a failure.

External Bending Moment
$650
Spec
MIL-C-38999 Method 4.5.16
Type
Electrical
For
Connector
Finished Wire Insulation Flaws
$1,940.00
Spec
AS22759 Method 5.3.3 AS4373 Method 505 MIL-DTL-25038J Method 4.6.13
Type
Electrical
For
Insulation

The test determines if there are any defects in a wire specimen through a spark-test voltage of 2,500 V rms at 60Hz or 3kHz or an impulse dielectric voltage of 5,000V. This is a preliminary test that is used to determine the condition of a wire sample.

Flammability
$1,430
Spec
ANSI -NEMA WC27500 Method 4.3.19 AS4373 Method 801 AS6070 Method 5.5.1 AS22759 Method 5.7.10 AS23053 Rev A Method 4.14 AS85485 Method 4.7.13 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-81381 4.6.4.16
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.

Flex Life – SAE Test Method
$1,170.00
Spec
AS4373 Method 704
Type
Physical
For
Conductor

SAE Test Method: In this test, the specimen is flexed 180Deg between two mandrels until there is a break in electrical conductivity of the conductor. The pass/fail criteria of is based on the particular specification, typically set at a minimum threshold for the number of flexing cycles with conductor loss.

Flexibility
$940.00
Spec
ASTM B470 EN3475 Method 704 ISO 19642-2 Method 5.3.4
Type
Physical
For
Cable

European Test Method: In this test, the specimen is flexed 180Deg between two mandrels until there is a break in electrical conductivity of the conductor. The pass/fail criteria of is based on the particular specification, typically set at a minimum threshold for the number of flexing cycles with conductor loss.

Forced Hydrolysis
$3,390.00
Spec
AS22759 Paragraph 5.7.14 AS4373 Method 602 J1128 Method 6.14
Type
Environmental
For
Insulation

The forced hydrolysis test places wire/cable specimen in a high-temperature water bath for an extended duration to evaluate the durability of a wire insulation in high-humidity conditions. Depending on the particular wire specification needs, the test may be required to run for thousands of hours. After the prolonged exposure, the sample is then examined and exposed to a dielectric voltage withstand (DVW) test.

Fuel Immersion – Secondary Support
$3,130.00
Spec
MIL-DTL-32554 Method 4.6.6
Type
Chemical
For
Secondary Support

Components that degrade in fuel exposed environments, when located inside of the fuel tank, may break off and create FOD that clogs fuel pumps. Thus, it is necessary to verify the performance of any secondary support product prior to use in these environments.

Fungus Resistance
$5,170
Spec
ASTM G21-13
Type
Environmental
For
Insulation

The purpose of the fungus resistance test is to determine the susceptibility of a specimen to fungus growth on the insulation. To do this, short sections of the specimen are exposed to a variety of common molds/fungus for several weeks then visually examined. A passing specimen will show no fungus growth on the insulation, a failed specimen will show some level of fungus growth susceptibility.

Gauge Location
$570.00
Spec
MIL-DTL-38999 Method 4.5.18
Type
Mechanical
For
Connector

To insure interchangeability between connectors, the mechanical configuration of connectors must remain consistent. The gauge location test verifies connector geometry. A standard test gauge (a test device shaped to particular dimensions) is installed in a connector cavity and the axial location of the front of the gauge is measured against a set reference location to test conformance. The pass/fail criteria for this test is based off of the particular measurements and configuration of the connector under test.

High Pressure/High Temperature Air Impingement (Burst Duct)
$2,130.00
Spec
AS4373 Method 802
Type
Environmental
For
Insulation

The bust duct test simulates the condition where a high-temperature, high-pressure air line has ruptured near a wire harness. The test objective is to determine how long the wire/cable can be exposed to these harsh conditions without impacting the insulation reliability.

High Temperature Exposure with Contact Loading
Call for pricing.
Spec
MIL-C-38999 Method 4.5.34.1
Type
Electrical
For
Connector

For this test, contacts are removed and crimped to a wire and then reinstalled. An initial measurement of the axial location is made with an 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 temperature.  Upon completion and at room temperature, the axial location is re-measured with the same axial load for any discrepancies.

Humidity – Connectors
Call
Spec
EIA-364-31 MIL-DTL-26482
Type
Environmental
For
Connectors and Sockets

Exposure to humidity is among the most common means of electrical equipment degradation. The humidity testing offers a means of assessing the potential for a in-service connector and/or crimped contact degradation due to heat and humidity. The problems are most pronounced on components with significant imperfections in the component plating. This test seeks to assess the impact of high relative humidity at various temperatures.

