Data Sheet: GORE-FLIGHT™ Microwave Assemblies, 6 Series

United States

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


Lightweight solution with lowest insertion loss before and after installation

Airframe cable assemblies are exposed to extreme conditions that can compromise their performance — beginning with the challenges of installation and continuing through the rigorous flight conditions that combine rapid temperature and pressure changes with potential contamination from fuels, oils, and fluids. Maintaining signal integrity in these challenging environments is essential to ensuring the reliability of the sophisticated electronic systems in the aircraft. At the same time, the assemblies must be lightweight and durable to improve fuel efficiency and reduce operating costs.

GORE-FLIGHT™ Microwave Assemblies, 6 Series are lightweight cable solutions that deliver the lowest insertion loss before and after installation, ensuring reliable performance for the life of the system (Table 1). The robust construction of these assemblies reduces total costs by withstanding the challenges of installation, reducing costly production delays, field service frequency, and the need for purchasing replacement assemblies. Also, the 6 Series are lighter weight, which improves fuel efficiency and increases payload.

The 6 Series has been qualified to the most stringent specifications for airframe assemblies. Gore controls the entire manufacturing process from purchasing raw materials and creating and applying the proprietary dielectric material, through testing and shipping the final cable assembly. This unsurpassed vertical integration allows Gore the complete control necessary to achieve tight specifications consistently. This process includes testing 100 percent of the assemblies for vapor leakage, dielectric withstanding voltage, VSWR, insertion loss, impedance, and velocity of propagation — ensuring that every assembly will deliver the highest-quality performance required for today’s civil and military aircraft.

Typical Applications

  • Airborne electronic surveillance/counter measures
  • Radar warning (electronic defense) systems
  • Missile approach warning systems
  • Radar interconnects
  • Electronic/signal intelligence
  • Navigation/communication systems

Rugged Construction for Longer Service Life

GORE-FLIGHT™ Microwave Assemblies, 6 Series are engineered with a rugged construction that withstands the challenging environments they encounter throughout an aircraft’s service life (Figure 1). The engineered fluoropolymers used in this construction help reduce abrasion caused by routing during installation, and they help maintain stable performance by resisting the effects of vibration during flight (Figure 2).

Figure 1: Cable Construction

Figure 1: Cable Construction

Benefits of GORE-FLIGHT™ Microwave Assemblies, 6 Series

  • Outstanding signal integrity with lowest insertion loss before and after installation
  • Lower installation costs due to fewer failures and reduced aircraft production delays
  • Improved fuel efficiency and increased payload with lightweight assembly
  • Longer system life and reduced downtime due to mechanically robust construction
  • Less RF interference among electronic systems due to superior shielding effectiveness
  • Proven compliance with MIL-T-81490 requirementsa

a See Table 2 for specific compliance data

Figure 2: Shake Stabilityb,c

Shake Stability

b Shake stability is a routine test conducted by Gore and is a good indication of the overall performance and stability of an assembly. The test is conducted by normalizing the assembly’s insertion loss and then forcefully shaking the assembly against a hard surface. Gore’s cable assemblies typically achieve less than 0.02 dB of change through 18 GHz.
c Data in this graph reflects 6E Series test results. Results for 65 Series are similar.

Figure 3: Shielding Effectivenessc

Shielding Effectiveness

c Data in this graph reflects 6E Series test results. Results for 65 Series are similar.

Outstanding EMI Shielding

The MIL-T-81490 standard requires a minimum shielding effectiveness of 90 dB. As the power and frequency requirements increase in today’s applications, radiating cable assemblies can interfere with mission-critical systems. These systems can also be susceptible to interference due to inadequate shielding effectiveness.

With proven EMI shielding performance, GORE-FLIGHT™ Microwave Assemblies, 6 Series improves signal integrity by reducing RF interference among multiple electronic systems (Figure 3).

Table 1: 6 Series Product Specifications

Property Value
Cable Type 6E Cable Type 65
Maximum Frequency (GHz) 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
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
Property Value
Cable Type 6E Cable Type 65
Overall Diameter [mm (in)] 8.9 (0.35) 6.1 (0.24)
Nominal Weight [g/m (lb/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

Proven Performance Through Testing

Gore has designed a simulator to evaluate the stress of installation on microwave airframe assemblies (Figure 4). The simulator has several features that replicate minimum bend radius conditions, routing guides that induce torque, and an abrasive edge to simulate routing across sharp edges or through access holes in the airframe structure (Figure 5).

The simulator enables Gore to evaluate the electrical performance of various cable assemblies after installation. Testing electrical characteristics such as insertion loss and VSWR before and after routing through the simulator verifies whether an assembly can withstand the rigorous challenges of installation — resulting in lower total costs and longer service life.

To evaluate the insertion loss of GORE-FLIGHT™ Microwave Assemblies, 6 Series, Gore ran a 10-foot assembly through the simulator for three cycles. The results of this simulation demonstrate the importance of testing insertion loss after installation (Table 2).

