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 theref
2、rom, 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 2012 SAE International All rights reserved. No part of this pub
3、lication 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: +1 724-776-4970
4、(outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS21608AAEROSPACESTANDARDAS21608 REV. A Issued 1999-06 Revised 2012-01Superseding AS
5、21608 Ferrule, Shield Terminating, Crimp Style FSC 5940RATIONALERevision required to incorporate AS2168-A1, update references, include qualifying activity requirements, and make minor technical changes. 1. SCOPE 1.1 Scope This specification covers crimp style, insulated and uninsulated, shield termi
6、nating ferrules for RF cable and shielded cable.1.2 Classification Shield terminating ferrules covered by this specification shall be of the following classes and types, as specified (see 6.2): Type I - Ferrule, uninsulated, two-piece Type II - Ferrule, insulated, two-piece Class 1 - Ferrules that c
7、onform to all the requirements of this specification when installed with the applicable crimping tool conforming to MIL-DTL-22520. Class 2 - Ferrules that conform to the material requirements of this specification, are replaceable by Class 1 ferrules, and conform to the performance requirements of t
8、his specification when crimped with a tool having crimping dies and motion conforming to the ferrule manufacturers control drawing required by 3.6. 2. APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications sha
9、ll apply. The applicable issue of the other publications shall 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 a
10、pplicable laws and regulations unless a specific exemption has been obtained. SAE AS21608A Page 2 of 16 2.1 Issues of Documents 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 (outsi
11、de USA), www.sae.orgAS50861 Wire, Electric, Polyvinyl Chloride-Insulated, Copper or Copper Alloy AS18121* Ferrule, Outer, Insulated, Shield Terminating, Type II, Two Piece, Class I, for Shielded Cable AS21980* Ferrule, Outer, Uninsulated, Shield Terminating, Type I, Two Piece, Class I, for Shielded
12、Cable AS21981* Ferrule, Inner, Uninsulated, Shield Terminating, Type I, Two-Piece, Class I, for Shielded Cable AS25036 Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, Bell Mouth, Type II, Class 1 *SAE AS21608 detail specifications. 2.1.2 U.S. Government Publications Available from the Do
13、cument Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/.MIL-DTL-17 Cable, Radio Frequency, Flexible and Semirigid, General Specification for MIL-STD-31000 Technical Data Packages MIL-STD
14、-2073-1 Military Packaging, Standard Practice for MIL-PRF-22191 Barrier Materials, Transparent, Flexible, Heat Sealable MIL-DTL-22520/5 Crimping Tools, Terminal, Hand, Wire Termination, Large For Coaxial, Shielded Contacts and Ferrules, Terminal Lugs, Splices, and End Caps MIL-DTL-22520/10 Crimping
15、Tools, Terminal, Hand, Wire Termination, Small for Coaxial, Shielded Contacts, Ferrules, Terminal Lugs, Splices, and End Caps. SD-6 Provisions Governing Qualification MIL-STD-129 Military Marking for Shipment and Storage MIL-STD-202 Test Methods for Electronic and Electrical Component Parts (Copies
16、of specifications, standards, drawings, and publications required by contractors in connection with specific procurement functions should be obtained from the procuring activity or as directed by the contracting officer.) 2.1.3 ASTM Publications Available from ASTM International, 100 Barr Harbor Dri
17、ve, PO Box C700, West Conshohocken, PA, 19428-2959 USA, www.astm.org.ASTM B545 Tin, Electrodeposited Coatings of ASTM B339 Pig Tin SAE AS21608A Page 3 of 16 2.1.4 ASQ Publications Available from American Society for Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203, Tel: 800-248-1946 (United
18、 States or Canada) or +1-414-272-8575 (International), www.asq.org.ASQC Z1.4 Sampling Procedures and Tables for Inspection by Attributes 2.1.5 National Conference of Standards Laboratories National Conference of Standards Laboratories, 2995 Wilderness Place, Suite 107, Boulder, CO 80301-5404, Tel: 3
19、03-440-3339, www.ncsli.org.NCSL Z540-1 General Requirements for Calibration Laboratories and Measuring and Test Equipment 3. REQUIREMENTS 3.1 Qualification The ferrules furnished under this specification shall be products which are qualified for listing on the applicable Qualified Products List (see
