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3.2.3 Modification Facilities 3
3.2.4 Military Maintenance and Operation Wiring Practices 3
3.3 Review of Service Data 4
3.4 Review of Prior Research and Test Data 4
3.5 Documentation Review Summary 4
4. TEST PROGRAM 4
4.1 Test Plan 5
4.2 Specimen Description 6
4.3 Wire Bundle Configurations 7
4.4 Wire Bundle Combinations 7
4.5 Crush Test Wire Combinations 9
5. DISCUSSION AND RESULTS 10
5.1 Group I Test Results 10
5.1.1 Visual Observations on Mounted Bundles 10
5.1.2 Electrical Testing 10
5.1.3 Wire-to-Wire Wear 11
v
5.1.4 Wire Wear From Clamps 18
5.1.5 Wire Wear From Straps and Lacing String 20
5.1.6 Wire Wear From Vibration Fixture Plate 21
5.1.7 Wear of Support Components 21
5.1.8 Wear of Single Wires vs Twisted Pairs 21
5.2 Group II Test Results 22
5.2.1 Visual Observations 22
5.2.2 Electrical Testing 22
5.2.3 Wire-to-Wire Wear 22
5.2.4 Wire Wear From Clamps 35
5.2.5 Wire Wear From Straps and Lacing String 38
5.2.6 Wire Wear From Vibration Fixture 39
5.2.7 Wear on Support Components 40
5.2.8 Wear of Single Wires Versus Twisted Pairs 40
5.3 Test Groups I and II Comparison 40
5.4 Group III Crush Test Results 41
5.5 Comparison to Previous Data 42
6. SUMMARY AND RECOMMENDATIONS 43
6.1 Summary 43
6.2 Recommendations 43
7. RELATED DOCUMENTATION 44
8. REFERENCES 46
APPENDICES
A—Regulations, Standard Practices, and Previous Test Documentation
B—Test Program
C—Test Data
D—Additional Photographic Documentation
vi
LIST OF FIGURES
Figure Page
1 Group I Testing: PVC/Glass/Nylon (Wire Code 1) Wire Damage After 500
Hours of Vibration Conditioning 11
2 Group I Testing: PI (Wire Code 2) Wire Damage After 500 Hours of Vibration
Conditioning 12
3 Group I Testing: Aliphatic PI, Alloy (Wire Code 3) Wire Damage After 500
Hours of Vibration Conditioning 12
4 Group I Testing: XLETFE (Wire Code 4) Wire Damage After 500 Hours of
Vibration Conditioning 13
5 Group I Testing: XLETFE, Alloy (Wire Code 5) Wire Damage After 500 Hours
of Vibration Conditioning 13
6 Group I Testing: PTFE (Wire Code 6) Wire Damage After 500 Hours of
Vibration Conditioning 14
7 Group I Testing: PTFE, Mineral-Filled (Wire Code 7) Wire Damage After 500
Hours of Vibration Conditioning 14
8 Group I Testing: PTFE/Glass Braid (Wire Code 9) Wire Damage After 500
Hours of Vibration Conditioning 15
9 Group I Testing: PI/PTFE (Wire Code 10) Wire Damage After 500 Hours of
Vibration Conditioning 15
10 Group I Testing: PI/PTFE, Alloy (Wire Code 11) Wire Damage After 500 Hours
of Vibration Conditioning 16
11 Wire Interactions in Group I Mixed Bundles 17
12 Moderate Wire-to-Wire Wear on Group I XPI in Bundle Mixed With PTFE 18
13 Moderate Wire-to-Wire Wear in Group I Nonmixed XPI Bundle 18
14 Moderate Wire Wear From Clamps on Nonmixed XPI Bundle in Group I 19
15 Moderate Wire Wear From Clamp on PI/PTFE and XPI in Group I 19
16 Group I: Tightness of Clamp vs Wear From Wire 19
17 Group I: Tightness of Clamp vs Wear From Clamp 20
18 Moderate Wear on Clamp From PVC/Glass/Nylon and MF-PTFE Group I Bundle 21
vii
19 Moderate Wear of Clamp From Nonmixed PTFE/Glass Bundle in Group I 21
20 Group IIF Testing: PVC/Glass/Nylon (Wire Code 1) Wire Damage After 250
Hours of Vibration Conditioning 23
21 Group IIF Testing: PI (Wire Code 2) Wire Damage After 250 Hours of Vibration
Conditioning 23
22 Group IIF Testing: Aliphatic PI, Alloy (Wire Code 3) Wire Damage After 250
Hours of Vibration Conditioning 24
23 Group IIF Testing: XLETFE (Wire Code 4) Wire Damage After 250 Hours of
Vibration Conditioning 24
24 Group IIF Testing: PTFE, Mineral-Filled (Wire Code 7) Wire Damage After 250
Hours of Vibration Conditioning 25
25 Group IIF Testing: PTFE/Glass Braid (Wire Code 9) Wire Damage After 250
Hours of Vibration Conditioning 25
26 Group IIF Testing: PI/PTFE (Wire Code 10) Wire Damage After 250 Hours of
Vibration Conditioning 26
27 Group IIF Testing: PI/PTFE, Alloy (Wire Code 11) Wire Damage After 250
Hours of Vibration Conditioning 26
28 Wire Interactions in Group IIF Mixed Bundles 28
29 Moderate Wire-to-Wire Wear in Group IIF Nonmixed PI Bundle 28
30 Moderate Wire-to-Wire Wear on PI When Mixed With MF-PTFE in Group IIF 28
31 Group IIM Testing: PVC/Glass/Nylon (Wire Code 1) Wire Damage After 250
Hours of Vibration Conditioning 29
32 Group IIM Testing: PI (Wire Code 2) Wire Damage After 250 Hours of Vibration
Conditioning 29
33 Group IIM Testing: Aliphatic PI, Alloy (Wire Code 3) Wire Damage After 250
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