 

Table 2: GORE-FLIGHT™ Microwave Assemblies, 6 Series Insertion Loss

Property Nominal Value
Cable Type 6E Cable Type 65
Typical Insertion Loss at 18 GHz (dB/ft) 0.198 0.342
Installed Insertion Loss at 18 GHz (dB/ft) 0.219 0.354

With GORE-FLIGHT™ Microwave Assemblies, a fit-and-forget philosophy is now a reality — providing the most cost-effective solution that ensures mission-critical system performance for military and civil applications.

For more information about the installation simulator, visit gore.com/simulator.

Figure 4: Installation Simulator

Figure 4: Installation Simulator

Figure 5: Abrasive Edge

Figure 5: Abrasive Edge

Excellent Signal Integrity for Improved Reliability

GORE-FLIGHT™ Microwave Assemblies, 6 Series improve system performance by withstanding the challenges of installation, maintenance activities, and flight conditions. When compared to alternative airframe assemblies (Figure 6), the 6 Series maintains the lowest insertion loss before and after installation (Figure 7) — providing stable and accurate system performance.

Likewise, the VSWR of alternative airframe assemblies is less reliable due to impedance changes from cable damage (Figure 8), while the VSWR for the 6 Series is well controlled (Figure 9). With this level of performance, the 6 Series maintains consistent impedance of 50 ± 1 ohms, eliminating insertion loss stack-up issues when routing through airframe bulkheads.

Figure 6: Alternative Airframe Assembly Insertion Lossc

 Alternative Airframe Assembly Insertion Loss

Figure 7: GORE-FLIGHT™ Microwave Assemblies, 6 Series Insertion Lossc

 GORE-FLIGHT Microwave Assemblies, 6 Series Insertion Loss

Figure 8: Alternative Airframe Assembly VSWRc

Alternative Airframe Assembly VSWR

Figure 9: GORE-FLIGHT™ Microwave Assemblies, 6 Series VSWRc

GORE-FLIGHT Microwave Assemblies, 6 Series VSWR

c Data in this graph reflects 6E Series test results. Results for 65 Series are similar

Connector Options

Connectors available for GORE-FLIGHT™ Microwave Assemblies are specifically engineered to optimize performance of the assembly (Table 3). Gore also offers an interface that allows the use of replaceable connectors (Table 4).

Connector Type Maximum Frequency (GHz) Connector Code
Cable Type 6E Cable Type 65
Standarde Lock-Wiref Standarde Lock-Wiref
TNCA Straight Male 18 C01 C0L C01 C0L
TNCA Bulkhead Female 18 C42   C42  
SMA Straight Male 18 R01 R0L R01 R0L
SMA Straight Female 18 R02   R02  
SMA Bulkhead Female 18     R42  
SMA Box Right Angle Male 18     R71 R7L
Size 8 – Male Contact 18     ZR3  
M8 Multiport Straight Male 18     ZXE  

d If your connector option is not listed, please contact a Gore representative.
e Coupling nuts do not have provision for wire locking.
f Coupling nuts are supplied with lock-wire holes

Torque Values

The recommended mating and installation torque values for Gore connector options are provided in Table 5.

Connector Installation Torque
in-lbs (Nm)
TNCAl
TNCA Bulkhead Mount Panel Nut
23 ± 3 (2.59 ± 0.33)
35 ± 5 (3.95 ± 0.56)
SMA 12 – 15 (1.35 – 1.69)
Type Nl Type N Bulkhead Mount Panel Nut 23 ± 3 (2.59 ± 0.33)
35 ± 5 (3.95 ± 0.56)
TK 19 – 21 (2.15 – 2.37)
HN
HN Bulkhead Mount Panel Nut
15 ± 3 (1.69 ± 0.33)
35 ± 5 (3.95 ± 0.56)
Replaceable Adapter 45 ± 5 (5.08 ± 0.56)
Size 8 – Pin Contact
(socket Microwave Interface)
Not applicable

l Based on MIL-T-81490

Connector Type Connector Code
Maximum Frequency (GHz) Standardi Lock-Wirej Self-Lockk
TNCA Straight Maleh 18 801 80L 80S
TNCA Straight Femaleh 18 802    
TNCA Bulkhead Female 18 842    
TNCA Flange-Mount Femaleh 18 852    
TNCA 45˚ Maleh 18 8P1 8PL 8PS
TNCA 90˚ Maleh 18 8V1 8VL 8VS
SMA Straight Male 18 701 70L 70S
SMA 45˚ Male 18 7P1 7PL  
SMA 90˚ Male 18 7V1 7VL  
Type N Straight Male 18 901 90L  
Type N Bulkhead Female 18 962    
Type N 45˚ Male 18 9P1 9PL  
Type N 90˚ Male 18 9V1 9VL  
TK Straight Male 18 ZVM    
TK 45˚ Male 18 ZVN    
HN Straight Male 4 ZJS    
HN 90˚ Male 4 ZNM    
HN Bulkhead Female 4 ZNL    
Multiport M8 Straight Male 18 ZTC    
Multiport M8 45˚ Male 18 Z1A    
Multiport M8 45˚ Male Extended 18 Z1B    
Multiport M8 Straight Female 18 ZTD    
Multiport M8 90˚ Female 18 Z1C    
Multiport M8 90˚ Female Extended 18 Z1D    