20、 4.3 and 6.3). 3.2 Detail Specification Requirements The components 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 specification, the latter shall govern
21、(see 2.1). 3.3 MaterialsThe ferrules shall be fabricated from the materials specified on the applicable MS. 3.4 Design and Construction Class 1 ferrules shall be constructed in accordance with the applicable detail specification and shall be designed for attachment to appropriate size shielded cable
22、 by having the ferrule reshaped around the conductor shield. The reshaping operation shall be accomplished by means of a tool conforming to the applicable MIL-DTL-22520 detail specification . The reshaping operation for the Class 2 ferrule shall be accomplished by means of tooling recommended by the
23、 ferrule manufacturer. The ferrule shall exhibit no evidence of fracturing or spalling as a result of being crimped to a suitable cable.3.4.1 Insulation: Type II ferrules shall be insulated over their outer surfaces. The insulation shall remain in its original position on the ferrule before and afte
24、r crimping. 3.4.2 Finish: Ferrule conductor parts shall be tin plated over their entire surface in accordance with ASTM B545 OR ASTM B339, Type I. 3.5 Performance Requirements The ferrules shall be designed to meet the following test requirements when crimped to each of the specified cable sizes wit
25、h the applicable tool. 3.5.1 Voltage drop: The voltage drop through the ferrules, when carrying test current, shall not exceed 6 millivolts for “initial” voltage drop and 9 millivolts for “after test” voltage drop, except for vibration testing. Before vibration testing, initial voltage drop shall no
26、t exceed 8 millivolts, and after tests, 11 millivolts. 3.5.2 Temperature cycling: The ferrules shall be subjected to the temperature cycling tests (4.6.2.2) after which they shall meet the “after test” voltage drop (3.5.1) and tensile strength (3.5.3) requirements. SAE AS21608A Page 4 of 16 3.5.3 Te
27、nsile strength: The mechanical connection between the ground wire and the ferrules shall have a tensile strength of not less than 15 pounds for size M5086/1-22-9 ground wire (see MIL-W-5086) and not less than 19 pounds for size M5086/1-20-9 ground wire. The mechanical connection shall not break or b
28、ecome distorted at tensile stresses less than the minimum values specified above. 3.5.4 Vibration: After being subjected to the vibration test (4.6.2.4), the ferrules shall meet the “after test” voltage drop (3.5.1) and tensile strength (3.5.3) requirements. 3.5.5 Corrosion resistance: The ferrules
29、shall meet the “after test” voltage drop (3.5.1) and tensile strength (3.5.3) requirements after being subjected to the corrosion resistance test (4.6.2.5). At the completion of this test, the basic metal of the ferrule shall not be exposed. 3.5.6 Ferrule insulation (dielectric strength - Type II):
30、The insulation on the Type II ferrule shall have a minimum dielectric strength of 500V rms at 60 Hz for 1 minute. 3.5.7 Conductor insulation distortion: The completed crimped termination shall not scratch, mar, or distort the inner conductor insulation. When subjected to the conductor distortion tes
31、t (4.6.2.7), the force necessary to remove the basic conductor from the crimped ferrule shall not exceed 9 pounds. Inner ferrules up to 0.134 inch ID shall have only one ground wire attached for this test. 3.5.8 Axial load (Type II): The insulation sleeve of Type II ferrules shall withstand a minimu
32、m axial force of 8 pounds in either direction without moving more than 1/32 inch on the barrel of the ferrule. This requirement applies to ferrules before and after installation. 3.6 Manufacturers Control Drawing The ferrule manufacturer shall prepare a control drawing for the crimping dies used to
33、crimp his Class 2 ferrules for the applicable tests. The control drawing shall specify the critical dimensions and motion of the dies and shall also specify the acceptance and in-service gaging requirements. The ferrule manufacturer shall certify to the ferrule user that the users dies are in accord
34、ance with the control drawing and shall furnish to the user the acceptance and in-service gaging requirements (see 4.3.2.1). 3.7 Identification of Product (Class 1) The manufacturers identification and the part number, including the dash number, shall be included in the marking for shipment and shal
