4 % IIII

aval Research Laboratoryishington, DC 20375,5000 ...

AD-A252 281 .AUN,,,46.,-92_,9861ill1 I1I! iIII IIII III II III I!! II!

Lightning Strike Tests of Composite Connectors

C. D. BOND. F. J. CAMPBELL. AND D. P. SMIHII::

Directed Emnrgy I-ýf•,ct.% Branch

Condensed Matter & RadiaiOi Sciences [)ivi.ioin

*SF4. lic.

June 19. 1992 DTIG CAf LECTE

UL 0 11992

A f rf

Approved for public release, distribution unlimited

Form ApprovredREPORT DOCUMENTATION PAGE OM N 0704-0188Public reoort-rt burden to, n -s oiiecrion of ,nformvation i eitirnatoo to a~erageq u e eote ntdrgtetme rrruWn ntut9n errn .s~r data W,,-ieatherin and maintanrng the jita ne-ded. and compoleting and re,,emng the tolleciron of information Send comment reg0aroing th,% burden estimate or .n, )ther asoect of tin.

rojlittron of nrmai ho i-dring suggeston% or, reducing rrr I burden, to W..shrngton 'eacluarners Srue Direcorate fricnformal'on Operahions and ReCithris 2 1- JeffersonOausfrHghav Suite 204 Aiingron, V A 22202-4302 and 1tothe Office of Management and Budget Pace-rork Re cto Oet (0 4 01088) Wifsh~o ngr C 200

1. AGENCY USE ONLY (Leave blankc) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED

IJune 19, 1992 Final Report _______________

4. TITLE AND SUBTITLE S. FUNDING NUMBERS

Lightning Strike Tests of Composite Connectors NAVAIR Airtask Number (TA)A51 1-51 15/058D, NAW4250000

6. AUTOR(S)NRL Funding, Document6. AUTOR(S)NO001991WXBE7KR

C.D. Bond. FiJ. Campbell. and D.P. Smith*

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATIONREPORT NUMBER

Naval Research LaboratorNWashington. DC 20375-5000 NRL'NIR 4654-92-0996

9. SPONSORING/ MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSORING /MONITORING

Naval Air Svstems Command AGEN4CY REPORT NUMBER

V-22 Avioni cs Srvstems Proji. Officer AIR-546D1FJefferson Plaza 2. 1421 Jefferson Davis HwyN.Arlington, VA 22202

11. SUPPLEMENTARY NOTESPrepared in cooperation with the Naval Li~ghtning Lab at the Naval Air Test Center and the Naval AvionicsCenter. (Nowk the Nava] Air Warfare Center . Aircraft Division at Patuxent and Indianapolis respectixcl\.A*SFA. Inc.

12a. DISTRIBUTION/ AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE

Approved for public release. distribution unlimited.

113. ABSTRACT (Maximum 200 words)

Tcst results are presented on the lightning strike effects on composite andi hybrid type mul.1tipin aircrattconnectors in comparison wkith the standard all metal connectors. These tests w\ere performed using ai unipolardouble exponential Induainpulse recommended by the SAE-AE4L- comnmittee at peak current lesels of 3kA. 10 kA. 15 kA. and 20 kA. Such peak current levels might he fo~und in all-compositec or partiall.\ comipositeaircraft or in exposed areas of all-mietal aircraft.

14. SUBJECT TERMS 1S. NUMBER OF PAGES

1.ie-htninL Strike Composite Aircraft 69

Comnposite Connectors, Pulse Current Limits,6.PICCD

17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACTOF REPORT I OF THIS PAGE I OF ABSTRACT

UNCLASSIFIED UNCLASSIFIED UNCLAS SIFIED UL

NSN 7540-01-280-5500 Standard ýorrm 298 (Rev 2-89)Pnc ~ ', Atui itO /14 'M"4'8 .2

CONTENTS

Page

BACKGROUND 1

TEST PROCEDURES 2

TEST RESULTS 5

TABLES AND WAVEFORMS 7

APPENDIX I 47

1 Aa@ession For,

NTIS GPA&I

DTIC TABcUnAnnounced

: " ,Justin ~c at lo C

By.. .

Distribution/

Dist | SpeoltelFAv8alibi1ItY Cods

iii. . .

LIGHTNING STRIKE TEST OF COMPOSITE CONNECTORS

BACKGROUND

Several connector manufacturers have recently introduced light weightmultipin wiring connectors that employ composite construction usingvarious combinations of non-metallic resins, metal platings and metalsleeves. The simultaneous development of composite airframes employingpartially conductive or non-conductive materials has reduced or eliminatedthe conventional protection of the all-metal airframe and connectors againstthe high current surges normally encountered during lightning strikes. Thisincreased vulnerability has become particularly critical with the increasinguse of advanced avionics and fly-by-wire control systems. The introduction ofthese new technologies has thus necessitated an independent evaluation ofthe electrical performance of these composite-hybrid connectors under theexpected operational environment of naval aircraft.

