The world of aerospace and aviation is a dynamic space that demands strict safety, performance, and reliability requirements. The wires used in aerospace and aviation are curated to withstand extreme environmental conditions, such as temperature fluctuations, vibrations, high altitudes, and electromagnetic interference. Hence, many factors affect the usage of wires in the aerospace and aviation industry. To simplify, we will discuss the wires and cables used in the aerospace and aviation industry.
What are the Types of Wires in Aerospace and Aviation?
Copper Wires
Traditional copper wire, or bare copper wire as it is popularly known, is typically coated with insulation and is highly conductive. It is widely used in power transmission in aerospace systems. Another type of copper wire is a tin-plated copper wire. As the name suggests, it is coated with a layer of tin to improve corrosion resistance. This type of wire is often used in harsh environments like an aircraft.
Stranded Wires
Stranded or stranded copper wire, as it is popularly known, consists of multiple smaller wires twisted together instead of a solid core. Because of its flexible nature, it is usually used where the wire needs to be routed through tight spaces or subjected to vibration.
Teflon Coated Wire
Teflon-coated wire or PTFE (Polytetrafluoroethylene) insulated wires, as they are commonly known, are often used in aerospace for their high-temperature resistance, durability, and non-reactivity. The coating of PTFE is essential for cables that need to operate in highly heated environments, such as near engines or electrical components.
Aluminum Wires
Aluminum conductors are lightweight and used in specific conditions where weight reduction is essential. Though they have a lower electrical conductivity than copper, they are used in particular applications where weight savings outweigh the need for higher conductivity.
Mil-Spec Wires
MIL-W-22759 is a military specification for high-performance wires in aviation and aerospace applications. These wires are designed to withstand harsh environments and offer fire resistance, abrasion resistance, and flexibility. MIL-C-27500 is a military specification for aerospace cables with advanced performance characteristics, including chemical resistance, heat, and electrical interference.
Shielded Wires
They are used when required to protect the signal from electromagnetic interference in aviation. Shielding generally involves a layer of conductive material, such as foil or braided wire, around the wire to stop external signals from corrupting data or power transmission.
High-Temperature Wires
Ceramic insulated wires suit extremely high-temperature environments, such as near turbines and engines. These wires are commonly used because of their ability to overcome temperatures far beyond what other traditional materials can withstand.
High-Voltage Wires
These wires are used in some avionics and power distribution systems requiring higher voltage transmission. These wires are designed with heavy-duty insulation to ensure safety and prevent breakdown.
Wires With Fire-Resistant Insulation
FEP (Fluorinated Ethylene Propylene) wire is fire-resistant and is often used in critical environments that require fireproof characteristics. These include aircraft wiring for safety systems and avionics. Another type of fire-resistance insulated wire is silicone-insulated wire. Silicone is used for wire insulation in systems where extreme temperatures are a concern because it can maintain flexibility and integrity in high and low temperatures.
Wires for Specific Uses
Wires like SXL and AS (Aerospace Specification) are designed to meet aviation standards. These include durability, flexibility, and impressive performance under stress.
What are the Types of Cables in Aerospace and Aviation
Coaxial Cables
Coaxial cables are made of a central conductor, a conductive shield, an inner insulating layer, and an outer insulating layer. They are used for high-frequency signals, such as communications and radar systems. They are designed to reduce EMI (Electromagnetic Interference).
Fiber Optic Cables
Fiber optics, including cockpit communications, entertainment, and avionic systems, are used for high-speed data transmission. They are immune to electromagnetic interference.
Ribbon Cables
Ribbon or flat ribbon cables, as they are popularly known, contain multiple parallel conductors. They are used where space and weight limitations are crucial, specifically for high-density applications such as avionics.
Hybrid Cables
These cables combine different types of conductors, such as power and signal wires, within one cable assembly. They are used in applications where data and power are transmitted over a single connection, minimizing the weight and wiring complexity.
Heliax Cables
Helical Air-Dielectric Cable is a specialized coaxial cable used for high-power transmission. It is often used in radar and communication systems in aerospace applications. It offers advanced performance in harsh environments and minimal to no loss.
Essential Aspects to Consider in Aerospace Wiring
Temperature Resistance: Always opt for lightweight materials such as aluminum and fiber cables. They are preferred in aerospace as they reduce the aircraft’s overall weight and improve fuel efficiency.
Weight: Wires and cables must be able to perform in extreme temperatures, from freezing altitudes to high temperatures near engines or electrical components.
Flexibility: Wires and cables must withstand vibrations without breaking or deteriorating. They must also be flexible enough to navigate tight spaces.
Durability and Safety: Wires are often subjected to wear and tear. Therefore, they must be insulated with fire-resistant and abrasion-resistant materials to prevent short circuits, fires, or electrical malfunctions and ensure safety.
Summing Up With a Bonus
To conclude, the world of aviation and aerospace wiring is immensely specialized. Each kind of wire and cable is designed to meet specific requirements to meet the unique challenges of high-altitude flights. Every wire and cable plays a vital role in ensuring the aircraft’s performance, safety, and reliability. As the aviation and aerospace industry technology evolves, so will the wiring methods and materials used in these systems. Therefore, exploring the sea of possibilities is even more critical. Hence, choosing the appropriate wire isn’t just a matter of function. It ensures that every power transmission, signal, and connection can withstand the challenges of a safe and efficient flight journey.
And the bonus? At Pelican Wire, we offer a broad range of wire services to meet all your needs and beyond. From resistance wire to type J, type K, type T, type N, type E, type B, type R, and type S thermocouple wire to custom wiring, we offer quality services with our experience and knowledge.
We specialize in custom heating wire and have over 50 years of experience in the field. Our industry-leading customizations allow us to offer performance tolerances as low as +/—1%, below the standard 5%. We take the time to understand your needs and seamlessly deal with all the challenges so that you can get your desired results after completing your project without lifting a finger. We also offer a wide range of alloys such as nichrome 60, nichrome 80, alloy 875, alloy 815, midohm, manganin, advance, evanohm, balco, nickel 200, alloy 30, alloy 60, alloy 90, copper, and stainless steel. Want to know more? Contact us today to discover the possibilities of the world of wires!