GORE-FLIGHT Microwave Assemblies for Military Aircraft

Lightweight, flexible airframe assemblies from Gore improve all aspects of protection and performance ensuring mission-critical success after installation, during use and over time. We offer two rugged series that deliver proven performance in the most demanding aerospace conditions for less downtime and reduced total cost of ownership.

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Resource Library

GORE-FLIGHT™ Microwave Assemblies, 6 Series

Coaxial & Microwave / RF Cable Assemblies

Provides technical information including benefits, typical applications, product specifications, qualification summary, comparison test data, connector options and ordering information.

English (U.S.)

All Resources For GORE-FLIGHT Microwave Assemblies for Military Aircraft

Overview

Maintaining signal integrity under difficult aerospace environments is essential to the reliability of mission-critical systems in military aircraft. Starting with installation all the way through harsh flight conditions, like rapid temperature/pressure changes and potential contamination from fuels, oils, and fluids. At the same time, airframe assemblies must be both lightweight and durable to improve fuel efficiency and reduce operating costs for the military.

In fact, we conducted independent studies and research showing that globally more than 75% of microwave/RF cable assemblies are frequently replaced due to damage during installation or operation. So, costs can quickly add up with replacing assemblies, extra labor, and more maintenance and downtime!

PROVEN, LONG-LASTING PERFORMANCE

We offer two series of GORE-FLIGHT Microwave Assemblies — our award-winning 6 Series and our first-generation Standard Series. Each series has a lightweight, flexible yet rugged construction that withstands a broad scope of challenges. Like continuous flexing during routing, repeated shock/vibration of flight, extreme altitude/temperatures changes, and harsh contaminants. Both series have been fully tested and qualified to meet stringent military specifications and requirements for current and future generation fighter jets and helicopters.

Whichever series you choose for your specific application, GORE-FLIGHT Microwave Assemblies are the proven, long-lasting solution offering easier installation, reliable signal integrity, reduced downtime, improved fuel efficiency, increased payload, and lower total costs.

Sikorsky Apache MH-53 Pave Low
F-16

The 6 Series delivers the lowest insertion loss before and after installation.

Benefits

GORE-FLIGHT Microwave Assemblies provide system architects and engineers with many benefits that improve electrical and mechanical performance such as:

  • outstanding signal integrity in demanding aerospace environments during use and over time
  • lowest insertion loss and more reliable VSWR before/after installation
  • less interference among critical systems due to superior shielding effectiveness
  • lower installation costs due to fewer failures and reduced aircraft production delays
  • longer product/system life and reduced downtime with rugged constructions
  • durable vapor sealing prevents ingress of aircraft contaminants
  • improved fuel efficiency and increased payload with lightweight assembly
  • Increased design flexibility with a variety of robust, low-profile connector options
  • proven compliance with stringent military specifications such as MIL-T-81490 requirements

For more information about the benefits of our assemblies, please contact a Gore representative.

6 Series

Military aircraft manufacturers no longer have to accept the practice of replacing microwave assemblies because they get damaged during installation. A fit-and-forget philosophy is now a reality because our award-winning 6 Series provides the most cost-effective, lightweight solution that ensures critical system performance for pilots.

6 Series Details

LIGHTWEIGHT SOLUTION WITH LOWEST INSERTION LOSS

We designed a simulator that replicates the conditions an assembly experiences while being routed during installation in an aircraft. Results proved that our 6 Series delivered the lowest insertion loss and more reliable VSWR before/after installation, ensuring stable and accurate performance compared to alternative airframe assemblies. These rugged airframe assemblies can easily withstand rigorous installation, maintenance activities and flight conditions, ensuring life-of-aircraft performance.

With this high level of performance, our 6 Series reduces costly production delays, field service frequency, and the need for purchasing replacement assemblies. They’re also 17% lighter weight compared to alternative designs, which improves fuel efficiency and increases payload.

Rugged construction of GORE-FLIGHT Microwave Assemblies, 6 Series
A
B
C
D
E
F
G
H

Engineered fluoropolymer jacket

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Liquid barrier

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Crush member

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Vapor barrier

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Torque-resistant braid

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Helically-wrapped, silver-plated outer conductor

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Silver-plated copper conductor

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Composite dielectric

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Rugged construction of GORE-FLIGHT Microwave Assemblies, 6 Series

PROPERTIES

These values demonstrate the electrical, mechanical and environmental performance of GORE-FLIGHT Microwave Assemblies, 6 Series.

Download the data sheet for more technical information, including qualifications, comparison test data, connector options, and ordering information.

