1、ASD Technical Report Rapport Technique ASD ASD Fachbericht TR 4680 Edition 1 May 2010 PUBLISHED BY THE AEROSPACE AND DEFENCE INDUSTRIES ASSOCIATION OF EUROPE - STANDARDIZATIONAvenue de Tervuren, 270 - B-1150 Brussels - Tel. 32 2 775 8126 - Fax. 32 2 775 8131 - www.asd-stan.orgICS: Descriptors: ENGLI
2、SH VERSION Aerospace series Contacts, electrical, qualification for change materials and process Srie arospatiale Contacts lectriques, qualification pour changement de matires et de procds Luft- und Raumfahrt Elektrische Kontakte, Qualifikationsanforderungen nach nderungen von Materialien und Prozes
3、sen 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. Edition approved for publication 10 May 2010 Electrical Domain Copyright 2010 by ASD-STAN Page 2 TR 4680:10-05 Cont
4、ents Page Foreword3 1 Scope 4 2 Normative references 4 3 Terms and definitions .4 4 Programmes of qualification tests.4 4.1 General4 4.2 Sampling and definition of specimens4 4.3 List of Tests4 4.4 Qualification test groups 7 4.4.1 Test programme Type A contacts.7 4.4.2 Test programme Type D or E co
5、ntacts 11 Page 3 TR 4680:10-05 Foreword The main task of ASD-STAN is to prepare EN standards. 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;
6、 type 2, a Technical Domain has collected data of a different kind from that which is normally 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
7、published in a trilingual version. Due to the volume of this document, the report is published, as an exception, in three separate language versions. Page 4 TR 4680:10-05 1 Scope This Technical Report is a guideline for the mandated body and the manufacturer to establish a programme of qualification
8、 tests for a change in material and process of contacts already qualified. 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 referen
9、ced document (including any amendments) applies. EN 2591-100, Aerospace series Elements of electrical and optical connection Test methods Part 100: General 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN 2591-100 apply. 4 Programmes of qualification t
10、ests 4.1 General Programmes of qualification tests are test groups defined per kind of change in design of contacts for each EN standard. They precise the sequence tests and the availability test per EN standard. The test severities and the initial and final measurement shall be in agreement with th
11、e qualification tests in the EN Standard concerned. 4.2 Sampling and definition of specimens The specimens shall be representative of the kind of change in design of contacts and the sampling equivalent to the number in the qualification groups. 4.3 List of tests See Table 1. Page 5TR 4680:10-05Tabl
12、e 1 List of tests Tests EN 2591- Applicable or not applicable (Change of metallic material) Applicable or not applicable (Change of non Metallic material) Applicable or not applicable (Change of protection material or protection process) Applicable or not applicable (Change of annealing process) Num
13、ber Designation 101 Visual examination Y Y Y N 102 Examination of dimensions and mass N N Y N 201 Contact resistance - Low level N N Y N 202 Contact resistance at rated current Y N Y N 203 Electrical continuity at microvolt level N N N N 204 Discontinuity of contacts in the microsecond range Y N N N
14、 206 Measurement of insulation resistance N Y N N 207 Voltage proof test N Y N N 210 Electrical overload N N Y N 211 Capacitance N Y N N 212 Surface transfer impedance N Y N N 213 Shielding effectiveness from 100 MHz to 1 GHz N Y N N 220 Contact / Conductor joint ageing by current and temperature cy
15、cling N N N N 221 Voltage Standing Wave Ratio (VSWR) N Y N N 222 Insertion Loss (I.L) N Y N N 223 Measurement of characteristic impedance (Zc) of a coaxial connector or contact N Y N N 301 Endurance at temperature Y Y Y Y 305 Rapid change of temperature Y Y Y Y 306 Mould growth N Y N N 307 Salt mist
16、 N N Y N continued Page 6 TR 4680:10-05Table 1 List of tests (concluded) Tests EN 2591- Applicable or not applicable (Change of metallic material) Applicable or not applicable (Change of non Metallic material) Applicable or not applicable (Change of protection material or protection process) Applica
17、ble or not applicable (Change of annealing process) Number Designation 315 Fluid resistance N Y N N 316 Ozone resistance N Y N N 319 Gastightness of solderless wrapped connections Y for Wrapping N Y for Wrapping Y for Wrapping 402 Shock Y Y N N 403 Sinusoidal and random vibration Y Y Y Y 406 Mechani