The purpose of these lightning strike tests is threefold:

(1) evaluation of a few typical commercial composite-hybrid connectors incomparison with the conventional aluminum connector,

(2) evaluation of the test procedures and(3) to provide information on modes of failure and possible improvements

The specific connector types and manufacturers were chosen in an effort torepresent presently available options in composite and hybrid connectorconstructions. The tests were not intended to provide a broad screening of allavailable composite-hybrid connectors nor are the results of these tests to beconstrued to be an endorsement or rejection of any particular type,component or manufacturer. As with all such electrical equipment, theappropriate use and specifications are determined by the service conditions.

The lightning strike test procedures described in this report evolved fromseveral sources; The Federal Aviation Administration (FAA AdvisoryCircular No. 20-136), The society of Automotive Engineers (SAESubcommittee SAE-AE4L), The Electronics Industries Association (EIASubcummittee P-5.1) and numerous communications with NAVAIR (V-22program office AIR-546D1F), the Naval Avionics Center (Code 916) and theNaval Air Test Center (Code SY-84).

The specific type of lightning strike threat that we wish to address is that forthe low impedance conduction path through cable shieids and connectorshells to ground as might be found in an all-composite aircraft or in exposedareas in a partially composite aircraft or all metal aircraft. While the threat

Manuscript approved March 3. 1992. 1

environment has not been fully characterized, there is at present, a generalconsensus that a lightning strike to a composite partially conductive aircraftstructure causes a diffusing attenuation and lengthening of the initial currentpulse to produce the so called long duration test pulse recommended by theSAE-AE4L committee (SAE-AE4L-87-3 Rev. B Waveform 5B). This waveformis for indirect effects testing and is a unipolar double exponential pulsehaving a rise time to peak value of 50 ps ± 20% and a decay time to 50% peakof 500 pis ± 20%. The SAE-AE4L report also suggests peak current test levels of3 kA to 20 kA. However, there is considerable controversy in the lighteningstrike community regarding the appropriate peak current test levels and themaximum level. The ranges suggested go from 100 A min.-+ 10,000 A max. upto 3,000 A min. -4 30,000 A max. In the interest of safety, we took aconservative approach and conducted the test at peak current levels of 3 kA,10 kA, 15 kA, and 20 kA.

TEST PROCEDURES

In order to minimize the variables and to facilitate ease of direct comparison,all test were conducted with as nearly identical connector components aspossible. The type connectors chosen for these tests is the MIL-C-38999 shellsize 9 either flange mount or jam-nut mount. The shell size 9, which is thesmallest size for this type circular connector, was chosen because it is the mostvulnerable to the effects of high current surges and serves to limit thenumber of tests required. i.e., survival without damage of this size connectorat a given peak current level would presumably indicate survival of all largersize connectors since they will have a correspondingly larger metal crosssection area and higher peak current capacity.

The specific MIL-C-38999 connectors, components and associated fittings wereprovided by the following major suppliers via the Naval Avionics Center:

1. Standard Aluminum Connector Bendix2. Composite with metal plating Deutsch ATD3. Composite with metal plating Amphenol-Bendix4. Hybrid with aluminum sleeve ITT-Cannon

Because of the different requirements of the V-22 program (AIR-546D1F) andthe NAC program (AIR 546D4), the tests include two different testconfigurations. (I) a systems test assembly and (11) a component test assembly.These two configurations are shown in Figure 1 at top and bottomrespectively. As indicated, the system test consists of a complete assembiy of areceptacle, plug, backshell, cable shield and termination. The system isassembled according to manufacturer specifications as it would be installed ina typical aircraft application. The component test assembly is designed to test

2

only a coupled receptacle-plug pair. i.e., the backshell and cable shieldassembly is replaced with a very low resistance copper adapter cap and insertto match the plug.

In order to limit the size of the test matrix and achieve a reasonable balancebetween statistical effects and the number of peak current levels, three newconnector assemblies (samples A, B and C) of each of the four types weresubjected to four progressively increasing peak current levels of 3 kA, 10 kA,15 kA, and 20 kA for both the system test and the component test. At eachpeak current level, starting with the 3 kA level, 3 systems tests (for samples A,B, and C) were carried our first for each of the 4 different type connectors. If asystem test failure (i.e., extensive damage which prevents the connectorassembly from functioning normally mechanically and/or electrically) occursin one or more of the three samples, then three component tests will also berun at the same peak current level. A component test is not required,however, if there is no system test failure since presumably the componentsseparately would also not fail. All connectors that experience no damage oronly slight to moderate damage (i.e., connector assembly can continue tofunction both mechanically and electrically) will be advanced to the nexthigher current level.

