High strength light weight metal clad aramid fibers can provide significant weight savings when used to replace conventional metal wire in aerospace cable. An overview of metal clad aramid fiber materials and information on performance and use in braided electrical shielding and signal conductors is provided

Allen, David B.

Dunham, Michael G.

Hunt, James E.

Santoleri, E. David

Tokarsky, Edward W.

English

NASA Technical Reports Server

N96-17095 '
METALCLAD ARAMIDFIBERS FOR AEROSPACEWIRE AND CABLE
Edward W. Tokarsky, MichaelG. Dunharn,James E. Hunt,
E. DavidSantoleri,andDavidB. Allen
DuPontCompany -_/_ ._ -"' ,
Wilmington,Delaware .--., .-.
_: /4
t
Highstrength,light wd_t metal dad _d fiberse_
providedgnificantweight savingswhen used to replace
conventionalmetalwire in aerospacecable. This paper
providesan overviewof metal dad mmmidfiber materials
andinfornmfionon performlmceand use in braided
electricalshielding and signalconductor.
Background
ARACON*combinesOuPompara-aramidfiber
technologywith metalcladdings...
r Para-aramidFiber_
u
High
ModulusSimilartoMetals
LowI)emity
FineDiameter
'nmmalStability
DimemNulSmibility(,_j Ml_llm_ -'_
i
* ARAUONis a tradenameof a productmanufacturedby the DuPont Company.Tradenames or
manufacturers'namesare used in this reportfor identificationonly. This usageaoes not constitutean
officialendorsement,eitherexpressedor implied,by the NationalAeronauticsandSpaceAdministration.
: 197
t
I
1986109911 -193
https://ntrs.nasa.gov/search.jsp?R=19960009929 2020-06-16T05:47:25+00:00Z
Base P-aramidFiber Properties
! Nominal
Tensile Strength 425 Ksi
Tensile Modulus 12 - 25 Msi
Elongation 3% - 4%
Specific Gravity 1.4
Filament Diameter 0.6 mil
Decompqsition Temperature .500°C
Comparison of Specific Gravities
M_.rial SpecificGravity
Copper 8.9
Nickel 8.9
Tin 7.3
Silver 10.5
- Aluminum 2.7
ARACON
65% metal 3.1
85% metal $.0
198
1986109911-194
ProductOffering
Properties BaseYam vs.Copper
Individmd Fiber Diameter 0.6 rail
(~ 54 AWG)
_ Fiber Tensile Strength, Ksi 350 min. 35 - 95
Fiber TensileMedulus_Msi 12 rain.
!,
KeyBenefitsofARACON
OverTraditionalCopper
.y ConductorsInclude:
: • Weight savings
• Strength and durability
• Flexibility
• Tailored electrical/
mechanical property
balance
_ 199
! i
1986109911-195
WeiGhtSavingsPotentialforCables
(VarietyofAerospaceCableTypes)
Concept
Replace Wire in
Shieldand/orConductorwith -i
MetalCladAramidFiber
!
1986109911-196
Produ_Typu
ARACON" No.of Filmnents
Size (No.ofConductors) Apprx.AWG
55 24 38
200 89 32
400 178 30
600 267 28
1125 500
Metamc clads available: Nickel
Copper
Tin
Silver
Range of metal cladding possible: 15 wt% to 90 wt%
Major interest to date in 65% to 85% metal content
MostExperienceto Datein BraidedShielding
z
Shielding
201
t_
1986109911-197
CopperWireBraid
•" ARACONBraid
,+
+
t
Coverage
ARACONoffersgreatercoveragein
shieldingapplicationswithoutimpairing
pushbackcapability.
• Large number of flexible,
+ finediameterconductors
2O2
i
+,
t
1986109911-198
td
TwistedPairCableComparison|
,. Cable ComponentWeights
3.0
2S
1.0,
0,5-
00.
_ TransferImpedance i
100:
O:
_'o m _ 4'o m _ m i m lm
CaseStudy-- Shieldingul
