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5.2.4.1 Group IIF Fluid-Soaked Bundles.
The only electrical failures detected in a fluid-contaminated bundle were on PI/PTFE wires
(code 10) that were mixed with XPI wires (code 3). Although a little wire-to-wire and wire-tofixture
plate wear was noted, the failures were attributed to the severe wear from the clamps, as
shown in figure 41.
FIGURE 41. SEVERE WEAR ON PI/PTFE FROM CLAMP WHEN MIXED WITH
XPI IN GROUP IIF
The XPI, XLETFE, PI/PTFE, and PI/PTFE alloy wire types (codes 3, 4, 10, and 11, respectively)
each exhibited more wear from clamps in mixed wire bundles than in the associated nonmixed
wire bundle. The XPI wire type exhibited moderate wear from clamps when mixed with
XLETFE, as opposed to a little wear in the nonmixed configuration.
Data was plotted to analyze whether the clamp diameter and bundle diameter difference or
slippage in the clamps that was documented after 100 hours of vibration exposure had a direct
correlation to the severity of wire-to-wire or wire-from-clamp damage.
Figure 42 indicates that a higher difference between the bundle and clamp diameters was not the
only factor in determining the severity of the wire-to-wire wear in Group IIF, but it does
correlate somewhat. The figure also indicates that slipping in the clamps did not necessarily
cause the wire-to-wire damage to be more severe. The wire type was probably a factor as well.
Figure 43 indicates that a higher difference between the bundle and clamp diameters was not the
only factor in determining the severity of the wire wear from the clamps in Group IIF. The
3 5
figure also indicates that slipping in the clamps did not necessarily cause the wire wear from
clamps to be more severe.
0
1
2
3
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Clamp and bundle diameter difference (in.)
Severity of Damage
No slippage
Slipped
FIGURE 42. GROUP IIF: TIGHTNESS OF CLAMP VS WEAR FROM WIRE
0
1
2
3
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Clamp and bundle diameter difference (in.)
Severity of Damage
No slippage
Slipped
FIGURE 43. GROUP IIF: TIGHTNESS OF CLAMP VS WIRE WEAR FROM CLAMP
5.2.4.2 Group IIM Metal Shavings Bundles.
The only wet electrical failures on the bundles contaminated with the metal shavings were on a
nonmixed bundle of PTFE/glass wires (code 9). This bundle exhibited severe wear from the
clamps (see figure 44), and showed signs of a little wear from the vibration plate and wire-towire
interaction.
3 6
FIGURE 44. SEVERE WEAR OF PTFE/GLASS WIRE FROM CLAMP IN GROUP IIM
NONMIXED BUNDLE
Data was plotted to analyze whether the clamp diameter and bundle diameter difference, or
slippage in the clamps that was documented after 100 hours of vibration exposure, had a direct
correlation to the severity of wire-to-wire or wire from clamp damage in group II.
Figures 45 and 46 indicate that for the wire bundles that did not slip within the clamps, the
severity of the wire damage increased as the difference between the clamp and bundle diameters
increased. However, the figures did not show the same direct correlation for the bundles that did
slip in the clamps.
0
1
2
3
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Clamp and bundle diameter difference (in.)
Severity of Damage
No slippage
Slipped
FIGURE 45. GROUP IIM: TIGHTNESS OF CLAMP VS WEAR FROM WIRE
3 7
0
1
2
3
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Clamp and bundle diameter difference (in.)
Severity of Damage
No slippage
Slipped
FIGURE 46. GROUP IIM: TIGHTNESS OF CLAMP VS WIRE WEAR FROM CLAMP
5.2.5 Wire Wear From Straps and Lacing String.
Posttest visual examination results were also reviewed to determine the amount of damage that
the wires sustained from the straps and lacing string. A summary of the results is provided in
appendix C, tables C-10 and C-11 and are discussed in the following sections.
5.2.5.1 Wear From Straps.
5.2.5.1.1 Group IIF.
Appendix C, table C-10 visual inspection results from the unassembled bundles indicate that the
PI, XPI, and PI/PTFE wires (codes 2, 3, and 10, respectively) were the only types to display
moderate wear from straps in mixed wire bundles that had been soaked in hydraulic fluid (see
figures 47 and 48). The PI wire also exhibited moderate wear in the nonmixed bundle. All the
other types displayed little or no wear at the straps in mixed and nonmixed bundles.
XPI wires (code 3) showed no wear from straps in the nonmixed bundle, but did show a little or
moderate wear when mixed in bundles with PI, MF-PTFE, and PI/PTFE (see figure 47).
PI/PTFE wires (code 10) showed less wear in the nonmixed bundle than in bundles mixed with
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