Figure 1 shows the details of the system test configuration and thecomponent test configuration. Considerable precaution was taken to insurethat the method of electrical connection to the pulse generator would notcompromise the connector test by premature failure. In the system test, theshield braid (1/2" fiat width x 3 1/2" length) was connected both to thebackshell and to the copper split clamp with stainless bands (Band-It TM)

assembled per manufacturer specifications using a special Glenair Band-Ittool. (Glenair recommended that the bands be double-looped through theband-buckle before inserting into the banding tool). The tool has a pre-settension spring that locks a ratchet before the band is cut so that the quality ofall shield terminations are accurately reproduced. The copper split reducingcollar was used to achieve a low resistance copper to copper slip fit which wasclamped tight to the 1/2" copper conductor tube with a standard hose clamp.At no point during tests did we experience a failure of this joint or the braidor braid attachment to the backshell tube (on one shot #61, the shield wasburned but this was caused by arcing flash-back through the shield tube).

In the case of the component test, the entire backshell, shield andterminations are replaced by a low resistance copper cap and insert suppliedby Electro Adapter Inc.. The threaded cap and serrated tooth insert aredesigned to accurateiy match and simulate the mechanical and electricalcontact of the usual backshell. This simulation design is not valid, however,for the MiT- Cannon backshell which uses non-metallic threads and employs

3

metal spring fingers as the primary electrical contact with rear of the plug.Figure 2A and B show photographs of a typical system test assembly (A) and acomponent test assembly (B).

Figure 3 shows a schematic of the NATC Hercules pulser which is a two stageMarx type generator. The circuit is basically identical to the lightning pulsecurrent generator suggested by the AE4L test set up with the exception thatthe current to ground through the connector assembly load RTL is measuredwith a calibrated Pearson 1330 transformer probe shown as P rather than acurrent viewing resistor to ground. The 500 g capacitors are charged inparallel through the 200 K Q and 100 K Q resistors and then discharged inseries through the gas switches S1, S2, and S3. The shape of the pulsewaveform (i.e., the peak current, the rise time to peak current T(P) and thedecay time to 50% peak T(50%) is controlled by selecting the appropriatevalues of the inductor coil Lws and the resistor Rws. A typical pulse waveformat - 15 kA is shown in Figure 4. The values of Rws (D2) and Lws(g.h) for theseries of shots are shown in Table I. Figure 5 shows a photograph of thecapacitor and gas-switch section of the Hercules pulser. Resistancemeasurements (RTL) of the test samples were measured according to theAE4L recommendations 4.7.48. Prior to the application of a test pulse, an endto end resistance measurement R(B) was measured before the test. Followingthe test pulse, and without disturbing the test sample, a second resistancemeasurement R(A) was made after the test. The sample components werethen uncoupled (where possible) and examined visually and mechanically bythree members of the test team*. The combined observations were thenrecorded in the enclosed test Data Sheets I through 16 (p 23 through 38 ) forall shots. Following this inspection, the components were reassembled and athird end to end resistance measurement R(AR) was made after reassembly.Note that the resistance R(AR) is also the initial R(B) for the next highercurrent level and was generally measured at that time unless otherwise notedin the Data Sheets. All connector resistance measurements R(B), R(A), andR(AR) were measured by using a Biddle Digital Low Resistance Ohmeter. (SeeCertification of Calibration, Appendix I). This ohmeter can measure from thelow 10-6 Q range up to 60 Q. The ohmeter uses a 4 terminal probe methodwhich delivers 10 A in the g± Q range and I A in the m Q range. The fourprobe points are fitted with spring loaded sharp contact points which rotate asthey are compressed to a pre-set minimum pressure in order to penetrate themetal oxide and to insure reproducible stable measurements. Figure 6 showsthe hand held probes being used during an end to end resistancemeasurement prior to a component test.

"C. D. Bond NRL, Dave Smith SFA Inc., and Hubert Hibbler NAC.

4

TEST RESULTS

Examples of some of the more prominent visual aspects of the test results areshown in Figures 7, 8, and 9. Figure 7 shows an example of a system test resulton a composite connector at 3 kA (shot no. 19). The top photo (A) showsassembly before test and the bottom photo (B) shows the same assembly aftertest. As indicated by the arrow, the rear of the backshell and shield tube areashows melted plating and carbonization. (Details are listed in Data Sheet No.3). Figure 8 shows an example of a component test of a composite connectorat 10 kA (shot no. 48). Again the top photo (A) is prior to the test and thebottom photo (B) is after the test. Here one sees extensive carbonization onthe plate with melted plating on the flange and at the rear of the plug lockingnut. (Details are listed in Data sheet No. 10).

Figure 9 shows a time sequence during a system test of a composite connectorat 10 kA (shot No. 42). The frames were taken from a 16 mm film camerarunning at a normal framing rate of 24 frames per second or 0.042 sec. perframe. The sequence starts at the top of the first frame approximately 42 msafter pulse initiation. Here one seen a shower of fragments of molten metalplating. the second photograph was selected at 126 ms later and shows areasand points of molten plating on the backshell and flange. The last frame atbottom, selected at 210 ms, continues to show points of molten metal platingon the flange and backshell. Since the peak current of 10 kA decays toapproximately zero in about 2.0 ms, all of the thermal phenomena shown inthis sequence is taking place long after the test pulse is terminated.

