1、ASD Technical Report Rapport Technique ASD ASD Fachbericht TR 4653 Edition 1 December 2008 PUBLISHED BY THE AEROSPACE AND DEFENCE INDUSTRIES ASSOCIATION OF EUROPE - STANDARDIZATIONAvenue de Tervuren, 270 - B-1150 Brussels - Tel. + 32 2 775 8126 - Fax. + 32 2 763 3565 - www.asd-stan.orgICS: Descripto
2、rs: ENGLISH VERSION Aerospace series Technical specification of plating of connectors Cadmium and hexavalent Chromium replacement Srie arospatiale Spcification technique pour le traitement des connecteurs en remplacement du Cadmium et du Chrome hexavalent Luft- und Raumfahrt Technische Spezifikation
3、 zur Oberflchenbehandlung von elektrischen und optischen Verbindungselementen Ersatz von Kadmium und hexavalentem Chrom This Technical Report was drawn up by the Electrical Domain of ASD-STAN. The reason which led to the publication of the document as a Technical Report is explained in the foreword.
4、 Edition approved for publication 31 December 2008 Electrical Domain Copyright 2008 by ASD-STAN Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 2 TR 4653:08-12Contents Page Foreword3 Introduction .4 1
5、 Scope 4 2 Normative references 4 3 Physical coating constraints5 3.1 Cadmium coating replacement 5 3.2 Stainless steel passivation replacement.5 4 Tests5 4.1 Tests according to EN 2591-100.5 4.2 Galvanic compatibility 10 5 Programme of qualification test 11 6 Sample distribution 13 6.1 Circular con
6、nectors 13 6.2 Rectangular connector. 14 6.3 Rack and panel connector . 14 Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 3 TR 4653:08-12 Foreword The main task of ASD-STAN is to prepare EN standards
7、. In exceptional circumstances, however, the publication of a Technical Report of one of the following types may be proposed: type 1, the subject is still under technical development requiring wider exposure; type 2, a Technical Domain has collected data of a different kind from that which is normal
8、ly published as a European Standard. The Electrical Domain decided to publish this document in the form of a Technical Report of type 2, as it contains only general guidelines. Technical Reports are normally published in a trilingual version. Due to the volume of this document, the report is publish
9、ed, as an exception, in three separate language versions. Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 4 TR 4653:08-12 Introduction The aim of this technical report is to describe test methods, req
10、uirements and schedule to validate the alternative plating and treatment for connectors and accessories in order to comply with DIRECTIVE 2002/95/EC OF EUROPEAN PARLEMENT AND OF THE COUNCIL of 27 January 2003. 1 Scope This standard specifies necessary tests and methods to validate alternate plating
11、compatible with existing plating. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) a
12、pplies. EN 2591-100*, Aerospace series Elements of electrical and optical connection Test methods Part 100: General. EN 2997 (series), Aerospace series Connectors, electrical, circular, coupled by threaded ring, fire-resistant or non fire-resistant, operating temperatures 65 C to 175 C continuous, 2
13、00 C continuous, 260 C peak. EN 3197, Aerospace series Installation of aircraft electrical and optical interconnection systems. 1)EN 3372 (series), Aerospace series Connectors, electrical, circular, medium and high contact density, scoop-proof with bayonet coupling, operating temperatures 65 C to 17
14、5 C or 200 C continuous. EN 3645 (series), Aerospace series Connectors, electrical, circular, scoop-proof, triple start threaded coupling, operating temperature 175 C or 200 C continuous. EN 3646 (series), Aerospace series Connectors, electrical, circular, bayonet coupling, operating temperature 175
15、 C or 200 C continuous. EN 3682 (series), Aerospace series Connectors, plug and receptacle, electrical, rectangular, interchangeable insert type, rack to panel, operating temperature 150 C continuous. EN 3909, Aerospace series Test fluids and test methods for electric components and sub-assemblies.
