SAE AS 6224-2015 Wrap-Around Insulation Repair and Protection Sleeve Permanent Electric Environment Resistant.pdf

1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there

2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2015 SAE International All rights reserved. No part of this p

3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497

4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS6224 AEROSPACE STANDARD AS6224 Issued 2015-12 Wrap-Around Insulation Repair and

5、 Protection Sleeve, Permanent, Electric, Environment Resistant FSC 5940 RATIONALE Specification needed to provide a repair sleeve for mechanical and electrical protection of damage wire insulation or cable jacket in installed aircraft. 1. SCOPE The AS6224 specification covers environment resistant,

6、permanent insulation repair sleeves for repairing different types of insulation damages of wire or cable jackets in installed applications. The repair sleeve is intended to repair damaged primary wire or cable jacket covers where the shielding and wire conductors are not damaged. 1.1 Type I Contains

7、 an insulation sleeve (outer sleeve) and a piece of adhesive (inner sleeve) that are manufactured in discrete lengths designed to clip over the damaged area and heated to recover and seal. 1.2 Type II Contains an insulation sleeve (outer sleeve) and adhesive (inner sleeve) that are laminated togethe

8、r and designed to wrap around the damaged area and heated to recover and seal. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications s

9、hall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption

10、 has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. AMS1424 Deicing/Anti-Icing Fluid, Aircraft, SAE Type I AMS-DTL-23053 Insulation Sleevi

11、ng, Electrical, Heat Shrinkable, General Specification For SAE INTERNATIONAL AS6224 Page 2 of 17 *AS6224/1 Repair Sleeve, Primary Wire Insulation Damage, Electric, Permanent, Environment Resistant, Type I, 150 C Max AS7928 Terminals, Lug: Splices, Conductor: Crimp Style, Copper, General Specificatio

12、n For AS22759 Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy AS22759/11 Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Silver-Coated Copper Conductor, 600 Volt AS22759/12 Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Nickel-Coated Copper Conductor, 600 Volt AS

13、50861 Wire, Electric, Polyvinyl Chloride Insulated, Copper or Copper Alloy AS81044 Wire, Electrical, Crosslinked Polyalkene, Crosslinked Alkane-Imide Polymer, or Polyarlyene Insulated, Copper or Copper Alloy *AS6224 detail specification 2.1.2 ASQ Publications Available from American Society for Qual

14、ity, 600 North Plankinton Avenue, Milwaukee, WI 53203, Tel: 800-248-1946 (United States or Canada), 001-800-514-1564 (Mexico) or +1-414-272-8575 (all other locations), www.asq.org. ANSI/ASQ Z1.4 Sampling Procedures and Tables for Inspection by Attributes 2.1.3 ASTM Publications Available from ASTM I

15、nternational, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM D1974/D1974M Fiberboard Boxes, Methods of Closing, Sealing, and Reinforcing, Standard Practice for ASTM D5118/D 5118M Standard Practice for Fabrication of Fiberboard Shipping B

16、oxes ASTM D5486/D5486M Standard Specification for Pressure-Sensitive Tape For Packaging, Box Closure, And Sealing 2.1.4 National Conference of Standards Laboratories (NCSL) Publications Available from NCSL International, 2995 Wilderness Place, Suite 107, Boulder, CO 80301, Tel: 303-440-3339, www.ncs

17、li.org. NCSL Z540.3 Calibration of Measuring and Test Equipment, Requirements for 2.1.5 U. S. Government Publications Copies of these documents are available online at http:/quicksearch.dla.mil. SD-6 Provisions Governing Qualification MIL-STD-129 Military Marking for Shipment and Storage MIL-STD-202

18、 Test Methods for Electronic and Electrical Component Parts P-D-410 Dishwashing Compound, Hand (Synthetic Detergent, Solid and Liquid Form) PPP-B-566 Boxes, Folding, Paperboard SAE INTERNATIONAL AS6224 Page 3 of 17 MIL-STD-2073-1 Military Packaging, Standard Practice for A-A-3174 Plastic Sheet, Poly