Humidity Resistance
$2,940.00
Spec
AS4373 Method 603 AS22759 Paragraph 5.7.8 EN3475 Method 412 MIL-DTL-81381 Method 4.6.4.19
Type
Environmental
For
Insulation

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

Humidity Test
$1,000
Spec
MIL-C-38999 Method 4.5.26 EIA-364-31
Type
Electrical
For
Connector

This test examines a connector's resistance to corrosion, and entrance of moisture, long-term durability in high moisture environments. This test method identifies several means of testing a connector in humid conditions.

Ice Resistance
$860.00
Spec
MIL-C-38999 Method 4.5.40
Type
Environmental
For
Connector
Impulse Dielectric Test
$620.00
Spec
NEMA27500 Method 4.3.3 MIL-STD-2223 Method 3002 AS4373 Method 503 AS4373 Method 505 ASTM D3032 Method 13 AS22759 Paragraph 5.2.3
Type
Electrical
For
Insulation

The impulse dielectric tests can be thought of a production line means of checking for insulation/jacket breaches in wires/cables. In this test, a voltage is placed on the specimen and the specimen is pulled under a 'chain mail' curtain connected to ground. The test is performed at a higher voltage than the standard dielectric tests performed on wires/cables, but this is necessary given the short duration of the voltage differential across the insulation/jacket.

Inherent Viscosity Measurement of Polyimide
$800
Spec
Lectromec Internal Procedure
Type
Chemical
For
Wire
Insulation Concentricity and Wall Thickness
$540.00
Spec
AS4373 Method 101 AS22759 Method 5.5.5 AS85485 Method 4.7.5 J1128 Method 5.4 MIL-DTL-24643C Method 4.7.1
Type
Mechanical
For
Wire

Measuring the insulation concentricity and wall thickness is a quality assurance test that can identify uniformity issues. Wires with non-uniform insulation (or cables with non-uniform jackets) will have an unbalanced insulation wall thickness that can make the wire/cable more susceptible to mechanical or electrical failure. This test can be performed on wire gauges ranging from 30AWG to 0000AWG and one wholly tape wrapped and extruded constructions.

Insulation Crosslink Proof
$1,080.00
Spec
AS22759 Method 5.3.10 AS4373 Method 811
Type
Thermal
For
Insulation

This test is to be used to evaluate the cross-linking certain types of wire insulation.

Insulation Resistance
$1,110.00
Spec
AS4373 Method 504 AS22759 Paragraph 5.4.2 AS85485 Method 4.7.18 ASTM 3032 Section 6 BSS7324 Method 7.34 EIA-364 Method 21 EN3475 Method 303 ISO 19642-2 Method 5.2.6 J1128 Method 6.15 MIL-STD-202 Method 302 MIL-STD-2223 Method 3003 MIL-DTL-24643 C Method 4.9.5 MIL-DTL-26482 MIL-DTL-38999 Method 4.5.10.1 MIL-PRF-55339 C Method 4.5.8 MIL-DTL-81381 Method 4.7.4.2 MIL-DTL-83513 Method 4.5.7
Type
Electrical
For
Insulation

This test determines the insulation resistance of a finished wire sample. Insulation resistance is of interest in high impedance circuits and as an insulation process quality control test. When used as part of a wire/cable environmental testing, prolonged thermal exposure, and/or extended high voltage testing, changes in the insulation resistance can be used as an indicator of insulation deterioration.

Insulation Resistance at Ambient Temperature
$600
Spec
MIL-DTL-26482 Method 4.6.7.1 EIA-364-21 MIL-DTL-83733 Method 4.7.16.1
Type
Electrical
For
Connector

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.

Insulation Shrinkage
$800.00
Spec
AS22759 Method 5.3.12 AS4374 Method 104
Type
Thermal
For
Insulation

The insulation shrinkage test objective is to evaluate a wire/cable’s insulation propensity for shrinkage with exposure to elevated temperature.

Insulation Tensile Strength and Elongation of Insulation
$460.00
Spec
AS4373 Method 705 AS85485 Method 4.7.16 ASTM D3032 Section 17 FED-STD-228 Method 3031
Type
Mechanical
For
Insulation

This test provides tensile property data on extruded electrical wire insulation removed from the wire/cable specimen. Identifying the insulation's tensile properties are useful to determine the ability to withstand mechanical stresses the wire/cable may experience in service conditions.