The detailed description of the test results measurements, calculations, andpulse waveforms for each connector type, sample and test shot are listed inthe data sheets 1 through 16 (p 23 to p 38 ), Tables I through VI and AppendixI. In order to present this somewhat extensive tabulation of data and resultsin a more rapidly understandable format, we have summarized the systemtest and component test results in Figures 10 and 11 respectively. Of necessitythese charts suppress much of the detail and present the results in three broadcategories of test results for each connector type and peak current level. Thethree categories of results as indicated in the data sheets and measurementsare as follows:

1. No visible damage. This is represented by an open circle (0) and indicatesthat the connector assembly can continue to function normally bothmechanically and electrically. (i.e., all components can be uncoupled andrecoupled smoothly with normal hand torque and the resistances R(A)and R(AR) are within acceptable limits relative to R(B) or R(A)/R(B) ___ 2and R(AR)/R(B) < 2).

5

2. Slight to moderate damage. This is represented by a half-filled circle (Q)and indicates that the connector assembly can continue to function bothmechanic,.ily and electrically. (i.e., all components can be uncoupled andrecoupled with normal hand torque but there may be evidence of localarcing, carbonization, pitting or loss of spring contact fingers but theresistances R(A) and R(AR) remain within acceptable limits relative toR(B). There may be however, a reduced ability to sustain further highercurrent strikes.

3. Extensive damage. This is represented by a filled circle (0) and indicatesthat the connector assembly can not continue to function normallymechanically and/or electrically (i.e., one or more of the components cannot be uncoupled with normal hand torque because of welding ofcomponents and/or the resistances R(A) and R(AR) are clearly outside ofacceptable limits relative to R(B). In this case a component test wasperformed.

Using the above definitions, Figure 10 shows a summary of the systems testresults. The chart is essentially self explanatory. In some cases more than onecircle symbol may appear for a particular sample (A, B, or C) and currentlevel. This indicates that this particular sample was subjected to more thanone shot at the indicated current level for various technical reasons whichare detailed in the corresponding data sheets. In some cases the symbol (Q)may be followed by the symbol (0) which indicates that no "additional"damage has occurred.

Figure 11 shows a summary of the component test results again using theabove definitions. In those cases where no component test was required, NA(not applicable) is listed. The asterisk in the 20 kA blocks indicate that theresults of these component test can not be considered valid in the case of theITI-Cannon connector for reasons previously discussed on p. 3.

In both the system test and component test, the charts clearly indicate a wideseparation in performance between the metal plated type of compositeconnectors and the metal sleeve hybrid type of connector. Over the 3 kA to20 kA test range, the hybrid type connector is comparable to the standard allaluminum connector. i.e., one sample of the hybrid (sample C) and onesample of the standard all metal (sample A) survived all four test levels insequence without any significant damage. In the system test (Figure 10), thecomposite connectors (plastic over-plated with metal) sustained extensivedamage at the 3 kA level with the exception of one sample (sample A ofAmphenol-Bendix) which survived to the 10 kA level. In the component test(Figure 11), however, we see a clear difference between the two different typecomposite metal plated connectors at the 3 kA level. i.e., the Deutsch ATD

6

connector sustained extensive damage in both the system and component testat the 3 kA level whereas the Amphenol-Bendix connector sustained nodamage in the component test at 3 kA. This indicates that, in the latter case,the backshell probably initiated the system test failure. Another factor whichmay have also contributed to the different results at 3 kA is the fact that theAmphenol-Bendix plug outer locking nut is metal plated whereas this samenut on the Deutsch ATD is not plated which reduces the number of currentconduction paths and metal-to-metal contact surfaces. The main mode offailure of the composite type of connectors was melting and vaporization ofthe metal plating with loss of conduction paths and subsequent increase inresistance from several ohms to complete open circuit.

In the case of the ITT-Cannon system test, the damaged observed at 15 kA(sample B) and 20 kA (samples A and B) was confined primarily to the area ofthe spring contact fingers of the backshell. (see details in data sheets 12 and14). The contact area of the spring fingers with the rear of the serrated edge ofthe plug is minimal and it is somewhat difficult to determine if the backshellis properly seated against the plug.

In most of the shots that did not result in extensive damage, we observed thatthe undisturbed end-to-end resistance after the test pulse R(A) was generallylower than the resistance R(B) before the test pulse. This was particularlynoticeable in the case of the standard all metal connector and the aluminumsleeve hybrid. (See Tables II through V). This effect has been observed byother investigators* and is attributed to "microwelding" at the interfacesurfaces. This phenomena in not considered a damage mechanism and in noway interferes with the uncoupling of the connector components. Indeed thiseffect is not detectable either visually or mechanically.