16、EN 4165 (series), Aerospace series Connectors, electrical, rectangular, modular Operating temperature 175 C continuous. *And all parts quoted in this standard. 1) Published as ASD Prestandard at the date of publication of this standard. Copyright ASD-STAN Provided by IHS under license with AECMA Not
17、 for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 5 TR 4653:08-12 3 Physical coating constraints 3.1 Cadmium coating replacement To preserve the to day industrial manufacturing conditions, the following recommendations should be considered: Thickness of protection
18、(15 m to 20 m included under plate); Adherence on copper under plate layer shall be demonstrated (composite connectors and accessories); Colour, shall be non reflective dark colour; Difference of electrochemical potential between cadmium and substitute shall be less than 0,25 V (see EN 3197). 3.2 St
19、ainless steel passivation replacement The passivation will use a process without any hexavalent chromium (Cr6) 4 Tests 4.1 Tests according to EN 2591-100 See Table 1. Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license fro
20、m IHS-,-,-Page 6 TR 4653:08-12 Table 1 EN 2591- Designation of the test Details 101 Visual examination Initial examination: examination of connectors, fittings, loose parts (contacts, etc.) Details to be examined: identification; appearance marking; surface finish. Final examination: no loosening of
21、 parts, crack, excessive wear or detached part shall be observed. 102 Examination of dimensions and mass Applicable 201 Contact resistance - low level Not applicable 202 Contact resistance at rated current Not applicable 203 Electrical continuity at microvolt level Not applicable 204 Discontinuity o
22、f contacts in the microsecond range Not applicable 205 Housing (shell) electrical continuity Measuring points: on the thread of the plug and the receptacle flange. Maximum resistance: Initial 2,5 m and 5 m after test On mixed couple samples and same protected version samples (Cd and substitute of Cd
23、) Initial 5 m and 10 m after test On mixed couple samples and same protected version samples passived stainless steel. 206 Measurement of insulation resistance Applicable for hermetic connector only 207 Voltage proof test Applicable for hermetic connector only 208 Temperature rise due to rated curre
24、nt Not applicable 209 Current temperature derating Not applicable 210 Electrical overload Not applicable 211 Capacitance Not applicable 212 Surface transfer impedance Not applicable 213 Shielding effectiveness from 100 MHz to 1 GHz Receptacle and plug with grounding spring system fitted with screeni
25、ng connection. On connectors initially compliant with that requirement. For the attenuation values see the dedicated technical specification of each connector or accessory. 214 Lightning strike, current and voltage pulse Applicable only current pulse continued Copyright ASD-STAN Provided by IHS unde
26、r license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 7 TR 4653:08-12 Table 1 (continued) EN 2591- Designation of the test Details 216 Engagement of contacts Not applicable 217 Voltage drop under specified current for terminal lugs and in-line s
27、plices Not applicable 218 Ageing of terminal lugs and in-line splices by temperature and current cycling Not applicable 219 Voltage strength for insulated terminal lugs and in-line splices Not applicable 220 Contact /conductor joint ageing by current and temperature cycling Not applicable 221 Voltag
28、e Standing Wave Ratio (VSWR) Not applicable 222 Insertion Loss (I.L) Not applicable 223 Measurement of characteristic impedance of a coaxial connector or contact Not applicable 224 RF leakage Not applicable 225 RF high potential withstanding voltage Not applicable 226 Corona level Not applicable 301
29、 Endurance at temperature Method B Temperature: according technical specification of each connector and accessory. Duration: 1 000 h 302 Climatic sequence Not applicable 303 Cold/low pressure and damp heat Not applicable 304 Damp heat steady state Not applicable 305 Rapid change of temperature Conne
30、ctors mated TA= 05+C TB= maximum temperature of the class of connector ( 6550) C 306 Mould growth Method A Duration: 28 d Growth 0 No prior washing No surface etching continued Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without l
31、icense from IHS-,-,-Page 8 TR 4653:08-12 Table 1 (continued) EN 2591- Designation of the test Details 307 Salt mist The connectors shall be suspended in the test chamber with non-metallic cords, so that no accumulation of condensed saline solution can occur. subjected to 50 cycles of mating and unma
32、ting at a rate 5 cycles/min; exposed to the salt mist: - mated for 452 h; - test EN 2591-205; - then unmated for 48 h; - cleaning; - test EN 2591-101. subjected to 450 cycles of mating and unmating at the rate 5 cycles/min for classes W and WS. Test EN 2591-205 before cleaning and unmating 308 Sand