Insulation Wrap Back Test
$560
Spec
AS4373 Method 708 AS22759 Section 5.7.2 AS85485 Section 4.7.29 MIL-STD-2223 Method 2003
Type
Mechanical
For
Insulation

This test is to be used to determine whether a specimen will crack when wrapped upon itself or around a mandrel.

Life Cycle
$1,440.00
Spec
AS4373 Method 807 AS6070 Method 5.3.1 AS22759 Method 5.7.5 AS85485 Method 4.7.10 MIL-DTL-81381 Method 4.6.4.17 MIL-STD-2223 Method 4001
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.

Low Fluoride Off Gassing
$1,370.00
Spec
AS4373 Method 608 AS22759 Paragraph 5.3.7
Type
Chemical
For
Insulation

During the degradation process of ETFE and XL-ETFE, fluorine gas is released from the insulation into the environment. This test seeks to quantify the amount of off-gassed material.

Maintenance Aging
$700.00
Spec
EIA-364-26 MIL-DTL-38999 Method 4.5.2 MIL-DTL-83733 Method 4.7.3
Type
Mechanical
For
Connector

The connector is mated and de-mated a dozen or more times. After the mating and de-mating cycles, the installation and removal forces are recorded for each of the contacts.

Marking Durability
$1,110.00
Spec
AS4373 Method 710 AS6070 Method 5.6.1 AS22759 Method 5.6.3 AS85485 Method 5.12 MIL-DTL-25038J Method 4.6.14
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.

Notch Propagation
$620.00
Spec
AS4373 Method 706 EN3475 Method 502
Type
Mechanical
For
Insulation

The notch test is a test that examines the propagation of nick in the top layer of a wire. Small notches are common during installation or maintenance of wires, and this test evaluates how well the insulation can withstand mechanical stresses after incurring a notch.

Overload Resistance – Smoke Resistance
$1,100.00
Spec
EN3475 Method 305 AS4373 Method 513 AS22759 Paragraph 5.7.9 BSS7324 7.16
Type
Electrical
For
Wire/Cable

The overload resistance test, also known as the smoke resistance test, is designed to examine the durability of the wire insulation under extended periods of internal heating caused by over-current conditions.

Plating Adhesion
$780.00
Spec
MIL-C-38999 Method 4.5.5
Type
Environmental
For
Connector

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 by immersion in a solvent or ice water. The connectors are then removed and visually examined for any separation or loosening of the plating.

Plating Continuity
$800.00
Spec
EN3475 Method 506
Type
Chemical
For
Silver or non-silver plated conductor.

The test is used to determine how thorough the plating process has been performed on conductor specimen when coiled around a mandrel and immersed in a oxidative accelerant.

Post Test Examination
$260.00
Spec
MIL-C-38999 Method 4.5.49 MIL-DTL-83733 Method 4.7.30
Type
Physical
For
Connector

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.

Rapid Change of Temperature
$1,400.00
Spec
EN3475 Method 415
Type
Thermal
For
Coaxial Cable

The Rapid Change of Temperature test evaluates the ability to withstand a series of rapid temperature changes without diminishing its performance.

Resistance to Fluids
$12,770.00
Spec
AS4373 Method 601 AS22759 Method 5.7.7 ASTM D3032 Section 23 EN3475 Method 411 J1128 Method 6.8 MIL-DTL-25038J Method 4.6.6
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.

Resistance to Oil: Insulation and Sheath
$880.00
Spec
FED-STD-228 Method 4221
Type
Chemical
For
Insulation

This method is intended for use in determining the effect of oil on oil-resisting insulation and sheath of insulated wire and cable. The procedure may be used for determining the resistance of insulation and sheath to oil at any desired temperature. The tensile strength and elongation, or other characteristic used for determining the degree of deterioration is determined immediately after exposure of the material.

Resistance to Ozone
$850
Spec
J1127 Method 6.8 J1128 Method 6.9
Type
Environmental
For
Insulation

In the resistance to ozone test, a sample is placed in a heated enclosure with an atmosphere containing a prescribed amount of ozone; typically the ozone count is in the parts per billion range. After the exposure, the sample is removed and visually inspected for cracks. For a sample to 'pass' the test, no insulation cracks should be detected during the post-exposure visual inspection.

