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 reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2010 SAE International All rights reserved. No part of this publication m
3、ay 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 (outside U
4、SA) 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/AS70991B AEROSPACE STANDARD AS70991 REV. B Issued 1999-08 Noncurrent 2006-10 Revised 2011-06
5、Superseding AS70991A Terminals: Lug and Splice, Crimp Style, Aluminum, For Aluminum Aircraft Wire FSC 5940 RATIONALE Revised to incorporate AS70991A-1A. 1. SCOPE This specification covers crimp style aluminum lug terminals and conductor splices for aluminum aircraft wire. Lug terminals and conductor
6、 splices are hereafter called “terminals”. 1.1 Classification Terminals shall be of the types specified on applicable standards specified in 2.1 and shall be of the following classes as applicable (see 6.2): Class 1 - Terminals which conform to this specification when installed with a crimping tool
7、and dies as specified in Standards AS5259/1 (see 6.1.1 and 6.1.4). Class 2 - Terminals which are replaceable by class 1 terminals and which, when installed with a tool recommended by the terminal manufacturer, conform to the performance requirements of this specification (see 6.1.2 and 6.1.3). (Clas
8、s 2 terminals and tools are not approved for use on items intended for use by the Air Force or for procurement by or for the Air Force.) 2. REFERENCES The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applica
9、ble 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 applicable laws and re
10、gulations unless a specific exemption has been obtained. 2.1 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. AS5259/1 Tool and Accessories, Electrical, Size 8 t
11、o 700 KCMIL, General Purpose Use, Die and Dieless, Crimping AS25435 Terminal-Lug, Crimp Style, Straight Type, For Aluminum Aircraft Wire, Class 1 SAE AS70991B Page 2 of 16 AS25436 Terminal-Lug, Crimp Style, 90 Upright Type, For Aluminum Aircraft Wire, Class 1 AS25438 Terminal-Lug, Crimp Style, Right
12、 Angle Type, For Aluminum Aircraft Wire, Class 1 2.2 ASQ Publications Available from American Siciety for Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203, Tel: 800-248-1946 (United States or Canada) or +1-414-272-8575 (International), www.asq.org. ASQC-Z1.4 Sampling Procedures and Tables f
13、or Inspection by Attributes. (DoD adopted) 2.3 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM-E11 Sieves, Wire Cloth, for Testing Purposes. (DoD adopted) ASTM-B117 Salt Spray (Fog) Tes
14、ting, Standard Test Method for. (DoD adopted) ASTM-E323 Sieves, Perforated-Plate, for Testing Purposes. (DoD adopted) 2.4 U.S. Government Publications Available from the Document automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-625
15、7, http:/assist.daps.dla.mil/quicksearch/. STANDARDS MILITARY MIL-STD-129 Marking for Shipment and Storage MIL-STD-202 Test Methods for Electronic and Electrical Component Parts MS25439 Splice Permanent Crimp Style, 2 Way Type, for Aluminum Aircraft Wire, Class 1 2.5 NASM Publications Available from
16、 Aerospace Industries Association of America 1250 Eye Street,N.W., Suite 1200 Washington, DC, United States, 20005-3924. aia-aerospace.org NASM 25540 Washers Used With Aircraft Aluminum Terminals NASM 315 Nut, Plain, Hexagon, Airframe 3. REQUIREMENTS 3.1 Qualification The terminals furnished under t
17、his specification shall be products which are qualified for listing on the applicable Qualified Products List at the time set for opening of bids (see 4.3 and 6.3). 3.2 Materials The material used in the manufacture of terminals shall be wrought aluminum exhibiting the hardness and conductivity as s
18、pecified on the applicable standard. SAE AS70991B Page 3 of 16 WARNING This document refers to fixtures and applications that includes cadmium as a plating material. The use of cadmium has been restricted and/or banned for use in many countries due to environmental and health concerns. The user shou
19、ld consult with local officials on applicable health and environmental regulations regarding its use. 3.3 Design and Construction Terminals as specified on applicable standards shall be designed for attachment to appropriate sizes of wire, by having the terminal receiving barrel reshaped around the