33、and dust Not applicable 309 Dry heat Not applicable 310 Cold Not applicable 311 Low air pressure Not applicable 312 Air leakage Not applicable 313 Driving rain (artificial) Not applicable 314 Immersion at low air pressure Not applicable 315 Fluid resistance For types of fluids, number of cycles, tem
34、perature and duration of immersion and temperature for the third phase: see Table 10 and Table 11. 316 Ozone resistance Not applicable 317 Flammability Not applicable 318 Fire-resistance Not applicable 319 Gastightness of solderless wrapped connections Not applicable 320 Simulated solar radiation at
35、 ground level Not applicable 321 Damp heat, cyclic test Connectors mated 10 cycles At the end of the 7thcycle, with the connectors still mated and subjected to high relative humidity, the insulation resistance is measured (test EN 2591-206). 322 Hermeticity Applicable 323 Thermal shock Not applicabl
36、e 324 Interfacial sealing Not applicable 325 Ice resistance Not applicable continued Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 9 TR 4653:08-12 Table 1 (continued) EN 2591- Designation of the tes
37、t Details 401 Acceleration, steady state Not applicable 402 Shock Not applicable 403 Sinusoidal and random vibration See technical specification of connector and accessory 404 Transverse load (external bending moment) Not applicable 405 Axial load Not applicable 406 Mechanical endurance Number of ma
38、ting and unmating operations: 500 The rate shall not exceed 5 cycles/min. 407 Durability of contact retention system and seals (maintenance ageing) Not applicable 408 Mating and unmating forces See technical specification of connector and accessory. 409 Contact retention in insert Not applicable 410
39、 Insert retention in housing (axial) Not applicable 411 Insert retention in housing (torsional) Not applicable 412 Contact insertion and extraction forces Not applicable 413 Holding force of grounding spring system Not applicable 414 Unmating of lanyard release connectors Not applicable 415 Test pro
40、be damage (female contacts) (Grounding block contact) Not applicable 416 Contact bending strength Not applicable 417 Tensile strength (crimped connection) Not applicable 418 Gauge insertion/extraction forces (female contacts) Not applicable 419 Stability of male contacts in insert Not applicable 420
41、 Mechanical strength of rear accessories Not applicable 421 Free fall Not applicable 422 Locking wire hole strength Not applicable 423 Connector rear accessories thread strength Not applicable 424 Stripping force, solderless wrapped connections Not applicable continued Copyright ASD-STAN Provided by
42、 IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 10 TR 4653:08-12 Table 1 (concluded) EN 2591- Designation of the test Details 425 Unwrapping capability, solderless wrapped connections Not applicable 426 Contact retention system ef
43、fectiveness (removable contact walkout) Not applicable 427 Robustness of protective cover attachment Not applicable 428 Sinusoidal vibrations with passage of current for crimped terminal lugs Not applicable 501 Soft solderability Not applicable 502 Restricted entry Not applicable 503 Contact deforma
44、tion after crimping Not applicable 505 Contact protection effectiveness (scoop-proof) Not applicable 506 Use of tools Not applicable 507 Plating porosity Not applicable 508 Measurement of thickness of coating on contacts Not applicable 509 Adhesion of coating on contacts Not applicable 512 Effective
45、ness of non-removable fixing of hermetically sealed connector shell Not applicable 513 Magnetic permeability Not applicable 514 Solderability of contacts with self-contained solder and flux 2 515 Hydrolytic stability Not applicable 4.2 Galvanic compatibility Difference of electrochimical potential b
46、etween to different protective material must be mesured with water solution of 2 % salt (Na Cl). See Table 2. Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 11 TR 4653:08-12 Table 2 Resistance to flu
47、ids Classes 175 C and 200 C Fluid per EN 3909 Immersion Stoving Category References (EN 3909 number) Durationmin Temp. C Temp. C Number of cycles Fuel 2 NATO F-44 5+ 2 0 25 85 7 Mineral hydraulic fluid 5 NATO F-515 15+ 5 0 85 100 5 Synthetic hydraulic fluid 3 Skydrol 500 B4 Skydrol LD 4 15+ 5 0 85 1
48、00 5 Mineral lubricant 7 NATO O-142 15+ 5 0 120 125 5 NATO O-156 Synthetic lubricant 8 NATO O-148 15+ 5 0 150 125 5 9 Cleaning products 10 5+ 2 0 25 25 5 De-icing fluid 14 NATO S-742 15+ 5 0 50 100 5 Extinguishing fluid 17 15+ 5 0 15 25 5 Cooling fluid 18 15+ 5 0 50 25 5 5 Programme of qualification test The qualification tests are defined in Table 3. Table 3 Designation of the test EN 2591- Remarks Group 0 All models Visual examination 101 Examination of dimensions and mass 102 Mating and unmatin
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