View Latest Blog Entries
Testing & Assessment Certification Aging Wires & Systems Standard & Regulation Management Conference & Report Maintenance & Sustainment Protection & Prevention Research Arcing Miscellaneous
Popular Tags
Visual Inspection MIL-HDBK MIL-HDBK-525 AS50881 FAR High Voltage FAR 25.1707 Electromagnetic Interference (EMI) Maintenance Wire System Arcing Damage AS4373
All Tags in Alphabetical Order
25.1701 25.1703 Accelerated Aging ADMT Aging Systems Aircraft Power System Aircraft Service Life Extension Program (SLEP) arc damage Arc Fault (AF) Arc Fault Circuit Breaker (AFCB) Arc Track Resistance Arcing Arcing Damage AS22759 AS22759/87 AS4373 AS4373 Method 704 AS50881 AS5692 AS6019 AS83519 AS85485 AS85485 Wire Standard ASTM D150 ASTM F2799 ATSRAC Attenuation Automated Wire Testing System (AWTS) batteries Bent Pin Analysis Best of Lectromec Best Practice bonding Cable cable testing Carbon Nanotube (CNT) Certification Chafing Chemical Testing Circuit Breaker circuit design Circuit Protection Coaxial cable cold bend comparative analysis Compliance Component Selection Condition Based Maintenance Conductor conductors conduit Connector connectors contacts Corona Corrosion Corrosion Preventing Compound (CPC) Cracking D-sub data analysis data cables degradat Degradation Delamination Derating diagnostic dielectric constant Distributed Power System DO-160 dynamic cut through Electrical Aircraft Electrical Component Electrical Testing Electromagnetic Interference (EMI) Electromagnetic Vulnerability (EMV) EMC EMF EN3197 EN3475 EN6059 End of Service Life End of Year Energy Storage engines Environmental Environmental Cycling ethernet EWIS Component EWIS Design EWIS Failure EWIS Thermal Management EZAP FAA AC 25.27 FAA AC 25.981-1C Failure Database Failure Modes and Effects Analysis (FMEA) FAQs FAR FAR 25.1703 FAR 25.1707 FAR 25.1709 fault tree Fixturing Flammability fleet reliability Flex Testing fluid exposure Forced Hydrolysis fuel system fuel tank ignition functional testing Fundamental Articles Future Tech Green Taxiing Grounding Harness Design Hazard Analysis health monitoring heat shrink tubing high current high Frequency high speed data cable High Voltage History Hot Stamping Humidity Variation ICAs IEC60172 IEEE Instructions for Continued Airworthiness Insulation insulation resistance IPC-D-620 ISO 17025 Certified Lab Kapton Laser Marking life limited parts life projection Lightning Maintenance Maintenance costs Mandrel measurement Mechanical Testing MECSIP MIL-C-38999 MIL-C-85485 MIL-DTL-17 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-1560 MIL-STD-1798 MIL-STD-464 MIL-T-7928 MIL-T-81490 MIL-W-22759/87 MIL-W-5088 Military 5088 modeling MS3320 NASA NEMA27500 No Fault Found off gassing Outgassing Overheating of Wire Harness Parallel Arcing part selection Performance physical hazard assessment Physical Testing polyimdie Polyimide-PTFE Power over Ethernet Power systems predictive maintenance Presentation Probability of Failure Product Quality Radiation Red Plague Corrosion Reduction of Hazardous Substances (RoHS) regulations relays Reliability Research Resistance Rewiring Project Risk Assessment SAE Secondary Harness Protection Separation Requirements Series Arcing Service Life Extension Severe Wind and Moisture-Prone (SWAMP) Severity of Failure Shield Shielding signal cable silver plated wire smoke Solid State Circuit Breaker Space Certified Wires Splice standards stored energy supportability Sustainment Temperature Rating Temperature Variation Test methods Test Pricing Testing Thermal Circuit Breaker Thermal Endurance Thermal Index Thermal Shock Thermal Testing Tin plated conductors Troubleshooting TWA800 UAVs USAF verification Visual Inspection voltage white paper whitelisting Wire Ampacity 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 an aircraft wire testing lab look like?