 

g If your connector option is not listed, please contact a Gore representative.
h Available in polorized versions.
i Coupling nuts do not have provision for wire locking.
j Coupling nuts are supplied with lock-wire holes.
k Coupling nuts include a self-locking mechanism, eliminating the need for wire locking

Ordering Information

GORE-FLIGHT™ Microwave Assemblies are identified by a 12-character part number. This number designates the cable type, connector types, and assembly length:

Ordering Information

Positions 1–2: Enter 6E or 65 to identify the specific assembly type of GORE-FLIGHT™ Microwave Assemblies, 6 Series. Positions 3–5 and 6–8: See Table 3 for the list of connectors available for each cable type. When reading the label, Connector A is on the left-hand side. Additionally, Gore offers an interface that can be used with replaceable connectors (see Table 4).

Positions 9–12: The length of the assembly is expressed in inches to the nearest tenth, including zeroes to fill positions if the length is less than three digits. For example, the length of a 24.0-inch assembly is specified as 0240 in the last four digits of the part number. To review your application needs and request a quote for an assembly, contact a Gore representative or visit our online cable builder at www.gore.com/rfcablebuilder. To calculate insertion loss, VSWR, and other parameters, visit our online microwave/RF assembly calculator.

Qualification Summary

Engineered to meet the stringent specification requirements of civil and military aircraft, these assemblies have undergone substantial qualification testing to ensure that they meet the specifications of the most current standard (Table 6).

Examination or Test Applicable Standards Status
Design and Construction MIL-T-81490 paragraph 4.7.1 Compliant
Markings MIL-T-81490 paragraph 4.7.1 Compliant
Workmanship MIL-T-81490 paragraph 4.7.1 Compliant
RF Insertion Loss MIL-T-81490 paragraph 4.7.3 Compliant
Voltage Standing Wave Ratio (VSWR) MIL-T-81490 paragraph 4.7.4 Compliant
Impedance MIL-T-81490 paragraph 4.7.5 Compliant
Seal - Vapor Leakage MIL-STD-202 method 112E, paragraph 5, test condition C, procedure IV Compliant
Velocity of Propagation MIL-T-81490 paragraph 4.7.7 Compliant
EMI Shielding Effectiveness EIA-364-66, mode stirred test Compliant
Thermal Shock MIL-STD-810 method 503.5, procedure I-C
MIL-STD-202 method 107, test condition A-1 and B-1
Compliant
Power Handling Capability MIL-T-81490 paragraph 4.7.13, procedure I Compliant
Flexure MIL-T-81490 paragraph 4.7.15, procedure I Compliant
Torque MIL-T-81490 paragraph 4.7.16, torque requirement of 50 in/lbs replaced by ±90° angular displacement Compliant
Tensile Load MIL-T-81490 paragraph 4.7.17 Compliant
Concentrated Load MIL-T-81490 paragraph 4.7.18, 100 ±2 lbs force Compliant Achieved ≥ 150 lbs
Abrasion MIL-T-81490 paragraph 4.7.19, procedure II Compliant
Sand and Dust MIL-STD-810 method 510, procedure I Compliant
Dielectric Withstanding Voltage MIL-STD-202 method 301 Compliant
Explosive Atmosphere MIL-STD-810 method 511, procedure I Compliant
Temperature, Humidity, Altitude, Vibration MIL-STD-810 method 520, procedure III with vibration as per MIL-STD-810 method 514, procedure I Compliant
Humidity MIL-STD-810 method 520, procedure III Compliant
Vibration MIL-STD-810 method 514, procedure I Compliant
Salt Fog MIL-STD-810 method 509 Compliant
Chemical Resistance MIL-STD-810 method 504 Compliant
Icing/Freezing Rain MIL-STD-810 method 521 Compliant
Fungus Resistance MIL-STD-810 method 508 Compliant
Mechanical Shock MIL-STD-810 method 516, procedure I, V Compliant
Drip MIL-STD-810 method 506, procedure III Compliant
Rain & Blowing Rain MIL-STD-810 method 506, procedure I Compliant
Corona Extinction Voltage MIL-DTL-17 paragraph 3.7.5 Compliant
Flammability FAR25.853 appendix F part I (b)(7) ABD0031 paragraph 7.1.6 MIL-STD-202 method 111 Compliant
Toxicity ABD0031 paragraph 7.4 Compliant
Smoke Density ABD0031 paragraph 7.3.5 (AITM 2.0008 B) FAR25.853 Appendix F part V Compliant
Impact Shock
  Cable Type 6E
  Cable Type 65
MIL-T-81490 paragraph 4.7.14
  with 1.5 lb
  with 1.0 lb
Compliant

 

NOTICE – USE RESTRICTIONS APPLY Not for use in food, drug, cosmetic or medical device manufacturing, processing, or packaging operations

GORE, GORE-FLIGHT and designs are trademarks of W. L. Gore & Associates ©2016 W. L. Gore & Associates, Inc. GMCA-0062-R3-DAT-US-JAN16