Overview

As the trend towards electrification and higher DC voltage increases in aircraft, wire insulation becomes critical to ensure system reliability, functionality and safety. But, higher voltages put more electrical stress on wiring, which means more risks from physical damage. You can increase the amount of insulation to add more durability, but increasing wire size and weight also add aircraft weight.

Best Combination of Durability & Long-Term Stability

The GWN3000 Series of GORE High Performance Aerospace Wires offers the best combination of superior mechanical strength and outstanding electrical reliability without increasing wire bundle size or weight. They meet higher mechanical and electrical durability levels for wire bundles operating in severe conditions.

The key is our proprietary fluoropolymer that has a higher PDIV/PDEV with a proven higher voltage breakdown and endurance than other materials. This unique insulation can easily resist extreme operating temperatures, harsh chemicals and humidity without degrading. Unlike other materials, our insulation is also proven to reduce chafing, abrasion and cut-through failures.

Ultimately, we’ve developed an optimal solution that OEMs and program managers want and need for future aircraft electrification. Our GWN3000 Series provides aircraft systems with a higher level of mechanical and electrical performance over time.

With GORE High Performance Aerospace Wires installed in your aircraft, you can ensure operational readiness and EWIS reliability, increase aircraft availability, improve safety and reduce your total costs.

Material Comparison

Review the table below to compare GORE High Performance Aerospace Wires, GWN3000 Series against other insulation materials.

Note that current wiring solutions either contain polyimide or exhibit limitations in physical and electrical properties. The yellow squares indicate good overall abrasion test results. But, the underlying polyimide is quickly exposed, which risks degradation, arc tracking, and more. Any Improvements to these materials are likely to involve an increase in wire size and weight.

Download the data sheet for more performance comparison data.

Critical Attributes Extruded Fluoropolymer (XLETFE) PTFE/Polyimide Composite Gore Engineered Fluoropolymer (EFP)
Mechanical Durability
Electrical Durability
Long-Term Material Stability

 

Green = Acceptable/Good
Yellow = Concern/Uncertainty
Red = Unacceptable/Low Performance

Features & Benefits

GORE High Performance Aerospace Wires, GWN3000 Series offers many features and benefits for improved system performance in aircraft, including:

  • less risk of wire damage with proven insulation strength that resists chafing, abrasion and cut-through over wide temperatures
  • chemically inert, non-flammable material resists harsh chemicals/fire for increased aircraft safety and improved system performance
  • no degradation over time due to hydrophobic, non-hydrolyzing material that ensures longer service life
  • low-permittivity material ensures higher PDIV/PDEV for improved electrical durability, reducing risk of voltage breakdown over time in demanding MEA applications
  • Greater EWIS reliability, increased aircraft availability, improved safety, reduced total costs
  • increased future-proofing with wires that can withstand higher voltage requirements
  • selected samples with short lead times for prototyping and evaluation

For more information about the features and benefits of our wires or to discuss your specific application needs, please contact a Gore representative.

Qualifications

GORE High Performance Aerospace Wires, GWN3000 Series, has undergone substantial qualification testing to ensure they meet the most current industry standards and our customers’ requirements.

We completed all testing according to SAE AS4373™ methods using size 20 AWG. We also compared performance results for our part number, GWN3001-20-NCC-U-9, against commonly used wire types.

Description Requirement Standard Status
Nominal Insulation Wall Thickness 8 mils for engineered fluoropolymer Compliant
Test Voltage Impulse: 8 kV (peak)
High-frequency test voltage: 5 kV (RMS)
Compliant
Partial Discharge Inception Voltage Minimum 900 V ASTM D3032, Section 25* Compliant
Partial Discharge Extinction Voltage Minimum 1900 V ASTM D3032, Section 25* Compliant
Dry Arc Propagation 70 out of 75 wires pass dielectric withstand post-test SAE AS4373, Method 508 Compliant
Wet Arc Propagation 70 out of 75 wires pass dielectric withstand post-test SAE AS4373, Method 509 Compliant
Flammability No incendiary particles; burn <3.0 mm (1.18 in); self-extinguish in 3 seconds SAE AS4373, Method 801 Compliant
Humidity resistance 5000 m per ohms / 1000 ft after exposure SAE AS4373, Method 603 Compliant
Dynamic Cut Through Resistance 23°C, 30 lb
150°C, 25 lb
200°C, 25 lb
260°C, 10 lb
SAE AS4373, Method 703 Compliant
Abrasion Resistance 23°C, 20,000 cycles
70°C, 3,000 cycles
150°C, 1,000 cycles
SAE AS4373, Method 301 Compliant
Tensile Strength Average >60 lb SAE AS4373, Method 705 Compliant
Wrap Back No cracks after wrapping SAE AS4373, Method 714 Compliant

* Test performed in dielectric fluid.

Fill out short form to receive a complimentary sample of our wires for prototyping and evaluation from our authorized global distributors, Air Cost Control (Europe) or WireMasters (US).

Resources

Recent News

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Join Us at the Aviation Forum

December 7, 2021 - December 8, 2021

Visit our Booth F16 to tell us about your latest airframe and aviation system developments and hear more about our solutions for the civil aerospace industry. We’re looking forward to meeting and talking in person again after so long!

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Visit Us at Cribbins

November 15, 2021 - November 17, 2021

We’re excited to be able to meet and talk in person again after so many virtual meetings! Stop by Booth 609 to talk with us about your latest aviation and airframe system developments. And you don’t want to miss our latest Fiber Optic Cables Demonstration, so come by and ask to see it.

W. L. Gore & Associates High Performance Aerospace Wires Set Gold Standard With Industry Award

Posted November 8, 2021

W. L. Gore & Associates (Gore) announced today that its GORE® High Performance Aerospace Wires, GWN3000 Series, were recognized among the 2021 Military & Aerospace Electronics Technology Innovators Awards. An independent panel of esteemed judges from the aerospace and defense community recognized Gore as a gold honoree for the second consecutive year. The company’s PHASEFLEX® Microwave/RF Test Assemblies were recognized in 2020.

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Gore Exhibiting at 2021 Global Defense Helicopter

November 2, 2021 - November 4, 2021

Visit our booth during Europe’s largest military helicopter event to see our extensive portfolio of proven solutions that the military has relied on and trusted for decades. On Thursday, November 4th, don’t miss the presentation from our experts about Gore’s aerospace interconnection solutions and materials for existing and next-gen rotorcraft.

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