Resistance to Pinch
$1,380.00
Spec
J1128 Method 6.10
Type
Mechanical
For
Wire

In the resistance to pinch test, the specimen is placed perpendicularly across a steel rod then compressed under an anvil. The force on the specimen is slowly increased until the insulation is breached and a conductive path is formed between the specimen's conductor and the test apparatus. The pass/fail criteria are product specific.

Scrape Abrasion
$730.00
Spec
AS4373 Method 301 AS22759 Paragraph 5.7.16 EN3475 Method 503 EN6059 Method 403 ISO 19642-2 Method 5.3.2.5
Type
Mechanical
For
Insulation

This test assesses the wire/cable's insulation durability to sharp edges at ambient temperature. The sample is abraded until there is electrical conductivity between the scrape abrasion jig and sample under test.

Scrape Abrasion At Temperature
$920
Spec
AS4373 Method 301 EN3475 Method 503
Type
Physical
For
Insulation

This test assesses the wire/cable's insulation durability to sharp edges at eleveated temperature. The sample is abraded until there is electrical conductivity between the scrape abrasion jig and sample under test.

Seamless Verification
$540.00
Spec
WC27500 Section 4.3.20 AS4373 Method 110 AS22759 Paragraph 5.3.6
Type
Physical
For
Wire

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.

Shell to Shell Conductivity
$430.00
Spec
EIA-264-83 MIL-C-38999 Method 4.5.25 MIL-DTL-22992H Method 4.6.26
Type
Electrical
For
Connector

For several applications, it is necessary to have a conductive connector shell. For example, harnesses that contain EMI sensitive circuity are typically shielded and need good grounding and EMI protection as the signals pass through connectors.

Smoke Resistance
$1,100.00
Spec
AS4373 Method 513 AS22759 Method 4.5.27
Type
Thermal
For
Wire

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.

Solder Contacts
Call for Pricing
Spec
MIL-DTL-26482 Method 4.3.2.1.1.1
Type
Thermal
For
Connector contacts

The Solder Contacts test as defined in MIL-DTL-26482 follows the procedure of a Solderability test in accordance with MIL-STD-202 but with a few different requirements.

Strippability and Adherence of Insulation to the Conductor
$540.00
Spec
EN3475 Method 701 ISO 19642-2 Method 5.3.1 J1128 Method 6.13
Type
Physical
For
insulation

The purpose of this test is to measure the level of difficulty to remove the insulation from the conductor. The insulation should not be easily removed from the conductor however should be able to be removed with the usage of a proper insulation removal tool.

Surface Resistance
$950.00
Spec
EN3475 Method 304 AS22759 Section 5.4.3 ASTM D3032 Section 7 FED-STD-228 Method 6041
Type
Electrical
For
Insulation

The purpose of this test is to measure the resistance of the outer surface of the insulation in a high humidity environment. This is to ensure that the resistance along the outer surface is large enough to prevent leakage current between connections.

Temperature Cycling
Call for Pricing
Spec
EIA-364 Method 32 MIL-DTL-38999 Method 4.5.4 MIL-DTL-83733 Method 4.7.4
Type
Environmental
For
Connector

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.

Tensile Strength and Elongation of Conductors
$800
Spec
AS22759 Paragraph 5.2.6 AS4373 Method 402 AS85485 Method 3.5.1.3 FED-STD-228 Method 3211 MIL-DTL-25038J Method 4.6.3 ISO 19642-2 Method 5.3.3
Type
Physical
For
Conductor

This method is intended for use in determining the tensile stress of conductors. Depending on the test method, this may be performed on an insulated or non-insulated conductor.

Tensile Test on Conductors
$800
Spec
EN3475 AS4373 Method 402
Type
Physical
For
Conductor

This method is intended for use in determining the tensile stress of conductors.

Thermal Endurance
$1,000
Spec
EN3475 Method 410
Type
Thermal
For
Insulation

This 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 by using 3 foot long samples from the wire specimen after the heat exposure.

Thermal Index
$9,450.00
Spec
ASTM D 3032 Method 14 AS4851 AS4373 Method 804 AS22759 Method 5.7.15
Type
Thermal
For
Wire

The thermal index test (also known as the Relative Thermal Life and Temperature Index) is based on multiple cycles of elevated temperature exposure, mechanical stressing, and electrical insulation integrity checks. The goal of this test is to determine the maximum continuous operational temperature for the wire/cable for a targeted time interval (the common goal for aerospace wires is to find the maximum continuous temperature for 10,000 hours of operation). This is achieved with long-term exposure to temperatures above this desired temperature rating.

