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ENSURE EWIS RELIABILITY OVER TIME WITH DURABLE, LIGHT WIRE BUNDLES.
The aerospace industry is trending towards electrification to reduce the toll that air transport takes on the environment. In turn, voltages are increasing to avoid weight gain in aircraft wiring systems, but this also places more electrical stress on wiring and increases the risks of physical damage. Thankfully, W. L. Gore & Associates is standing by with an optimal solution. GORE High Performance Aerospace Wires feature proven electrical and mechanical durability to ensure the reliability of electrical wire interconnection systems (EWIS) over time.
ENSURE RELIABLE AIRCRAFT ELECTRIFICATION
When it comes to aircraft electrification, aircraft wire insulation must be durable enough to ensure reliable EWIS (electrical wire interconnection systems). But electrification requires higher aircraft voltage, which stresses wiring more and causes potential physical damage. Typical insulation materials are often limited in durability and degrade over time when exposed to harsh airborne conditions. You can add extra aerospace wiring insulation for more durability, but it increases wire bundle size and weight, plus adds unwanted aircraft weight.
Gore offers a single optimal solution that OEMs (original equipment manufacturers) and program managers want and need for future military aircraft electrification.
Best Combination of Durability & Long-Term Stability
GORE High Performance Aerospace Wires offer greater mechanical strength and exceptional electrical reliability over time without adding to wire bundle size and weight. They meet higher durability levels for aircraft electrical wire bundles operating in severe airborne conditions.
Our wire insulation is proven to have a higher PDIV/PDEV while displaying higher voltage breakdown and endurance than alternative aerospace wire and cable materials. This unique aircraft wire insulation offers other proven advantages over alternative materials, like resistance to extreme operating temperatures, humidity and harsh chemicals without degrading. And our insulation is proven to resist chafing, abrasion and cut-through failures.
On top of that, our flexible, lightweight design not only eases routing in confined spaces but also won’t increase wire bundle size or add extra weight to the aircraft.
Meet all your electrical wire system needs with GORE High Performance Aerospace Wires that ensure EWIS reliability over time, increase aircraft availability, improve safety and reduce total costs.
Review the table below to compare the insulation material in GORE High Performance Aerospace Wires against common insulation materials for aircraft wires and cables.
Keep in mind that current aircraft electrical wiring solutions either contain polyimide or show limitations in physical and electrical properties. The yellow squares indicate good overall results from our abrasion testing. But, the underlying polyimide is quickly exposed, risking degradation, arc tracking and more. Any improvements to these materials in commonly used aircraft electrical wire types to add durability will likely add size and weight.
|Critical Attributes||Extruded Fluoropolymer (XLETFE)||PTFE/Polyimide Composite||Gore Engineered Fluoropolymer (EFP)|
|Long-Term Material Stability||■||■||■|
Green = Acceptable/Good
Yellow = Concern/Uncertainty
Red = Unacceptable/Low Performance
Features & Benefits
GORE High Performance Aerospace Wires are engineered with unique features that make them more durable against challenging environmental factors and aircraft conditions, including:
- low-permittivity, higher PDIV/PDEV material
- temperature-resistant, chemically inert, non-flammable material
- abrasion- and cut-through resistant material
- hydrophobic, non-hydrolyzing material
- lighter weight wire bundle design
Our aircraft power wires provide system architects and engineers with many benefits that improve electrical, mechanical and environmental performance such as:
- proven strength against chafing, abrasion and cut-through over wide temps
- resist chemicals/fire for increased aircraft safety and improved system performance
- no degradation over time from hydrophobic, non-hydrolyzing material
- improved electrical durability and less voltage breakdown over time in demanding MEA applications
- greater EWIS reliability, increased aircraft availability and reduced costs
- increased future-proofing with wires that can withstand higher voltage requirements
- selected samples with short lead times for prototyping and evaluation
- low risk based on validated product performance in real-world conditions
For more information about the features and benefits of our wires, contact a Gore representative today.
GORE High Performance Aerospace Wires for Defense Aircraft have undergone substantial qualification testing to ensure they meet the most current aircraft wiring standards and our customers’ requirements.
For available test data and more information about the qualifications of our wires, contact a Gore representative today.
|Nominal Insulation Wall Thickness||8 mils for engineered fluoropolymer||—||Compliant|
|Test Voltage||Impulse: 8 kV (peak)
High-frequency test voltage: 5 kV (RMS)
|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.
LEARN MORE ABOUT GORE HIGH PERFORMANCE AEROSPACE WIRES OR ORDER NOW
Our wires offer a single optimal solution with the best combination of durability and long-term stability without adding size or weight. We’re pleased to provide complimentary samples of our aerospace cables and wires for prototyping and evaluation in your application within 48 hours of your request.
For more technical information about our high-performance wire and cable solutions, connect with a Gore representative for defense aircraft today. When you’re ready to order our wires, get in touch with one of our trusted distributors.
Posted September 27, 2022
W. L. Gore & Associates (Gore) announced today the addition of a new European distributor for its aerospace high-speed data cables. A.E. Petsche Company is now an authorized distributor for Gore’s entire selection of cables, including fiber optics, Ethernet, quadrax, HDMI, USB, shielded twisted pair, and more. Gore also offers higher-level cable protection systems and an abrasion-resistant cable jacket for packaging copper wires and cables.
Posted June 16, 2022
W. L. Gore & Associates (Gore) announced a new higher-frequency 40Ghz option for its GORE-FLIGHT® Microwave Assemblies. The new option will help EW and C5ISR users and customers who want to transport electrical signals reliably with minimal size, weight and power. The newest capability for GORE-FLIGHT Microwave Assemblies will allow for higher frequency applications that will offer low loss, high integrity and greater longevity cables.
April 3, 2022 - April 5, 2022
Come by Booth 305 to watch demonstrations so you can see the durability and flexibility of GORE® Aerospace Cables and Materials and how they continually outperform leading alternatives before and after installation and over time.
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!
FOR INDUSTRIAL USE ONLY
Not for use in food, drug, cosmetic or medical device manufacturing, processing, or packaging operations.
Cables & Cable Assemblies
- Ethernet Cables for Defense Aircraft
- Shielded Twisted Pair Cables for Defense Aircraft
- CAN Bus Cables for Defense Aircraft
- Quad Cables (Specialty Versions) for Defense Aircraft
- FireWire® Cables for Defense Aircraft
- Fibre Channel Cables for Defense Aircraft
- USB Cables for Defense Aircraft
- HDMI Cables for Defense Aircraft
- DVI Cables (Digital Only) for Defense Aircraft
- Fiber Optic Cables for Defense Aircraft
- Cable Protection Systems for Defense Aircraft
- Abrasion Resistant Cable Jacket for Defense Aircraft
- MIL-STD-1760 Assemblies for Defense Aircraft
- GORE-FLIGHT® Microwave Assemblies for Defense Aircraft
- Microwave/RF Assemblies, 7 Series for Defense Aircraft
- Microwave/RF Assemblies for Defense Aircraft