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clamps
wear from
plate
FIGURE 37. GROUP IIM 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 38. GROUP IIM TESTING: PI/PTFE, ALLOY (WIRE CODE 11) WIRE DAMAGE
AFTER 250 HOURS OF VIBRATION CONDITIONING
Figure 31 indicates that PVC/glass/nylon exhibits very low wire-to-wire wear, whether in a
nonmixed or mixed bundle.
Figure 32 indicates that PI wire exhibits low wire-to-wire wear in the nonmixed and mixed
bundle conditions.
3 2
Figure 33 indicates that the XPI wire exhibits moderate wire-to-wire wear in the nonmixed
condition, but less wear in combination with other wire types.
Figure 34 indicates that low wire-to-wire wear was observed on XLETFE wire when mixed with
the PI/PTFE wire types (codes 10 and 11), but slight or negligible wear was noted in
combination with other wire types and in the nonmixed bundle.
Figure 35 indicates that MF-PTFE wire exhibits low wear in both the mixed and nonmixed
bundles.
Figure 36 indicates that PTFE/glass wire consistently exhibits low wear in both the mixed and
nonmixed bundles.
Figure 37 indicates that the wire-to-wire wear of PI/PTFE wire is very low or negligible in all
bundles.
Figure 38 indicates that the wear of PI/PTFE wire is low when mixed with XLETFE (code 4),
but negligible or very low in other combinations tested.
Figure 39 provides a summary of six mixed wire bundle combinations from Group IIM in which
one or both of the wire types exhibited more severe wire-to-wire wear than in the nonmixed
bundle. Although the level of damage of one or both wire types in these combinations was
worse in the mixed bundle than in the nonmixed bundle, the overall level was of damage was
low. These combinations are discussed below.
• 1, 4 (PVC/glass/nylon, XLETFE): XLETFE was adversely affected by the harder
PVC/glass/nylon wire, but the damage was only slightly worse than in the nonmixed
bundle.
• 3, 4 (XPI, XLETFE): XLETFE exhibited only slightly more damage when mixed with
XPI than in its baseline bundle. The XPI exhibited a lower level damage in this mixed
bundle than in the baseline bundle.
• 7, 4 (MF-PTFE, XLETFE): XLETFE exhibited slightly more damage when mixed with
MF-PTFE than in its baseline bundle. The MF-PTFE showed a similar level of damage
in both the nonmixed bundle and this mixed combination.
• 9, 4 (PTFE/glass, XLETFE): The XLETFE reacted similarly with PTFE/glass as it did
with MF-PTFE and PVC/glass/nylon.
• 10, 4 and 11, 4 (PI/PTFE, XLETFE and PI/PTFE alloy, XLETFE): The XLETFE had
slightly more wear when mixed with either PI/PTFE wire type than in the baseline
bundle. The PI/PTFE alloy was damaged slightly more than in the baseline bundle. The
alloy wire was damaged slightly more by the XLETFE than was the annealed copper
conductor wire.
3 3
• 10, 11 (PI/PTFE, PI/PTFE alloy): The alloy conductor wire was damage slightly more
when mixed with annealed copper conductor wire than in the baseline, but the annealed
copper conductor wire exhibited a similar level of damage.
0
1
2
3
1, 4 3,4 7,4 9,4 10,4 11,4 10,11
Combinations (wire codes)
Severity of Damage (0-3)
Damage to First
Wire
Damage to Second
Wire
First Wire baseline
Second Wire
Baseline
FIGURE 39. WIRE INTERACTIONS IN GROUP IIM MIXED BUNDLES
Overall, only the XLETFE (code 4) and PI/PTFE alloy (code 11) wire types exhibited more wear
in mixed bundles contaminated with metal than in nonmixed bundles (see figures 34 and 38), but
even then the amount of wear was slight. In addition, the XPI wire (code 3) was the only
nonmixed bundle that exhibited moderate wire-to-wire wear in the metal contaminated bundles
(see figures 33 and 40). The same wire type showed little wear in the mixed configurations.
FIGURE 40. MODERATE WIRE-TO-WIRE WEAR ON XPI IN NONMIXED
GROUP IIM BUNDLE
3 4
5.2.4 Wire Wear From Clamps.
The visual examination results from the unassembled bundles were also summarized in
appendix C, table C-12 so that the data regarding wire wear from the clamps could be analyzed.
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 noted.
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