TABLES AND WAVEFORMS

Each data sheet 1 through 16 list results on three samples (A, B, and C) for aspecific type of connector and manufacturer at a given current level asfollowing:

1. Type of test (system or component)2. Type of connectors (Standard, composite, hybrid & mfg.)3. Peak current level(nominal)4. Sample A, B, and C5. Shot number6. R(B), R(A), and R(AR) as defined7. Observation and remarks

*"Lightning Strike Hazards For Composite Connectors", Gerald E. Walters and David E. Welch,

NAVAIR E3 Progress Review Meeting, P. 16 and/or D-117, May 7-11 1990, Jacksonville, FL.

7

At each current level 3 kA, 10 kA, 15 kA, and 20 kA, the system test results arelisted first followed by the component test results. The data sheets and shotsare numbered sequentially as they were performed. The pulse waveformassociate with each shot number is shown in Appendix I.

The test measurements and calculations are summarized in Tables II, 111, IV,and V which lists the following parameters for each peak current level,connector type, sample and shot number.

1. R(B) = resistance before test2. R(A) = resistance after test3. R(AR) = resistance after reassembly4. I(P) = peak current measured from waveform5. T(P) = time to peak current from wawv-')rm6. T(50%) = time to 50% decay point from waveform7. A = action intefral over pulse from 0 to -8. Q = total charge transferred during pulse

It should be noted that in the case of the system tests, all resistancemeasurements R(B), R(A), and R(AR) include a 1/2" wide x 3 1/2" length ofbraid shielding as shown in Figure 1 and 2A. The average resistance of thisbraid as assembled was 0.390 mQ . Thus the connector backshell to plateresistance can be obtained by subtracting 0.390 mil from R(B), R(A), andR(AR). In the case of the component tests, the resistance of the adapter cap isnegligible so that the values of R(B), R(A), and R(AR) are also the resistancefrom the rear of the plug to the mounting plate.

The action integral, which is listed in column A, is related to the total energyE which has been absorbed by a connector of resistance Rc. i.e.,

(1) E=Rcf I2 (t) dt0

A=- f 12 (t)dt0

and for the general unipolar double exponential pulse waveforms used here,

(2) I(t) = lo [ e-a t - e-0 t I

Here E is measured in joules, Rc in ohms, A in amp2 sec or joules per ohm,

8

I(t) in amps, and t in sec.. The connector resistance Rc will vary for differenttype of connectors. However, the magnitude of the action integral A is ameasure of the ability of a particular current pulse I(t) to deliver energy to Rc.Since the current pulse waveforms used here decay to approximately zero in1.5 to 2 ms, insufficient time is available foi" significant transfer of heat awayfrom the connector assembly. Thus essentially all of the energy E results inheating the connector to a temperature T that depends on the metallic mass,cross s'ction, specific heat, resistivity and contact resistance of the metalsinvol w.J in the connector design.

The action integrals A listed in Tables 1, III, IV, and V have been calculatedusing the Hercule• pulse waveforms listed in Appendix 1, shots #6 through#67. The value of each action integral, as integrated from zero up to 1,000 pis,was provided by NATC using direct integration of the scope digitation. Thisscope digitation time scale was chosen so that the peak current, the peak risetime T(P) and the 50% decay time '(50%) could be dearly displayed andmeasured for each pulse. However, in most cases, as can be seen in AppendixI, the pulse amplitude still shows significant current levels at the 1000 Pspoint. This is particularly true ;n the 3 kA shots. In order to extend theintegration from 0 to 0 as indicated in equations (1), a NRL program"EXPULSE 8" was used to fit the theoretical pulse waveform of equation (2) tothe actual Hercules pulse waveforms from t = 0 to t = 1000ps. The programthen extrapolates the actual pulse and calculates the action integral exactlyfrom 0 to - for each shot. EXPULSE 8 also calculates the total chargetransferred (Q) over the duration of the pulse by evaluating the integralJ I(t)dt from 0 to 0.

Figures 12 and 13 show two computer output examples of the above fittingprocess. In Figure 12 (shot #57 at 20 kA) the pulse is decaying somewhat toorapidly (T(50%) - 380 ps) so that at 1,000 gs the pulse amplitude is relativelylow (-2 kA). Thus the difference in the value of A between integration for 0to - and integration from 0 to 1,000 gs is not large. i.e., 113,000 A.2-sec. and106,649 A2-sPc. respectively. However, in Figure 13 (shot #14 at 3 kA) thepulse is decaying too slowly (T(50%) - 800 js) so that at 1,000 Ps the pulse isstill relatively high (-1.2 kA) and the value of A integrating from 0 to - is4,940 A2-sec. as compared to a value of A = 2,033 A2-sec. integrating from 0 to1,000 pgs. In this case there is a lrge difference. All of the values of (A) listedin the tables have been calculated by integration of the fitted pulses from 0 toco so as to give an accurate value of A for the actual pulse current delivered tothe test sample.