18、cal endurance Y N Y Y 416 Contact bending strength Y N N N 417 Tensile strength (crimped connection) Y N Y Y 418 Gauge insertion/extraction forces (female contacts) Y N N Y 424 Stripping force, solderless wrapped connections Y for Wrapping N N N 425 Unwrapping capability, solderless wrapped connecti
19、ons Y for Wrapping N Y for Wrapping N 428 Sinusoidal vibrations with passage of current for crimped terminal lugs N N N Y 501 Soft solderability N N Y N 502 Restricted entry N N N N 503 Contact deformation after crimping Y N N Y 507 Plating porosity Y N Y N 508 Measurement of thickness of coating on
20、 contacts Y N Y N 509 Adhesion of coating on contacts Y N Y Y 513 Magnetic permeability Y N N N 514 Solderability of contacts with self-contained solder and flux Y N N N 515 Hydrolytic stability N N N N Page 7 TR 4680:10-05 4.4 Qualification test groups 4.4.1 Test programme Type A contacts 4.4.1.1 C
21、hange of metallic material The qualification approval tests are defined in Table 2. Table 2 Breakdown of specimens wired with Number of specimens per size maximum gauge minimum gauge Tests EN 2591- Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger Size 12 and smaller Size
22、 10 and larger GROUP 0 Visual examination 101 Magnetic permeability 513 a aaaaaGROUP 1 Visual examination 101 Contact deformation after crimping 503 Contact resistance at rated current 202 Rapid change of temperature 305 Gauge insertion/extraction forces (female contact) 418 Contact resistance at ra
23、ted current 202 Tensile strength (crimped connection) 417 Stripping force, solderless wrapped connections 424 8 4 6 3 2 1 GROUP 2 Visual examination 101 Contact deformation after crimping 503 Contact resistance at rated current 202 Mechanical endurance 406 Sinusoidal and random vibrations 403 Shock
24、402 Contact resistance at rated current 202 Gauge insertion/extraction forces (female contact) 418 16 or 8 4 12 or 6 3 4 or 2 1 continued Page 8 TR 4680:10-05 Table 2 (concluded) Breakdown of specimens wired with Number of specimens per size Maximum gauge Minimum gauge Tests EN 2591- Size 12 and sma
25、ller Size 10 and larger Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger GROUP 3 Visual examination 101 Contact deformation after crimping 503 Contact resistance at rated current 202 Endurance at temperature 301 Contact resistance at rated current 202 Contact bending str
26、ength 416 8 - 4 - 4 - GROUP 4 Visual examination 101 Unwrapping capability, solderless wrapped connections 425 Measurement of thickness of coating on contacts 508 Adhesion of coating on contacts 509 4 2 - - - - GROUP 5 Gas tightness of solderless wrapped connections 319 3 - - - - - GROUP 6 Mechanica
27、l endurance 406 Plating porosity 507 8 8 - - - - aAll specimens of group 1 to 6. Page 9 TR 4680:10-05 4.4.1.2 Change of protection material or protection process The qualification approval tests are defined in Table 3. Table 3 Breakdown of specimens wired with Number of specimens per size Maximum ga
28、uge Minimum gauge Tests EN 2591- Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger GROUP 0 Visual examination 101 Magnetic permeability 513 a aaaaaGROUP 1 Visual examination 101 Examination of dimensions and mass 102 Contact deformat
29、ion after crimping 503 Contact resistance-Low level 201 Contact resistance at rated current 202 Rapid change of temperature 305 Contact resistance at rated current 202 Tensile strength (crimped connection) 417 Stripping force, solderless wrapped connections 424 8 4 6 3 2 1 GROUP 2 Visual examination
30、 101 Contact deformation after crimping 503 Contact resistance at rated current 202 Endurance at temperature 301 Mechanical endurance 406 Sinusoidal and random vibrations 403 Salt mist 307 Contact resistance at rated current 202 16 or 8 4 12 or 6 3 4 or 2 1 GROUP 3 Visual examination 101 Unwrapping
31、capability, solderless wrapped connections 425 Measurement of thickness of coating on contacts 508 Adhesion of coating on contacts 509 4 2 - - - - GROUP 4 Gas tightness of solderless wrapped connections 319 3 - - - - - GROUP 5 Mechanical endurance 406 Plating porosity 507 8 8 - - - - aAll specimens
32、of group 1 to 5. Page 10 TR 4680:10-05 4.4.1.3 Change of annealing process The qualification approval tests are defined in Table 4. Table 4 Breakdown of specimens wired with Number of specimens per size Maximum gauge Minimum gauge Tests EN 2591- Size 12 and smaller Size 10 and larger Size 12 and sma
