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.
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.
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.
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.
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.
This test is used to determine the insulation elasticity and propagation of damage through the wire/cable 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.
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.
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.
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.
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.
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.
This test determines the diameter of the conductor after the insulation has been removed. This physical test can be very useful when trying to conduct tests or determining if a wire sample can be used in a specific machine. At the end of this test, we will report each measured conductor diameter and the average conductor diameter for each specimen measured.
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.
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 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.
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.
This test examines the axial force necessray to displace a contact from the proper location when inserted into a connector.
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.
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. Th contrast measurement test examination evaluates the contrast of the UV laser marked area with the unmarked parts of the wire.
In this test, the sample is exposed to a high voltage to determine the corona inception and corona extinction voltage(CEV).
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.
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.
This test evaluates tape wrapped insulation for sealing between wraps after thermal stress.
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.
The Delamination and Blocking test is used to evaluate the performance of cable insulation when subjected to thermal shock conditions.
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.
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 a couple of 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.
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.
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.
The test evaluates a wire's ability to prevent arc-propagation to other wires in the sample harness.
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.
When using connectors in wire system design, the regular and consistent contact between contacts on both sides of the connector. To determine this, the electrical engagement test examines the mating length of the connector contacts.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
The humidity resistance test evaluates the impact of prolonged heat and humidity exposure to wire/cable insulation.
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.
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.
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.
This test is to be used to evaluate the cross-linking certain types of wire 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.
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.
The insulation shrinkage test objective is to evaluate a wire/cable’s insulation propensity for shrinkage with exposure to elevated temperature.
This test is to be used to determine whether a specimen will crack when wrapped upon itself or around a mandrel.
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.
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.
The connector is mated and demated a dozen or more times. After the mating and demating cycles, the installation and removal forces are recorded for each of the contacts.
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.
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.
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.
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.
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 test standard
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
This method is intended for use in determining the tensile stress of conductors.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
The wicking test focuses on the wire insulation's propensity for drawing fluids into the 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.
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.