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AIR FORCE RELIABILITY LABORATORY WPAFB, OHIO.
Comment: The U.S. Air Force has allowed composite and aromatic polyimide insulated wire to
be used together in particular instances, and they do not have specific data at this time to indicate
that this combination is detrimental to the performance of those applications. Decisions to make
wire substitutions, which may result in combinations of wire types, are made by the system
program director on a case-by-case basis.
3. NAVAL VEHICLE AIRCRAFT WIRING ACTION GROUP (NAVWAG) WIRE
SUBSTITUTION CHART
Comment: The Naval Vehicle Aircraft Wiring Action Group (NAVWAG) published a wire
substitution chart for all wire being used in the fleets in order to permit standardization of wire
types in cable repair shops. This action has permitted mixed wires to be used in U.S. Navy
aircraft. No field failures have been reported.
4. NAVAL AVIONIC CENTER (NAC) AND RAYTHEON RECOMMENDATIONS TO
NAVAIR FOR WIRE SUBSTITUTION OF CANCELED WIRE SPECIFICATIONS
Comment: In December 2000 Raytheon recommended MIL-W-22759/32 wire be used as a
replacement for the cancelled MIL-W-81044/18 wire. Prior to this time similar NAC
recommendations were made for cancelled MIL-W-5086 wire and wires with known application
problems such as MIL-W-81381 wire.
5. INTERVIEWS WITH LOCKHEED MARIETTA SENIOR WIRE ENGINEER
Comment: Lockheed Marietta has conducted numerous vibration tests (sometime with
temperature) for various aircraft (C-130, C-141, C-5, F-22, P3 and L-1011) as new wires were
developed in order to substantiate the use of the new wires in combination with the original wire
types. No formal reports were written. Over 2 million rubs were performed to get one failure.
Lockheed Marietta concluded that mixed wires was not an issue.
6. FIELD DATA ANALYSIS FROM RAYTHEON REPORT “AIRCRAFT WIRE
SYSTEM RECOMMENDATIONS FOR A TSO TO ADDRESS MINIMUM SAFETY
PERFORMANCE” JUNE 30, 2003
The field data from the following databases were reviewed for possible mixed wire incidents.
There were reported cases of abraded wires, but no indication the abrasions may have been
caused by mixing of various wire types.
A-7
TABLE A-1. FIELD DATA SOURCES
Field Data
Description 1
Time Frame Data
was Collected Source of Information 2, 3
NTSB Aviation Accident
Incident Data System
1983 – July 2002 https://nasdac.faa.gov/pls/nasdac/ 1, 2
NTSB Aviation Safety
Reporting System
1988 – July 2002 https://nasdac.faa.gov/pls/nasdac/ 1,2
Service Difficulty
Reports (SDRs)
October 2000 – July 2002 http://av-info.faa.gov/ 3
Airworthiness Directives
(ADs)
1979 – July 2002 http://av-info.faa.gov/
Navy Safety Info 1/10/97 to 5/2/01 Information obtained from Cmdr. Bowers
Miscellaneous and
ATSRAC Info
October 1978 – August 2000 Information obtained from the intrusive
inspection final report and other various
sources
NALDA Cable and
Connector Shop
January 1996 - July 2002 NALDA 3M Data
NALDA Electrical Shop January 1996 - July 2002 NALDA 3M Data
Notes:
1. During the investigation several web sites were under construction and may no longer be directly accessible
since the time that the data was gathered.
2. www.ntsb.gov/ntsb/query.asp was used as an alternate source for backup information.
3. Several incident reports, which were not on the NTSB website contained information deemed useable and were
included in this database.
7. NAC PUBLICATION TR-2333 “TESTING OF SELECTED AIRCRAFT WIRES
INSULATIONS” 8 JUNE 1983
Page 2
A particular wire type could be selected for use in a given part of an aircraft depending upon the
combination of environmental and mechanical stresses encountered in that particular part of the
airframe. None of the wires tested demonstrated acceptable qualities for optimum use in all
areas of Navy aircraft.
Page 4
It is recommended that until a universal insulation is developed, a wire should be chosen based
on its application.
Comment: In vibration, three bundles of two wire types (15 wires of each type) were tested for
100, 250, and 512 hours at the AV-8B aircraft cruising test level. One bundle contained
M22759/16 and M22759/34 wire types, one contained M81381/11 and M22759/16 wire types,
and one bundle contained M22759/32 and M81381/11 wire types. The wires were tested to
failure to their maximum dielectric voltage withstand capability.
A-8
Comment: Statistically, the results indicated, in general, that harder insulation dielectric
characteristics are reduced significantly more than the softer insulation. In some cases, the
reduced voltage capability is nearly 50% from the initial values, but it should be recognized even
　
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