33、ller Size 10 and larger Size 12 and smaller Size 10 and larger GROUP 0 Visual examination 101 Magnetic permeability 513 a aaaaaGROUP 1 Visual examination 101 Contact deformation after crimping 503 Contact resistance at rated current 202 Endurance at temperature 301 Mechanical endurance 406 Sinusoida
34、l and random vibrations 403 Contact resistance at rated current 202 Sinusoidal vibrations with passage of current for crimped terminal lugs 428 Visual examination 101 16 or 8 4 12 or 6 3 4 or 2 1 GROUP 2 Visual examination 101 Unwrapping capability, solderless wrapped connections 425 Measurement of
35、thickness of coating on contacts 508 Adhesion of coating on contacts 509 4 2 - - - - GROUP 3 Gas tightness of solderless wrapped connections 319 3 - - - - - GROUP 4 Mechanical endurance 406 Plating porosity 507 8 8 - - - - aAll specimens of group 1 to 4. Page 11 TR 4680:10-05 4.4.2 Test programme Ty
36、pe D or E contacts 4.4.2.1 Change of metallic material The qualification approval tests are defined in Table 5. Table 5 Breakdown of specimens wired with Number of specimens per size Maximum gauge Minimum gauge Tests EN 2591- Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and lar
37、ger Size 12 and smaller Size 10 and larger GROUP 0 Visual examination 101 Magnetic permeability 513 a aaaaaGROUP 1 Visual examination 101 Contact deformation after crimping 503 Contact resistance at rated current 202 Rapid change of temperature 305 Gauge insertion/extraction forces (female contact)
38、418 Contact resistance at rated current 202 Tensile strength (crimped connection) 417 8 4 6 3 2 1 GROUP 2 Visual examination 101 Contact deformation after crimping 503 Contact resistance at rated current 202 Mechanical endurance 406 Sinusoidal and random vibrations 403 Shock 402 Gauge insertion/extr
39、action forces (female contact) 418 16 or 8 4 12 or 6 3 4 or 2 1 aAll specimens of group 1 to 2. Page 12 TR 4680:10-05 4.4.2.2 Change of non metallic material The qualification approval tests are defined in Table 6. Table 6 Breakdown of specimens wired with Number of specimens per size Maximum gauge
40、Minimum gauge Tests EN 2591- Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger GROUP 2 Visual examination 101 Measurement of insulation resistance 206 Voltage proof test 207 Voltage standing Wave Ratio (VSWR) 221 Insertion Loss (I.L)
41、 222 Measurement of characteristic impedance (Zc) of a coaxial connector or contact 223 8 - 4 - 4 - GROUP 3 Moult growth 306 4 4 - - - - GROUP 4 V Fluid resistance 315 1 specimen for each fluid Page 13 TR 4680:10-05 4.4.2.3 Change of protection material or protection process The qualification approv
42、al tests are defined in Table 7. Table 7 Breakdown of specimens wired with Number of specimens per size Maximum gauge Minimum gauge Tests EN 2591- Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger GROUP 0 Visual examination 101 Magne
43、tic permeability 513 a aaaaaGROUP 1 Visual examination 101 Examination of dimensions and mass 102 Contact deformation after crimping 503 Contact resistance at rated current 202 Rapid change of temperature 305 Contact resistance at rated current 202 Tensile strength (crimped connection) 417 8 4 6 3 2
44、 1 GROUP 2 Visual examination 101 Contact deformation after crimping 503 Contact resistance at rated current 202 Mechanical endurance 406 Sinusoidal and random vibrations 403 Salt mist 307 Contact resistance at rated current 202 16 or 8 4 12 or 6 3 4 or 2 1 GROUP 3 Visual examination 101 Measurement
45、 of thickness of coating on contacts 508 Adhesion of coating on contacts 509 4 2 - - - - GROUP 4 Mechanical endurance 406 Plating porosity 507 8 8 - - - - aAll specimens of group 1 to 4. Page 14 TR 4680:10-05 4.4.2.4 Change of annealing process The qualification approval tests are defined in Table 8
46、. Table 8 Breakdown of specimens wired with Number of specimens per size Maximum gauge Minimum gauge Tests EN 2591- Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger Size 12 and smaller Size 10 and larger GROUP 0 Visual examination 101 Magnetic permeability 513 a aaaaaGRO
47、UP 1 Visual examination 101 Contact resistance at rated current 202 Mechanical endurance 406 Sinusoidal and random vibrations 403 Contact resistance at rated current 202 Sinusoidal vibrations with passage of current for crimped terminal lugs 428 16 or 8 4 12 or 6 3 4 or 2 1 GROUP 2 Visual examination 101 Measurement of thickness of coating on contacts 508 Adhesion of coating on contacts 509 4 2 - - - - GROUP 3 Mechanical endurance 406 Plating porosity 507 8 8 - - - - aAll specimens of group 1 to 3.