20、conductor. For class 1 terminals, it shall be possible to perform this reshaping operation by means of tool and dies as specified in AS5259/1. Terminal barrels shall exhibit no evidence of fracturing or spalling as a result of the reshaping operation. For class 2 terminals, it shall be possible to p
21、erform this reshaping operation by means of tooling recommended by the terminal manufacturer. 3.3.1 Dimensions Terminals shall conform to the dimensions after plating as shown on the applicable standard. 3.3.2 Tinning Terminals shall be either electro or hot-dipped tin plated over their entire surfa
22、ce. The quality and thickness of the tin shall be sufficient to withstand the tests of Section 4. 3.3.3 Abrasive Mixture An abrasive mixture shall be provided within the conductor receiving barrel of the terminal (see 6.5). The mixture shall occupy 40 to 60 percent of the interior barrel volume. The
23、 mixture shall be uniformly composed of nickel powder or equivalent, and a suitable elastomeric binder. The nickel powder or equivalent shall be 50 percent by weight of the mixture, and the nickel powder or equivalent shall be of such size that 100 percent passes through a number 200 sieve as specif
24、ied in ASTM-E11 and ASTM-E323. The elastomeric binder shall maintain its physical characteristics during the tests specified hereafter, and shall remain compatible with the metal used in the terminal, and the wire and insulation used in. 3.3.4 Inspection Plug The inspection plug shall not work loose
25、 during the insertion of the wire, the crimping operation, or the tests as specified herein (see 6.6). 3.4 Installation Tool The installing tool for class 1 terminals shall conform to AS5259/1. The dies shall conform to AS5259/1. Only one crimp shall be necessary for wire sizes 8 through 00. Two cri
26、mps shall be necessary for wire sizes 000 and 0000. 3.5 Performance Terminals crimped with the tool specified in 3.4 or as specified by the manufacturer shall perform satisfactorily when subjected to the following performance requirements. 3.5.1 Voltage Drop The voltage drop through the terminals wh
27、en carrying current shall not exceed the values shown in Table 1. 3.5.2 Life Cycle 3.5.2.1 Vibration: After the vibration test (4.7.4.1), the terminals shall conform to the requirements for voltage drop specified in Table 1. SAE AS70991B Page 4 of 16 3.5.2.2 Thermal shock: After the thermal shock te
28、st (4.7.4.2), the terminals shall show no evidence of a physical breakdown and the measured voltage drop values shall conform to Table 1. 3.5.2.3 Accelerated aging: After accelerated aging (4.7.4.3), the terminals shall conform to the requirements for voltage drop as specified in Table 1. 3.5.2.4 Co
29、rrosion resistance: After the corrosion resistance test (4.7.4.4), the terminals shall not indicate blistering of the plating and the base metal shall not be exposed. Surface discoloration shall not be cause for rejection. In addition, the terminals shall conform to the requirements for voltage drop
30、 as specified in Table 1. 3.5.2.5 Tensile strength: After being subjected to the vibration, thermal shock, accelerated aging, and corrosion resistance tests, the terminals shall be subjected to the tensile strength test (4.7.4.5). The mechanical connection of the wire and the terminal shall not brea
31、k or become distorted before the minimum tensile strength as specified in Table 1 is reached. 3.5.3 Current Cycling The terminals, when subjected to the current cycling test (4.7.5), shall remain 10 C less in temperature than the conductor temperature for any given cycle, and at the end of the 60th,
32、 70th, and 80th cycle, it shall conform to the requirements for the voltage drop as specified in Table I. In addition, the difference in voltage drop between the 60th and 80th cycle shall not exceed 20 percent. 3.5.4 Metal Relaxation (Lug terminals only) The temperature of the terminals under test s
33、hall not exceed that of the conductor. The terminal tongue load shall not relax more than 15 percent of the preset pressure load at any time during the test and the terminals shall not exceed the maximum value for voltage drop as specified in Table 1. TABLE 1 TEST REQUIREMENTS Specification MIL-W-70
34、72 wire size Test Current (amperes) Maximum Voltage Drop (milivolts) Tensile Strength (minimum pounds) Initial After Test AL8 60 7 11 130 AL6 83 6 11 200 AL4 108 6 8 300 AL2 152 6 8 500 AL1 174 6 7 700 AL0 202 6 7 900 AL00 235 6 7 1100 AL000 266 6 7 1300 AL0000 303 6 7 1500 3.6 Manufacturers Drawing
