Aging analyses of aircraft wire insulation
Over the past two decades, Sandia has developed a variety of specialized analytical techniques for evaluating the long-term aging and stability of cable insulation and other related materials. These techniques have been applied to cable reliability studies involving numerous insulation types and environmental factors. This work has allowed the monitoring of the occurrence and progression of cable material deterioration in application environments, and has provided insights into material degradation mechanisms. It has also allowed development of more reliable lifetime prediction methodologies. As a part of the FAA program for intrusive inspection of aircraft wiring, they are beginning to apply a battery of techniques to assessing the condition of cable specimens removed from retired aircraft. It is anticipated that in a future part of this program, they may employ these techniques in conjunction with accelerated aging methodologies and models that the authros have developed and employed in the past to predict cable lifetimes. The types of materials to be assessed include 5 different wire types: polyimide, PVC/Glass/Nylon, extruded XL-polyalkene/PVDF, Poly-X, and XL-ETFE. This presentation provides a brief overview of the main techniques that will be employed in assessing the state of health of aircraft wire insulation. The discussion will be illustrated with data from their prior cable aging studies, highlighting the methods used and their important conclusions. A few of the techniques that they employ are widely used in aging studies on polymers, but others are unique to Sandia. All of their techniques are non-proprietary, and maybe of interest for use by others in terms of application to aircraft wiring analysis. At the end of this report is a list showing some leading references to papers that have been published in the open literature which provide more detailed information on the analytical techniques for elastomer aging studies. The first step in the investigation of aircraft wiring is to evaluate the applicability of their various techniques to aircraft cables, after which they expect to identify a limited subset of techniques which are appropriate for each of the major aircraft wiring types. The techniques of initial interest in the studies of aging aircraft wire are as follows: optical microscopy; mandrel bend test; tensile test/elongation at break; density measurements; modulus profiling/(spatially-resolved micro-hardness); oxygen induction time/oxygen induction temperature (by differential scanning calorimetry); solvent-swelling/gel fraction; infrared spectroscopy (with chemical derivatization as warranted); chemiluminescence; thermo-oxidative wear-out assessment; The first two techniques are the simplest and quickest to apply; those further down the list tend to be more information rich and in some cases more sensitive, but also generally more specialized and more time consuming to run. Accordingly, the procedure will be to apply the simplest tests for purposes of preliminary screening of large numbers of samples. For any given material type, it can be expected that only a limited number of the other techniques will prove to be useful, and therefore, the more specialized techniques will be used on a limited number of selected samples. Samples of aircraft wiring have begun to be released to the authors in late April; they include in this report some limited and preliminary data on these materials.