19、olefin MIL-PRF-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-PRF-7808 Lubricating Oil, Aircraft Turbine Engine Synthetic Base MIL-PRF-22191 Barrier Materials, Transparent, Flexible, Heat-Sealable MIL-PRF-23699 Lubri

20、cating Oil, Aircraft Turbine Engines, Synthetic Base, NATO Code Number 0-156 MIL-DTL-81381 Wire, Electric, Polyimide-Insulated, Copper or Copper Alloy MIL-DTL-83133 Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-34) and JP-8+100 (NATO F-37) MIL-PRF-87937 Cleaning Compound, Aerospace Equipment 2

21、.2 Definitions 2.2.1 CRITICAL DEFECTS A critical defect is a defect that judgment and experience indicate would result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the product, or a defect that judgment and experience indicate is likely to prevent performan

22、ce of the actual function of a major end item such as a ship, aircraft, tank, missile, or space vehicle. 2.2.2 DEFECT A defect is any nonconformance of the unit of product with specified requirements. 2.2.3 MAJOR DEFECT A major defect is a defect, other than critical, that is likely to result in fai

23、lure, or to reduce the usability of the unit of product for its intended purpose. 2.2.4 MINOR DEFECT A minor defect is a defect that is not likely to reduce materially the usability of the unit of product for its intended purpose, or is a departure from established standards having little bearing on

24、 the effective use or operation of the unit. 3. REQUIREMENTS 3.1 Detail Specification The product requirements shall be as specified herein and in accordance with the applicable detail specification. In the event of any conflict between the requirements of this specification and the detail specifica

25、tion, the latter shall govern. 3.2 Qualification A qualified component shall be a product that has been tested and has passed the qualification tests specified herein, and has been listed on or approved for listing on the applicable Qualified Products List (see Section 4 and 6.3). 3.3 Materials The

26、materials used shall be specified in detailed specification. SAE INTERNATIONAL AS6224 Page 4 of 17 3.4 Design and Construction Design and construction shall be specified in detailed specification. 3.4.1 Wire Acceptance Each size of repair device shall be designed to accommodate wire sizes as specifi

27、ed in the detailed specification. 3.4.2 Sleeve and Adhesive Length 3.4.2.1 Type I The pre-cut length of the sleeve and adhesive shall be specified in the detail specification sheet. The sleeve and adhesive shall not be cut by the users of the repair sleeve, unless otherwise instructed by the manufac

28、turer. 3.4.2.2 Type II The laminated insulation repair sleeve shall be cut to length during installation in accordance with the process specified in the detailed specification. 3.5 Performance The device shall conform to the following requirements: 3.5.1 Insulation Sleeve and Adhesive Materials 3.5.

29、1.1 Dimensions (see 4.7.1) The sealing sleeve component of the device assembly shall conform to the dimensions of the applicable detail specification. 3.5.1.2 Fungus Resistance (see 4.8.7) Unless otherwise specified in detail specification, the outer shell and inner adhesive shall be fungus resistan

30、t in accordance with AMS-DTL-23053. 3.5.2 The Repaired Wire Assembly The repaired wire assembly shall confirm to the following requirements when the damaged insulation is repaired with the device with the applicable tooling specified (see 3.4). 3.5.2.1 Insulation Resistance When tested in accordance

31、 with 4.8.1, installed assembly shall have the minimum value of 5000 M:. 3.5.2.2 Dielectric Withstanding Voltage When tested in accordance with 4.8.2, the device shall show no evidence of damage, arcing, or breakdown and the leakage current shall be less than 2 mA. 3.5.2.3 Slip Resistance Strength W

32、hen tested in accordance with 4.8.3, the slip resistance strength shall be as defined in the detailed specification. SAE INTERNATIONAL AS6224 Page 5 of 17 3.5.2.4 Environmental Conditioning Device assemblies shall meet the applicable performance requirements listed in Tables 1 and 2, when tested in

33、accordance with test methods listed in Tables 1 and 2. Discoloration of the sealing sleeve materials during these tests shall not be cause for rejection (see 4.8.4). 3.5.2.5 Flammability (see 4.8.5) The assembled device shall be self-extinguishing within 5 seconds after removal of the external flame