Thermal Shock
$1,240.00
Spec
AS4373 Method 805 AS22759 Paragraph 5.7.4 ASTM D3032 Section 21 EN3475 Method 404 MIL-DTL-25038J NEMA 27500
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.

Thermal Shock
$480.00
Spec
MIL-C-38999 Method 4.5.3
Type
Physical
For
Connector

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 the connector.

Time/Current to Smoke
$830.00
Spec
AS4373 Method 507
Type
Electrical
For
Wire

The purpose of the time/current to smoke test is to determine the time (and electrical current) necessary for a wire specimen to produce smoke. The pass/fail criteria for this test is based on the particular wire/cable specification but is typically based on the specimen able to sustain an electrical current level (e.g. 15A) without producing visible smoke.

Torsion
$1,400.00
Spec
EN3475 Method 504
Type
Mechanical
For
Cable

On aircraft, cables can be exposed to straining conditions that cause the cable to loose its electrical integrity and damage to insulation. This test assesses the effects of this longtime exposure to straining conditions.

Transfer Impedance
$970.00
Spec
EN3475 MIL-C-24758 Method 4.4.2.5 AS85485 Method 4.7.24
Type
Electrical
For
Cable Shielding

Transfer impedance is the measurement of the current flowing on a shield surface to the voltage developed on the opposite side of the surface. Cable shields are designed to reduce transfer impedance, thus increasing shield effectiveness.

Velocity of Propagation
$670.00
Spec
AS6070 Method 5.2.15 ASTM D4566 Method 46 EN3475 Method 804
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.

Visual Examination
$170.00
Spec
EN3475 Method 201 MIL-DTL-25038
Type
Physical
For
Cable

In general, a visual inspection can be used to determine any cracks, conductor exposure and wire degradation which are good indicators for determining the electrical integrity of a wire specimen or cable.

Voltage Drop
$400.00
Spec
AS6324 Method 5.2.5 AS7928 Method 4.7.2
Type
Electrical
For
Conductor

DC resistance measurements and voltage drop calculations are conducted on insulated wires to determine the voltage drop across crimp joints and on re-terminated insulated wires. This evaluation is an effective means of determining the electrical efficacy of a crimp.

Voltage Proof Test
$380.00
Spec
EN3475 Method 302 NEMA 27500 Method 4.3.7 ASTM D3032 Method 8 AS4373 Method 510
Type
Electrical
For
Insulation

This test is typically run as part of posttest assessment procedures to evaluate the sample's insulation/jacket integrity after an environmental or other tests.

Weight
$440.00
Spec
AS22759 Method 4.5.5 AS6324 Method 5.2.2 MIL-DTL-25038J
Type
Physical
For
Cable

The weight assessment test is used as a test to determine if the final cable weight it within the range listed in the product specification.

Wet Arc Propagation Resistance
$5,730.00
Spec
AS4373 Method 509 AS22759 Paragraph 5.7.11 ASTM D3032 Section 28
Type
Electrical
For
Insulation

The wet arc-resistance test for wire insulation provides an assessment of the ability of an insulation to prevent damage in an electrical arc environment.

Wet Arc Propagation Resistance (European Method)
$5,590.00
Spec
EN3475 Method 603
Type
Electrical
For
Insulation

The wet arc-resistance test for wire insulation provides an assessment of the ability of an insulation to prevent damage in an electrical arc environment.

Wet Short Circuit Test
$5,590.00
Spec
EN3475 Method 605
Type
Electrical
For
Wire

The Wet Short Circuit Test is the European Standard methodology of wet arc track resistance testing. The test identifies the general electrical arcing characteristics of a small harness of wires in contact with a general contaminant.

Wicking
$620.00
Spec
AS22759 Paragraph 5.3.13 MIL-DTL-25038J AS4373 Method 607
Type
Chemical
For
Insulation

The wicking test focuses on the wire insulation's propensity for drawing fluids into the insulation.

Wrap Back Test
$660.00
Spec
AS4373 Method 708 AS22759 Method 5.7.2 EN3475 Method 413
Type
Thermal
For
Insulation

The wrap back examines a wire/cable's insulation susceptibility to breach when tightly wrapped around itself and exposed to elevated temperatures. This test is usually required in the individual wire specifications as part of the insulation integrity assessment. After the elevated temperature exposure, the specimen is visually examined for any insulation cracks (or delamination in the case of tape wrapped insulations). The insulation integrity is then examined with a wet dielectric test.

Wrinkle Test
$210.00
Spec
AS4373 Method 709
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.