Electrical Properties Cable Type
6E 65
Maximum Frequency 18 18
Typical VSWR through 18 GHz (straight connector) 1.25:1 1.25:1
Guaranteed VSWR through 18 GHz (straight connector) 1.40:1 1.40:1
Typical Insertion Loss at 18 GHz (dB/ft) 0.198 0.342
Guaranteed Insertion Loss at 18 GHz (dB/ft) 0.208 0.384
Installed Insertion Loss at 18 GHz (dB/ft)* 0.219 0.354
Impedance (Ohms) 50 ± 1 50 ± 1
Dielectric Constant (Nominal) 1.35 1.35
Velocity of Propagation (Nominal) (%) 86 86
Time Delay (Nominal) (ns/cm [ns/in]) 0.0387 (0.0984) 0.0387 (0.0984)
Shielding Effectiveness through 18 GHz (dB) 90 90

* Based on 10-foot assembly after three cycles through the installation simulator.

Mechanical / Environmental Property Cable Type
6E 65
Overall Diameter (mm [in]) 8.9 (0.35) 6.1 (0.24)
Nominal Weight (g/m [oz/ft]) 125 (0.084) 60 (0.040)
Minimum Bend Radius (mm [in]) 48.3 (1.9) 25.4 (1.0)
Temperature Range (°C) -55 to 125 -55 to 125
Concentrated Load per MIL-T-81490 paragraph 4.7.18 (lb) > 150 > 150
Innovators Awards

GORE-FLIGHT™ Microwave Assemblies earned a platinum award for product innovation from Military & Aerospace Electronics.

Find out more

APPLICATIONS

GORE-FLIGHT Microwave Assemblies, 6 Series is engineered to perform reliably in a variety of military airborne applications, including:

  • airborne electronic surveillance / countermeasures
  • electronic / signal intelligence
  • missile approach warning systems
  • navigation / communication systems
  • radar interconnects
  • radar warning (electronic defense) systems

If you have any questions or to discuss your specific application needs, please contact a Gore representative.

Standard Series

Our Standard Series is the first generation of GORE-FLIGHT Microwave Assemblies. They have a high level of robustness and flexibility like our 6 Series, so military aircraft manufacturers and personnel can be confident in their capabilities and performance.

Standard Series Details

Standard Series Details

Our airframe assemblies have an internally ruggedized construction that withstands concentrated loads well in excess of those specified by MIL-T-81490 — reducing the likelihood of crush damage during installation and throughout service life. The lightweight design of our Standard Series coupled with flexibility and an inherent resistance to over-bending makes them easier to install in small spaces of an aircraft.

These assemblies also offer vapor and liquid barriers to prevent any ingress of fuels, oils, coolants or cleaning fluids — ensuring reliable electrical performance even in the harshest of environments.

PROPERTIES

These values demonstrate the electrical, mechanical and environmental performance of GORE-FLIGHT Microwave Assemblies, Standard Series.

Download the data sheet for more technical information, including qualifications.

Electrical Properties Cable Type
04 02 08 05 0B 06 0E 0L
Maximum Frequency GHz 18 18 18 18 18 18 18 7
Characteristic Impedance Ohms 50 50 50 50 50 50 50 50
Typical Insertion Loss dB/m (dB/ft) @ Max Frequency 2.03
(0.62)
1.33
(0.41)
1.33
(0.41)
1.15
(0.35)
0.95
(0.29)
0.75
(0.23)
0.69
(0.21)
0.33
(0.10)
Velocity of Propagation % 85 85 85 85 85 85 85 85
Time Delay ns/cm (ns/in) 0.04
(0.103)
0.04
(0.103)
0.04
(0.103)
0.04
(0.103)
0.04
(0.103)
0.04
(0.103)
0.04
(0.103)
0.04
(0.103)
Dielectric Constant 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4
Shielding Effectiveness dB to 18 GHz >100 >100 >100 >100 >100 >100 >100 >100
Mechanical / Environmental Properties Cable Type
04 02 08 05 0B 06 0E 0L
Center Conductor Solid Stranded Stranded Solid Solid Solid Solid Stranded
Overall Diameter mm (in) 4.55
(0.18)
6.96
(0.27)
7.25
(0.29)
6.96
(0.27)
7.50
(0.29)
9.50
(0.37)
9.93
(0.39)
12.7 (0.50)
Nominal Weight g/m (oz/ft) 41
(0.43)
105
(1.13)
137
(1.47)
105
(1.13)
128
(1.37)
190
(2.04)
204
(2.19)
345
(3.70)
Minimum Bend Radius mm (in) 12.5
(0.49)
25.0
(0.98)
25.0
(0.98)
25.0
(0.98)
38.0
(1.49)
50.0
(1.97)
55.0
(2.16)
62.5
(2.46)
Temperature Range °C (°F) -58 to 200*
(-72 to 392*)
-58 to 200*
(-72 to 392*)
-58 to 200*
(-72 to 392*)
-58 to 200*
(-72 to 392*)
-58 to 200*
(-72 to 392*)
-58 to 200*
(-72 to 392*)
-58 to 200*
(-72 to 392*)
-58 to 200*
(-72 to 392*)
Crush Resistance kgf/cm (lb/in) >31.3
(>175)
>31.3
(>175)
>31.3
(>175)
>31.3
(>175)
>31.3
(>175)
>31.3
(>175)
>31.3
(>175)
>31.3
(>175)