35、l be in accordance with MIL-STD-129 (see 5.3). 3.8 Interchangeability All parts having the same manufacturers part number shall be directly and completely interchangeable with each other and with respect to installation and performance. The drawing number requirements of MIL-STD-31000 shall govern c
36、hanges in the manufacturers part numbers. 3.9 Workmanship Ferrules shall be uniform in quality and free from all defects which may affect their serviceability and appearance. 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility for Inspection Unless otherwise specified herein, the contract or purchase
37、 order, the supplier is responsible for the performance of all contract inspection requirements. Except as otherwise specified herein, the contract or purchase order, the supplier may use any facilities suitable for the performance of the inspection requirements. The Qualifying Activity has the righ
38、t to perform any of the inspections set forth in the standard where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. SAE AS21608A Page 5 of 16 4.1.1 Responsibility for Compliance: All items must meet all technical requirements of the product s
39、tandard. The inspection set forth in this standard shall become a part of the suppliers overall inspection system or quality program. The absence of any inspection requirements in the standard shall not relieve the supplier of the responsibility of assuring that all products comply with all requirem
40、ents of the contract or purchase order. Sampling in quality conformance does not authorize submission of known defective material, either indicated or actual, nor does it commit the purchaser to acceptance of defective material 4.1.2 Test Equipment and Inspection Facility: Test and measuring equipme
41、nt and inspection facilities of sufficient accuracy, quality and quantity to permit performance of the required inspection 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
42、be in accordance with ANSI/NCSL Z540-1 or equivalent standards. 4.1.3 Inspection Conditions: The conditions for the inspections are specified as applicable and all test data shall be compiled in accordance with an acceptable method, such as chapter 4 of SD-6. 4.2 Classification of Inspection The exa
43、mination and testing of ferrules shall be classified as follows: a. Intial Qualification inspection (4.3) b. Retention of Qualification (4.3.6) c. Quality conformance inspection (4.4) 4.3 Intial Qualification Inspection Initial qualification inspection shall be performed or witnessed by the qualifyi
44、ng activity (see 6.3) for Class 1 ferrules (see4.3.1) and in-plant by the supplier for Class 2 units (see 4.3.2). Sample units shall be subjected to the qualification inspection specified in Table 2. All sample units shall be subjected to the inspection of Group I. The sample units shall then be div
45、ided into Groups II through VIII as shown in Table 2 and subjected to the inspection in sequence for their particular group. 4.3.1 Qualification Inspection Procedure: A request for qualification shall be made to the qualifying activity (see 6.3 prior to initiating testing. Testing cannot begin until
46、 the supplier has received an authorization letter. The supplier is recommended to provide the qualifying activity a test plan based on the authorization letter to ensure the supplier and qualifying activity maintain communication and document changes as needed. The qualifying activity shall not app
47、rove a component that does not meet the requirements specified herein. The qualifying activity has the authority to impose specific specification test requirements to resolve test failures/discrepancies and to waive testing to verify specific product manufacturing change Any change in the suppliers
48、process control inspections, quality conformance inspections, or manufacturing control drawings (editorial changes are acceptable) without the express approval of the qualifying activity may result in loss of qualification for that product.4.3.2 Class 1 initial qualification inspection sample sizes:
49、 Samples shall consist of those designations in Table 1 (see Table 2). Corresponding Inner Ferrules will be selected based upon the Outer Ferrule and the conductor under test. Once testing has been completed the inner ferrules selected shall be representative of the entire product line. Class 1 ferrules shall be crimped with a tool conforming to MIL-DTL-22520/5 or MIL-DTL-22520/10. The conductor lead wire may be folded back on itself