Table VI lists the values of the peak current I(P) and the action integral A forthe ideal SAE-AE4L pulse in comparison with the actual average valuesachieved during the NRL/NATC tests (i.e., the average of the values of I(P)

9

and A in the Tables II, III, IV and V). The error listed is the standard deviation(rms deviation) in each case. As can be seen, the test values of the peakcurrents I(P)av are quite close to the desired values I(P) whereas the testvalues of the action integrals Aav exhibit a much larger deviation from thedesired values A. This results mainly from the fact that A depends on theintegral of 12(t) and is thus quite sensitive to the magnitude of current at the500 Is point which should be 1/2 I(P) ideally.

I0

w w

R --

SOn 0-

Uwe

(A)

(B)

Figure 212

C'!L>

CDI

II I<- I W- IW

~CJlc3 to R- S

13

0.. . .. . . - - I , ii l ii l il i i ill

S.... i.....i ............ ........."..... ! H .I E r l.. ?......SO.. OO 5lip/.: NOT FOUNDO- .H>RJ$. ~SHOT# :996855

PEAK CURRENT1.48E+04

+4E+83) .. ....

a AP- -.

-4E+63) ... . . . ........ .

IE-04 SE /D IU --- )

HURC-FI COMNT :PEARSON PROBE

Figure 4

14

F-4 I~ -CD CD C0 C C4 C C

U)

0 0

z OF-

00C4-

r-4 0 0e t Lf

Uf)

15

LL-

16

1.0

0)U-

17

Figure 719

(A)

(B)

Figure 8 2

42 mS

126 mS

210 mS

Figure 9 23

- @000 (U

C14 0

Ln~~ 00 0z~~(

Z (

u (Uu

t(UlzU

Eq(

.q 000 2 002

00

D 0

0 0000 00 00 0

u' 00 00

9:0 Z-~0 C> 3 Zin00

0 -

z~ ~ ~ w .=

24

<EJ.4 t1 n.

41 0

00

0 mU

z r0 in( 0 4w

g0 .~ r

U1 U

xLa bo

0.

r. 0.

z~~ = .caPQQ <u -.o

Lu *u 0

LO w

z - E

'*n 0 w

j E)

0I cJ Lu(

R z r

~3~ 6 0 EW 2o

*6 0 0 b~ P z

P- z- .:z c

u > Z Zj .0 6

z. zLUp C5 '-

u0* 0

> to 0 0 0 0s00

6~U U~U0 z ~ .

z z M~'.

uu~

N V'0

~E

Z- N Go

a u rp

26

<~ U

00 Q

ot

w2 w tj(

-0 q.

J -l r. z

J.-

oV Cs

tu b.

r.. mCl > b wgui

C4N

>U -

uo27

3~ -3

02 2'

m in 0

- 2.

y-6M .9(

0-0

low~. toll

z ~ zcN 0Cd

0W 4

CA Ac

LI cc

±0

ad T

28

0 8

00

-3 -3 -3

II W 4 -. ~a

~ EU

E 8~

0 a..

o n xE EU(

w 0

cc V 0% C

0 0

su 2xi~I - - m

Y-q.~ EU

29

-04

w E

rL 8

-n o ,

CA C

0p *.'_0= . o•.

0

0... m• • I

bo M

• -4 0 0 0

ChC

~zJ

-03

d m

z -20 - _ _ _ _ _

z z

Leie

uo

UU

0- 0

30

-030'.j'

zC

OZ z U~

OZ~

F >~:3 * I-

U~'U

C4 N

00

(U31

.0 . r

w~ol

'U 0

I-Ip . - .zD M

C6C

tucoo

w w> U)

0 0 0 '

t; -* -

> 0%m0 -u05c N115

.2 2l68

0 I- C4

t - __ _ _

(a, (.4

0% H!

32

GD

en X~

u 8- n

U >G > (A

Z Ao

~ e~ ttu

I- r- Icc < - -

0c 0 w DD'U j~e.

Z Z Z GD G

< o.

ChGwdGw ~ t

6Q~

'u DGI

0

tu0

A.

GD W~33

.0

0. 0

Cz

00

co-c

1:1 CA

Ln E

~~34

010

z z~ m04 GD aOl

~4

-~ GD GWw h

ou >t

0~ 0106.

C41

me C4 e40

I- F G~j~IT

1 go li I 4U

0 35

0 U)

so 0law.

8 8s41 1.6

44 > C

cn041 4

89U

>00 S: 00 ~& 00o~.

In -

-Z~

I- I- 4VCK V4U1

gugg3> ' 4C41ag anL

(U (

CM( $6fl

ii.:36

.0 co z z24

CC

0u E

-Z~

0 E

=1 -

UU

0

- >GD. GD

<~

<- a

Ep EU cd -~ c

CDD

0 0~

oo

u 6z

GD 6 37

FA-

4,T

.JI00o

LU00uLu 4

<W C1A<C

(A '

L9su

8- s6C

0o 006.CA U JU~ -'ch

Mo ~ U-*

j~ ~ to 0 b .

