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results are considered suspect.
5.2.3 Wire-to-Wire Wear.
The visual examination results of the group II unassembled bundles are compiled in appendix C,
tables C-10 and C-11. The results are summarized in table C-12 so that the wire-to-wire wear
data for each type, mixed and unmixed, could be analyzed and the different wire types could be
compared. Each column in table C-12 provides a comparison of the nonmixed bundle to the
mixed bundle combinations selected. The table also indicates whether the bundle was slipping
within the cushion clamps after 100 hours of vibration, provides a damage rating for the wires
rubbing against the fixture plate, and quantifies the electrical failures that were detected.
5.2.3.1 Group IIF Fluid-Soaked Bundles.
Figures 20 through 27 provide graphic representations of the wire-to-wire wear for each wire
type in mixed and nonmixed bundles.
Figure 20 indicates that negligible wire-to-wire wear occurs with PVC/glass/nylon wire, whether
in a mixed or nonmixed bundle.
22
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to wire
Wear from
clamps
wear from
plate
FIGURE 20. GROUP IIF TESTING: PVC/GLASS/NYLON (WIRE CODE 1) WIRE
DAMAGE AFTER 250 HOURS OF VIBRATION CONDITIONING
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to wire
Wear from
clamps
wear from
plate
FIGURE 21. GROUP IIF TESTING: PI (WIRE CODE 2) WIRE DAMAGE AFTER 250
HOURS OF VIBRATION CONDITIONING
23
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to wire
Wear from
clamps
wear from
plate
FIGURE 22. GROUP IIF TESTING: ALIPHATIC PI, ALLOY (WIRE CODE 3) WIRE
DAMAGE AFTER 250 HOURS OF VIBRATION CONDITIONING
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to
wire
Wear from
clamps
wear from
plate
FIGURE 23. GROUP IIF TESTING: XLETFE (WIRE CODE 4) WIRE DAMAGE AFTER
250 HOURS OF VIBRATION CONDITIONING
24
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to
wire
Wear from
clamps
wear from
plate
FIGURE 24. GROUP IIF TESTING: PTFE, MINERAL-FILLED (WIRE CODE 7) WIRE
DAMAGE AFTER 250 HOURS OF VIBRATION CONDITIONING
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to
wire
Wear from
clamps
wear from
plate
FIGURE 25. GROUP IIF TESTING: PTFE/GLASS BRAID (WIRE CODE 9) WIRE
DAMAGE AFTER 250 HOURS OF VIBRATION CONDITIONING
25
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to
wire
Wear from
clamps
wear from
plate
FIGURE 26. GROUP IIF TESTING: PI/PTFE (WIRE CODE 10) WIRE DAMAGE AFTER
250 HOURS OF VIBRATION CONDITIONING
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to wire
Wear from
clamps
wear from
plate
FIGURE 27. GROUP IIF TESTING: PI/PTFE, ALLOY (WIRE CODE 11) WIRE DAMAGE
AFTER 250 HOURS OF VIBRATION CONDITIONING
26
Figure 21 indicates moderate wire-to-wire wear of PI wire in the nonmixed bundle and moderate
or low wear in the mixed bundles.
Figure 22 indicates that XPI wire exhibits low wire-to-wire wear in all combinations except with
XLETFE (code 4), in which case, the wear is moderate.
Figure 23 indicates that negligible wire-to-wire wear was observed on XLETFE wire in the
nonmixed and mixed bundles.
Figure 24 indicates that MF-PTFE wire exhibits negligible wire-to-wire wear in the nonmixed
bundle, but slightly more wear when mixed with PVC/glass/nylon (code 1), PI (code 2), or
PI/PTFE wire (code 10).
Figure 25 indicates that PTFE/glass wire exhibits moderate wire-to-wire wear in the nonmixed
condition, but low or negligible wear in the other combinations tested.
Figure 26 indicates that negligible wear was observed in the PI/PTFE nonmixed bundle, and low
wear when mixed with XPI (code 3) or PI/PTFE (code 10) wire.
Figure 27 indicates that PI/PTFE alloy wire has negligible wire-to-wire wear in the nonmixed
bundle, but slightly more when mixed with XLETFE or PI/PTFE.
Figure 28 provides a summary of seven mixed wire bundle combinations from Group IIF in
which at least one of the wires exhibited more severe wire-to-wire wear than in the nonmixed
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