34、 source from the device assembly. 3.5.2.6 Blocking (see 4.8.6) The outer shell of the individual sleeves in the test bundle shall not stick together (see 4.8.6). The exposed adhesive may stick and shall not be a cause for a reject. 3.6 Identification of Product (see 4.7.1) The device shall be color

35、coded in accordance with the applicable detail specification for identification purposes. Color coding shall be readily discernible before/after the installation. 3.7 Workmanship (see 4.7.1) The repair sleeve when installed shall be free of gross defects such as for example, blisters, cuts, holes, e

36、tc. 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility for Inspection Unless otherwise specified herein, in the contract or in the purchase order, the supplier is responsible for the performance of all contract inspection requirements. Except as otherwise specified herein, in the contract or in the

37、purchase order, the supplier may use any facilities suitable for the performance of the inspection requirements. The Qualifying Activity has the right to perform any of the inspections set forth in the standard where such inspections are deemed necessary to assure that supplies and services conform

38、to prescribed requirements. 4.1.1 Responsibility for Compliance All items must meet all technical requirements of this standard and the applicable detail specification. The inspections set forth in this standard shall become a part of the suppliers overall inspection system or quality program. The a

39、bsence of any general or specific inspection requirements in the standard shall not relieve the supplier of the responsibility of assuring that all products comply with all requirements of the contract or purchase order. Sampling in quality conformance does not authorize submission of known defectiv

40、e material, either indicated or actual, nor does it commit the purchaser to acceptance of defective material. 4.1.2 Inspection Equipment and Facilities Test and measuring equipment, and inspection facilities of sufficient accuracy, quality and quantity to permit performance of the required inspectio

41、ns shall be established and maintained by the supplier. The establishment and maintenance of a calibration system to control the accuracy of the measuring and test equipment shall be in accordance with NCSL Z540.3 or equivalent standards. SAE INTERNATIONAL AS6224 Page 6 of 17 4.2 Classification of I

42、nspection The examination and testing of sleeves shall be classified as follows: a. Component-materials inspection (see 4.3). b. Qualification inspection (see 4.5). c. Quality conformance inspection (see 4.6). 4.3 Component-Materials Inspection Component-materials inspection shall consist of verific

43、ation that the component materials as specified in the detailed specification. Component materials used in fabricating the sleeves and adhesive are in accordance with this standard and applicable detail specification prior to such fabrication. 4.4 Inspection Conditions Unless otherwise specified her

44、ein, all inspections shall be made at ambient temperature, and humidity as specified in the general requirements of MIL-STD-202. 4.4.1 Sample Preparation, Test Specimen Assembly (Qualification Specimens) Unless otherwise specified in the detail specification, the sleeve/adhesive specimens shall be a

45、ssembled to an insulated wire, see detailed specification, with damaged insulation (simulated) by the testing activity using an appropriate heat source (see 3.4). The wire shall conform to AS22759/11 or AS22759/12. The simulated damage shall be created by scraping the insulation with a knife or remo

46、ving part of the insulation by cutting the insulation 360 degrees radially and removing part of the insulation to expose the conductor or shield. The length of the exposed conductor or shield shall be defined in the detail specification. The specified number of sample units for testing shall be sele

47、cted and divided between the minimum and the maximum wire and/or cable size within the wire range listed on the applicable detail specification for the size splice to be qualified. These sizes will qualify all sizes specified for the splice by similarity (see 4.5.3). Detailed specification shall spe

48、cify based on the intended use of the product the test wire or cable as required. 4.4.2 Temperature Stabilization Voltage drop measurements shall be made after the temperature of the wire has stabilized. Temperature stabilization shall be determined by three consecutive readings within 1 C at interv

49、als of 3 minutes each. All tests performed after exposure to high or low temperature shall be conducted after sleeves have been conditioned for at least 1 hour at the inspection conditions specified (see 4.4). 4.4.3 Water Bath Unless otherwise specified in the applicable test method, a water bath containing 0.5% of an anionic wetting agent (P-D-410) and 5.0% sodium chloride shall be used whenever immersion is specified. Free ends