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

Press Release

Gore Jolts Emerging Electric Aviation Market with New High-Performance Aerospace Wires

Posted October 13, 2020

W. L. Gore & Associates announced today a new solution that meets higher voltages as the trend continues towards aircraft electrification to reduce the impact of air transport on our environment. GORE® High Performance Aerospace Wires, GWN3000 Series, deliver the best combination of superior mechanical strength and outstanding electrical reliability without increasing wire bundle size or weight.

Press Release

GORE® PHASEFLEX® Microwave/RF Test Assemblies Honored, Set Gold Standard with Industry Innovators Award

Posted September 16, 2020

W. L. Gore & Associates announced that its GORE® PHASEFLEX® Microwave/RF Test Assemblies were recognized among the 2020 Military & Aerospace Electronics Innovators Awards. An esteemed and experienced panel of judges from the aerospace and defense community recognized Gore as a Gold honoree. These assemblies are being recognized for their durability and reliability for precision testing of electronic warfare (EW) / radar suites; electronic surveillance/counter measures; radar warning systems; missile approach warning systems; and navigation/communication systems.

Event

W. L. Gore & Associates Goes Virtual at IMS2020

August 4, 2020 - August 6, 2020

Due to the ongoing challenge of COVID-19, IMS2020 has been moved to virtual with live streaming. A key topic at the symposium is 5G connectivity, and Gore will present a portfolio of reliable microwave/RF test assemblies for 5G testing. We’ll describe how our cable assemblies provide durable, stable, and consistent performance to ensuring accurate and reliable testing results.

Press Release

Gore Products to Enable Mars 2020 Mission Communications

Posted July 30, 2020

W. L. Gore & Associates (Gore) today announced the company’s involvement in the Mars 2020 Mission scheduled for launch on July 30 from Cape Canaveral Air Force Station in Florida. This U.S. mission addresses high-priority scientific goals for exploration to help answer the questions of potential life on Mars.

View all News & Events

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