CoaxialCableComparison
A_very high(GHz)frequ_nde_ ARACON can
improveshieldingand reducewright
ShieldiH _mm. dB
%wt_ 2-46HZ 16-18GHz
$_rZesrmkr
RG$8 100 57 52
RC,_ARACON 77 68 85
Do_/e Bn_
RC,2_ 100 94 107
RG27.3 I_,_,LL,ON 72 124 110
203
1986109911 -199
BraidResistanceBeforeandAfter
1OKampsLigldmingStrikeTests
Resislance
Besisllnce Allw Six
AlterSix MdiGmull
Initial Sugms. SUgum.
Cable Shield Cable Resillance Wlvefonn1" WavMonn5P"
Nundm"Omui" Oia.(im(mOl._ mOl._ (mOlu_
1
2 Control -Wh'¢ 0.68 1.70 1.70 1.50
5 ARACON 0.40 12.00 12.50 ll.O0
.?0_k- 85%
Cu/Ni
; AI_CON 0.68 46,50 44.00 42.50
70% - 85%
i 7 ARACON 0.40 80.50 68.00 5"7..$0$0% - 69%
8 ARACON 0.68 30.00 M.00 30..$0
$0% - 69%
9 ARACON 0.40 11.50 10.50 10.20
70% - 85%
Cu/N_n
10 ARACON 0.68 14.00 14,50 14.50
(hn/Ni_n
_,C,mnMr_ul adm:rafirut wuvllbrm
**Militaryui_wrt umt_
MinimaleffectofliglRing strike,variationsdependon
metal contut anddimnetm.
Conductor
2O4
1986109911-200
ARACONLinearWeightvs.% Metal
200dBaseProduct
• ,b_ , r---'--m" , ,
, _ ,I"-.--o.--_ Je_ , ,'-- --
L
: ..I,- i, . . .m ,, "" . ,; '
• ARACON offers an opportvnity to
provide lightweightconductors with the
t abilityto separatelytailor weight,strength
and electricalpropertie_
Cem_nts4m d Dimeters
, Bid.ll_ded AWGvs. Araeo_
"° l.i: ,,.-, , _
' ....... .'# _." _ IX,_)
I0!
m m Ill / ,,,,0"'o, 9(400)
I-......
l
'° _" ......... / _ " -_ ,,,,_
T l . __J _a,",
. L
Ik
205
1986109911-201
ARACON Resistivityvs.MetalComtent
- EstimatedVaI.Jes
I
|
i
o
-_ 711 m IB w m
i
i
PreliminaryTypicalPrope_esComparison
OC
Wi. Irlmk
Dial IIm. 11¢ lUWqlil
AW6 Mulmial [nil) Collmc_o,, T_ IOiIA4) IIIIAIIQ lib1
2. {'ii'_._ 2,t.1l-"3." 19;.Id) I.ililli) _i.(, 1.45 I,I
(_%.O¢ _...I.1_,-4.1i ItJl.l_i) L llil'.-'t "l_4 1.FI 14
("_ -q_'_"II l_ LI._ _,.I,.X IiJ'.'_l_ll L hi|d% _5.1J I -..¢_. .14
Cll,:%i :t.(I-:,.,i.II Iq!.l_; I'nillc, "F2 I_fl 13
%R4t.O"*, Z%-=._ ) .r_AId_L,-.lill I nllll) 1?l'i._15 iJ.._"_.tl...¢_ _4,.4_l't
_1%("(1% {t-2# l iZSdi_-l-lCll ! ilib'", 110-1"7,(; 0,.52-11." ,iil-4_i
_.R,tCi')k 23-2_ _-hlcl/qii-97 l.'ilil._ 9.¢,-1tl ti,,62.11._I +l(1.3_
26 Cu/A I 18,A.Lq.0 19/'341 UiMy 37._ 0.932 9
CS-I_I lllb20.0 _ Ulil_ 5"/.4 _ 21£
(FP!_AII 18.8-111.0 !t/38 Uilll_ S41.4 0312 21,$
CI/Ni 11.4.19.2 19/3l U/lI_ 41 OJ_ i
AiiJICON ILS-10 l12.qdP_-79 Uill_ 400-1200 0.111-0.21 40.45
ARACON' 18.S-i0 i4011t44 U/l_ 210,-MO 0.11-0.39 30..._
AXACON IIL_20 _ _ !20-1_ _ l&18
'2.,"; ("u,;_ 14.i)-14.ti 19,"ill I ilillll," &t.I tLFt_2
(-'._-It_ 14.4-1_,6 t_.'40 I lil,ly _ 0,.,_194 1".7
i"._.qS/&g 144.15,6 Iq/.lO Iml,_) .').l,_iO_¢Qq 12.7
Cu/Ni 14JI-i._,l 19#_0 Lnil',) '%,".6 ,,j.(_13 ,_
%RA(.ON 14-I,_ 41XId/_ I.iilliy lYik,141l IL2,.li,27 ih-lll
)11 ('u/%g IZ.Ibl3,O 1914_ C%n 16,,.I tl,ll4 _,
(_-_ ] I._- I.'LII I q,'42 C,,n I .'I" n.t92 g.2
f .'_,-'.h _,,,,:, II.!l.l_.0 Iq142 (on I,ill u.31_ 8.2
Cu/hl I t,.ll-14.tl I I_/,,1_ f'Oll II_J IJ.*i(Il) l
ARI( (l:_ 12-14 41ttk¢"l'.X5 l _*_li_ lilll.lllq 0.11-tl. "_ lt'_-IX
,kit.Ai:Oh L2-14 :llOd,_2-gF. I nil,,y :_l-40(i 0.11,1-ii.3 %9
:._ ( 'lU,li g 9,U.q,6 ";r4ti Ciin I (llll _L_II .*
( .'_._ 9.4- !11.,¢ I9_4,S ( ,, "42 O._,.""r'6 ¢,I