0 >~ n.z Jr.

u ~~V(.3 - U- to

0 =-

2 9 ~ CI

LI)I

LurCh

38

A-

0 : o- w - 08 U

> Eu

LU l .

4o to0

1 - -

0S0

d > to

ou I~t U)< f -

CD z

0 0

LUL _ _ _ _ _

0. 0

0u z

0 39

00(

8 E

r*4 If 8. tUEIn)

W%& = ZZu 0 'n -

EUL - J

- ~ - .z tu (E

tu 0

0 00'-

= = 0- 0E EU0

ag >~ C

U Lfwi > EU/ (0E

qj~ 0) u w)U0t .b

ot Z 40a00 r.'uu o o

zz C4

0)

r 0o

0 Zu

r.ir

o 0Lu

04

to 00

00

w bw

Euu

00

0 <0 0

* E G03

U)z

GJ 441

0cz

000 0-m V C)0UM N t f v 6C

9z 2

0 R 2 Lo LI 2nL

00 000 000L

< Cl Ln 07 00 (tZ f)- 70 i

mU ow V

Cf)N 4%Il

o.- N (Go 0U ý< .

a, 2nN 4 ný oO

< <u < u <u <u~(n ~C*

42

0

LZf

0 6

Lq 0 U

U o

I-3

0

00

CD 0 t

I-D

0 2 nu s 0) C5 C) C z z

otF-s)Uu

0 < < u'- -

0,-44

0

zN

oa

0-'-v

UU

<- ci k

oo

U '-U

u < I- -9

~4

0

C04

.2 000

CLO I- a

2n

00 010 m c

o 0 06

U:U-

.- ~F.

C: .-!E "o

toV~ u o m

~c46

0

LO)

0 0

a; C

(0J LJ0 C'

0/) V)Ol C

II I < (

00 Lu L

U))Off

Lu< Lu <C

CA8 1<0 0 =

Zn 02LC)L0

V- NIi~ d :

0< 47

0.0

j-(3

0 0

r*-) L-

C) 0cLLJ LUI < 0l

< < -J i)

0) 0 LJCL144 . c, - m9

0 U< < 0

0 0~ L)

w zi

if) rr)CN0

Výi NI iN~ddflD

48

LO~

4q -H +1 -H

f C-

00

Z0

+1 >+1 +1 -H

<0 CD

w

c-o

<li

0

z -

49

APPENDIX I

Page

PULSE WAVEFORMS FORSHOTS #6 THROUGH #67 48

CERTIFICATION OF CALIBRATIONFROM NATC & NRL 64

CONNECTOR COMPONENTS ANDFITTINGS WITH MANUFACTURERSAND PART NUMBERS 66

50

Liz TO 9ir/ RISE TINE1.371-05

11E-HSEC Dig

* NO~SI ~ SHOTI :9663

PEA CURRUIT

.~~~2 831..63 . .

LE-94 SEC/DIV --- )

INRC-R cowII :PERSON PROBE

51

IN: NOT fOUNDs

........ $NRESOT# 90U14

PEAR CUMUMN

11K-U SEC/big

NUM-Nf COhW01 : MRSON PROB

...... ..... ... 52

..... ..... .. ... . ...... .... ......

f fol $1 1 MN. NO?# 1111111

11-k SEC / IV-

ieee-rnlox NOen EDD POB

No.Rlist ill. S1OTI 980i1

11-H4 SEC /lip

NIK-U Cow KON5M

S. . . . . . .. . . . . . • . . . . . . • . . . : . . .• . . . . . . . ..* . . 1NOT frulso

... .. ...... .. J SHOT# 9

' " " ' ! .. .i . .. 2 .... i .... .... ;.... i..... i..... i.......' ' ...i . ...... i .... i .... • ... i ... i .... i .... "A CURRENT

*6Esfl)2.9IE.63AN? ...- .. .. .... i.... .... i.... !..... !..... i.......-9146) . ..

11-64 SI / DIV ---

U11.p- PENO( MOMlwfw

-. 61.r2)

* " " i ..~ ~.. . .i .... .... ! .... i.... i.... !.... i.........• " i. .. .. i..... i.. ... i.. ... .. ....i.... i... .. i..... i. .... ..

" " " ' i ... i.... .... i.... .... i.... i..... i..... i.......

1E-4$EC/ DIg --- )

IUC-RF CONN : PRISON MR

S " /: NOT FOU•5......... l• •, SHOUi 6=022

•SE•O• ) ' . . ~.. . .: .... : .... -. ... :. . .: . .: . .. : . .

I I • .. . ! . . : . .. : . . . : . . .: . . .: . . . .: . . .. i. . . . !. . ... ..

"I|•I•) .. .: .... i.... .... i .... : .... !.... : ... : .... i.... 3. 5E 6

IE-94 sic ) IV --- )

KU-U COM MRSO MOE

- f9 PST INS.i.. SHOS 0 9992

..... . ..../ D IV -

...1...) . ..