 

APPLICATIONS

GORE-FLIGHT Microwave Assemblies, Standard Series is engineered to perform reliably in a variety of military airborne applications, including:

  • airborne electronic surveillance / countermeasures
  • electronic / signal intelligence
  • missile approach warning systems
  • navigation / communication systems
  • radar interconnects
  • radar warning (electronic defense) systems

If you have any questions or to discuss your specific application needs, please contact a Gore representative.

Installation Simulator

Gore has long been a proponent of showing accurately how its products and technologies function in real-world environments before bringing them to market. Because nearly one-third of cable failures occur during installation, this is a crucial risk factor that shouldn't be minimized. Damaged airframe assemblies can lead to compromised signal integrity and failures over time, as well as additional testing, maintenance and replacement costs. With our Cable Installation Simulator, civil and military aircraft manufacturers can be confident they are getting a reliable cable assembly solution that withstands the rigors of installation and reduces the total cost of ownership.

Jim Foreman, Product Specialist

Jim Foreman, Product Specialist

"Aircraft manufacturers need reliable solutions that can be installed deep within an aircraft and left there for the life of the platform. Therefore, we want to create 'fit-and-forget' solutions that will survive the demanding environments within an aircraft," said Jim Foreman, Product Manager at Gore. "We're committed to designing next-generation products that solve key challenges, and mitigate risk for aircraft," said Paul Pino, Lead Principal Design Engineer at Gore. "To do this, we test and simulate real-world conditions to ensure that our products do what we say they will do, consistently and reliably even in harsh conditions."

For more information about our Installation Simulator, download the white paper,  Proving Installed Performance of Airframe Microwave Assemblies.

Also, download the white paper, Reducing Life Cycle Costs with Reliable Airframe Microwave Assemblies.

Videos

Watch these videos and more on YouTube of Gore engineers demonstrating the benefits of GORE Microwave/RF Assemblies.

Online Tools

Easy to Use, Fast Results

Gore’s online resources are designed specifically to make it easy for you to select the right microwave/RF assembly for your specific application requirements.

Microwave/RF Cable Assembly Builder allows you to configure a Gore assembly for different cable types based on your application needs.  You can also request a quote.

Microwave/RF Cable Assembly Calculator allows you to calculate insertion loss, VSWR and other parameters of Gore’s assemblies for different cable types. Select and compare up to 3 cables at a time.

If you have questions about our assemblies and want to discuss your specific application needs, please contact a Gore representative.

Resources

Recent News

Press Release

Preview Gore High-Performance Technical Solutions for Military and Defence Applications at DVD2018

Posted September 18, 2018

Gore will display field-proven and battle-tested technical solutions at the Defence Vehicle Dynamics (DVD) event at the Millbrook Proving Ground in Bedfordshire, UK on 19-20 September, Booth C-707.

Event

Preview GORE® Aerospace Cables and Materials Approved for Use on the F-16 at 2018 TCG Worldwide Review (WWR)

September 10, 2018 - September 13, 2018

Stop by our booths 133 & 134 to check out our broad portfolio of proven aerospace cables and materials approved for use on multiple military aircraft, including the F-16

Find out more

Event

Gore at Farnborough Airshow 2018

July 16, 2018 - July 22, 2018

Come see us at this year’s airshow in Hall 1, Booth 1265 to see GORE® Cables and Materials and GORE® Military Fabrics.

Find out more at gore.com/FIA2018

Press Release

Gore Featuring Proven & Trusted High-Performance Solutions for Aerospace & Defense Applications at 2018 Farnborough Airshow

Posted July 9, 2018

Gore will showcase a wide selection of high-performance solutions at the world’s biggest airshow in Farnborough, 16-22 July in Hall 1, Booth 1265.

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