35、 for Class 2 Tools The manufacturer shall submit to the qualifying activity a drawing indicating the critical dimensions of the crimping dies furnished with the tool used to qualify class 2 terminals. This drawing shall be identified by the manufacturers drawing number. Upon approval by the qualifyi
36、ng activity, such numbers will be listed in the applicable QPL. 3.7 Identification of Product Each terminal shall have the aircraft wire size followed by AL for which designed and the manufacturers name or trademark legibly stamped in its surface. The marking shall be located so that it will not be
37、obliterated during crimping or installation. SAE AS70991B Page 5 of 16 3.7.1 Use of Military Designations Military designations shall not be applied to a terminal, except for qualification test samples, until notice of approval has been received from the qualifying activity. 3.8 Additional Requireme
38、nts The requirements specified herein apply to crimp-style aluminum terminals covered by applicable standards. Additional requirements will be specified on the individual standard. In the event of any conflict between requirements of this specification and the requirements of the standard, the latte
39、r shall take precedence. 3.9 Workmanship Workmanship shall be in accordance with high grade electrical manufacturing practice. The occurrence of defects shall not exceed the applicable acceptable quality levels. 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility for Inspection Unless otherwise speci
40、fied in the contract or purchase order, the supplier is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified, the supplier may utilize his own facilities or any commercial laboratory acceptable to the Government. The Government reserves th
41、e right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. 4.1.1 Test Equipment and Inspection Facilities Test equipment and inspection facilities shall be of sufficient accu
42、racy, quality, and quantity to permit performance of the required inspection. The supplier shall establish calibration of inspection equipment to the satisfaction of the Government. 4.2 Classification of Inspection The inspection of terminals shall be classified as: a. Qualification inspection (4.3)
43、 b. Quality conformance inspection (4.4) 4.3 Qualification Inspection The qualification inspection of terminals shall consist of all the examinations and tests of this specification specified under 4.6 and 4.7. 4.3.1 Qualification Inspection Samples (Class 1) The qualification test samples shall con
44、sist of 50 terminals for each barrel size, and 5 terminals for each stud size for each barrel size, and in addition, 5 unplated terminals for each barrel size for which qualification is desired (see 6.2). SAE AS70991B Page 6 of 16 4.3.1.1 Identification of samples: Samples for each part number shall
45、 be separately packaged and forwarded to the activity responsible for qualification designated in the letter of authorization (see 6.3). Samples shall be identified by marking each package with the following information: Sample for qualification test Specification MIL-T-7099E Type _ Class _ MS Part
46、No. Name of Manufacturer Manufacturers Part No. Submitted (date) under authorization (reference letter authorizing the test) 4.3.2 Qualification of Class 2 Terminals Class 2 terminals will be approved for inclusion in the Qualified Products List upon approval of the manufacturers test report. At the
47、 discretion of the qualifying activity, the satisfactory performance of the terminals may be checked by a Government laboratory under any of the inspection conditions specified (see 4.5 and 6.4). 4.3.2.1 Test report: The contractor shall furnish the activity responsible for qualification a certified
48、 test report, in duplicate, showing quantitative results for tests of Class 2 terminals required by this specification and further certified in the forwarding letter by an officer of the contractor. The report shall designate the MS part number of the Class 1 terminal which will replace the Class 2
49、terminal submitted. The report shall also include the manufacturers drawings as specified in 3.6. 4.3.3 Qualification Routine The samples for each barrel size shall be subjected to the examination and tests in the order and quantity specified in Table 2. The specimens comprising Groups I and II shall subsequently be divided for Groups III, IV and V. 4.3.4 Qualification Facilities Qualification inspection shall be c