It is quite possible many aerospace professionals have never seen the inside of an aircraft wire testing lab. If you haven’t had a chance to see our lab, here we present a quick tour.

aircraft wire
Lectromec’s ISO 17025:2005 Certification

Aircraft wire testing starts with quality control and process management. Lectromec’s aircraft wire testing laboratory is an ISO/IEC 17025:2005 certified lab. It is the first aerospace wire and cable testing in the world to earn this certification. This commitment to quality has been the foundation of Lectromec’s thirty-year history. We have worked on projects from NASA, the Air Force, and many other organizations.

aircraft wire
Humidity Chamber


Not everyone realizes this, but aircraft wires are expected to last from 20 to 30 years! Since we can never know the exact storage and operation conditions that aircraft wires will be exposed to, in our lab, we create the most likely conditions that a wire will be exposed to, while accelerating the aging of the wire to mimic the passing of time over a 20 to 30 year period. The humidity chamber pictured here, has the capability to perform accelerated aging of components with an eight cubic foot capacity. The humidity levels range from ambient to 98% and the temperatures go as high as 150 degrees Celsius.

aircraft wire
High Voltage Test Equipment


What happens to wires and connectors when higher voltages are used? Here are our AC and DC high voltage testers. The AC system has a voltage range of 0 to 15,000 VAC. The DC system has a voltage range from 0 to 5,000 VDC. High frequency, high voltage capabilities are not shown. This unit can test to most UL, CSA, VDE, IEC, and MIL for dielectric withstand standards.

aircraft wire
Scientific Oven


This is a mechanical convection oven with a capacity of 1.4 cubic feet. It has a range of +30° to 325° Celsius (the equivalent of 617 degrees Fahrenheit!). The scientific oven is used to certify performance for many kinds of aircraft wire insulation.

aircraft wire
Low Temperature Freezer


Not only does aerospace wire have to withstand heat, but also cold. Here is our -85oC freezer. Aircraft wire must be able to withstand quick transitions of temperature, called thermal shock. Finally, these wires must still be able to sustain flexing at cold temperatures – called cold bend capability.

aircraft wire
Force Tester


This unit can apply up to 225 pounds of force. It is used for wire elongation testing, dynamic cut-through, and can be augmented to perform testing at elevated temperatures. This is a typical test for new components, and it frequently performs ten trials for each wire.

aircraft wire
Scrape Abrasion Unit


Wires can be subjected to abrasion from poor design, broken clamps, or inadvertent damage during routine maintenance. Over the years, Lectromec has manufactured a wide range of devices to determine scrape abrasion. This device examines the mechanical wear resistance for wire and cable. Some tests can be performed at elevated temperatures as high as 250oC.

aircraft wire
Arc Resistance Test Equipment


Aerospace wires can get damaged and arcing can occur. In order to ensure that collateral damage is limited, arc track resistance testing is necessary. These are Lectromec’s wet and dry arc track resistance test systems. These units were custom manufactured by Lectromec to comply with the industry test standards.

Most modern aerospace wires require this test.

This equipment is used to show that wires are in compliance with specifications from SAE, MIL Spec, EN, and EASA.

aircraft wire
Custom Test Equipment


We’d love to perform your aerospace wire testing. However, we can also provide custom manufactured testing units for you to do your own testing. This is a picture of a wet/dry arc testing device. We have manufactured equipment for the U.S. Navy and other organizations, domestically and abroad.


Thanks for taking a “virtual” tour of our aircraft wire testing laboratory. If you are ever in the Washington, D.C. area we’d love to give you a personal tour of all the devices we use.

Contact Lectromec if you would like information on our aircraft wire testing, EWIS evaluation, or service life extension programs (SLEP) for aircraft services. To view a list of tests performed and the prices associated with those test, check out our test listing page.

If you would like more information on other aerospace issues, please go to our blog.