(.'S.9_I#.%1_ Y.4,-Ill...ll I9/i,,i Ctm 2.t4 O,_* ._.l
('t.i._i _.(I.Q,14 "t41) Ciln I,'77 IL" II 2
Al(,lll'('i% IJ.lf).l "_(M)(_'?k._Q'_ I nlh,_ hlNl-I.lql(I II.il.',41.1: !.q
2O6
,t
i
1986109911-202
1Conductancevs.SI]'ength
1
Q/I,OOOn • lb/l,O00rt
0.030,
"Conductance"o.o2o,
0s-95 x
*R
0.010 ,_ -x-
0.000 i ' I !o.o ,;.o 80.o,2o.o1_.o2&o
Terminatio, Performance
BraidedShield
Soldered:
• Good results from Raychem solder sleeve connection.
• Other soldered connections _ no problems.
Crimped:
• Excellentresultsfrom band-typeconnectorsmade by !
Glenair,Inc. [
f
Conductor *
C_: _
• Preliminarydata from Daniels Mfg. Corp.sl:owed -
consistentpull-outstrengthswith22 D contactswith
highsettingoncrimpingtool.
Soldered:
• Datanot yet complete,uo problemsanticipated.
Experienceto dateshewsthat ARACON can be .,
tonninatodutilizingpresentindusW/procedures.
i'
207 i f
¢
i.
(,, •
1986109911-203
tConductorCrimpedTermination
BasedARACON
PolishedCrossSections
LowandHighMagnifications
ARACONCrimpTestResults
Daniels Manufacturing Corporation
ARACON YarnSizes
• 200d,400d
Contacts
• WireBarrelSize-- 22D
• M39029/$7-354
• Tri-StarF.,]ectronics
i
Tooling
• ToolFrame M22520/2-01
• PosWoner M7_29/2-06
Results
Number
Number Broken *
Number __ Numbar Broken Outside
Denier ofTom low High Avg. ofPullouts,,antCrimp,,Crimp
200 4S 3,? 7.0 &2 0 6 39(_'_)
(s.t2AWG)
_o so _.z v.3 9-_ s o 4z(u_t)
208
i
1986109911-204
DanielsManufacturingCorporation
Conclusio.s
• ARACON fibers are crimpable and
void-free terminations are achievable.
• Strength of crimp is comparable to coF;_er
conductors of similar diameter, but with a
far greater strength-to-weight ratio.
• ARACON compresses and becomes more dense
on crimping, whereas metal extrudes from the
crimp joint.
• ARACON is likely to be less sensitive to,!
fl_x damage.
i • There is no evidence of work hardening
as with copper.
Safety/Handling/Disposal
• Three-day test during braiding, rewinding for i
respirables; better than OSHA and DuPont _
permissible exposurelevels. -i:
• Safe to bury or incinerate.
• MSDS sheets available.
2O9
1986109911-205
7I
ARACONDisposal
• Recommendation
; • Safe to bury.
_" - P-aramid is not listed as hazardous waste by RCRA.
, - No newhazardsfor metalliccomponents.
• Incineration OK where allowed for cable.
- P-aramid can be incinerated.
> nigh carbon yield, low smoke. _-
:' > Off-gasesimilartowooLy-
• Recydabmty?
" - No defined route at this time.
- W'dl consider after commercialization.
Wedo notbelieveAIM,CON to be
a worse hazardthancurrentcable disposal.
SummaryandConclusions
ARACON-- New technologyfor
conductorsandshielding insignal cable.
• Features:
• Greater strength ]
' • Reducedweight
• Better flexibility ,!
j • Wide temperature capability
• Tailored electrical properties
• High braid coverage with pushback
• Cables can be made with present equipment
• Terminateswith existingtools
• Trialtestresults-- betterthananticipated
. plusaddedbenefitsobserved, "
' •WHlingtowork withyou on new trialinstallations.
210
!
1986109911-206


Metal clad aramid fibers for aerospace wire and cable

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