LE-94 SEC /pig --

HUR-RJ' CO9SIIT PEARSON PROME

..............5 5

* .. . * 1t~~ NOT IOUHINHOSD,92

.8 . .. .. ..... .. . .

-8142) ..

11-94 SEC /Dig -RDRC-11 COmI? : RASON MRO

1 WX NOT oum,'.. O . IS ... SHOTS NW097

PEAK CURRENT

IE-84SEC/DIV---)

* * 19? NOT FOUND'- NO. RISE. [INE.~ SHOT SM9028

. . .PEAK CUJRREN1T.. .. . . .. .. . 2-96E+83

11494 sic/ Div --- )

56

.... .. .. . ... ... ..... ..... ..... ..... ....

it/ NOT FOUNDO...... 1. st[INS~.. SHOT#I um

11-H4 SIC/big

HoC-Il coamI : PAON PROB

ley.OTI 69HOT941

li-H SnC /HT DIV

HURC-Un~PO COCURRENTSO POB

..... .63E57

...... . . :. ... .. .. . .. .. .. _".. . .. :..... :.. ... :... .. :.. ... .mIL;L3 SNOT6#: omI

• .. ... : .. . ;... .. .. .... : .... :. ....-. ..... ....

9.631+83

-U+O)• .... i.... i.....i .... !.... i... ..:.. ..i..

13-4 SI / DIv -)

HUE-El COlMla : 1it301 MRO

58

I W/ . No . lDI

11-04 SIC NV1U-

NoC-Mwi CommW : P1*150 PBX

....... soE. listfl .0 .. SHOTI:Boom4

1t~PU CHUNON~

RURC-Rf CommD1 PERSON MROB

.... .. .. .... .... .... .. 5 9

i i i ! i i lw.: •0T Tom!,

SI•IK allUH

1.60E+04

tGtW) ..........

, a• - .... i .... ! .... i .... ! .... -.... i .... ! .... i .... i .... !-a ,m • .... i .... ] .... i .... ! .... i .... ! .... i .... i .... i .... i

'Ll•-H SIC / Jig -- )

HE-D1 CON•m : l•lilKON lqt01E

. .. . : . . . . : . . . . • . . . . : . . . . • . . . . : . . . . . . . . . . . . . . . . . . . :

S. . . . . . 10'/.: NOT TOU@•.i•.RISE.'•II• ,t.. tHO'rl : 60004?

S......... : .... : .... : .... ,• .... : .... [ .... : .... : .... :

. .. . . . . . . . . . . . . . . . . : . . . .. . . . . : . . . . : . . . . ; . . . . : . . . . .

PEAX •!1•

i 1.101:•64

.•.o3), , - ...i .... i .... i .... i .... • .... ! .... i .... i .... • .... i-e o,3• i .... i .... ! .... i .... i .... i .... i .... ! .... i .... i

[ • o .

IE-04 tic / Dig -- )HUE-•I ¢.0Nggff : •L•I•01t r•H

: : : i : : 19'/,: HOT FOUHD•, :S.... :: .... i .... ] .... ! .... i .... i• xsE•I•,; :: SMOT,', • 8

S......... • ..... 1.04£÷04

•03) ....e m,..i

-4EtO3)

IE-04 t• / Dttl --- )HUllO-lIT1 ¢0Hill• ', I•ilSOH PROlllt

...... IV. E inE.. SHOT# no@S

NRC-Nfl~PEA CURRENTAR~h P0

........... .... . ..NJ E .T N .. .. S H.3 I :+ . u

+4 # 3) . . ... . .. . .. . ..... T tO ND

11-94 SEC DIV )

NUIC-ail mmW~i PukRON PROBE

..... ..... .. 61

19.NOT FOUND'... ...... . ISS1TINEUi .. SHOTI 09993

nix aUInT1. 46E+94

11-94 SKC DIV -

M hIU,....................f

Itz: NOT FOUND'NO ISETIE p.. SHOTI 99994

-41493) ...

1E-94 SE /Div ---)

INC-Rn COMhINT PARMSON PROBE

lozx NOT FOUND'NO...... .. I... PRIE,~ SHOTS 698955

PZAX CURRVIT1.48E+94

11-94 SEC /DIV --

HUIC-Rl COIIMIT PERSON PROBE

62

* Ilax NT POUND,- NO. list. [in.~ H o w?: 9

-4113).1...3 ). .

11-64 SEC / 1, -

IUIC-IF COISIEif MASOiNC PRO

11PA NOT FOUNDto list R iSETN f. SHOTS : 9695

PONK CURRDENT2.911+41

11-64 SEC /DIV --

NURC-Rl CONIENT MPARSON PROB

* .. . . IW: NOT POUNDO.. ..... R ISE ...... SHOT#: 91995

PEAK CUJRRENT..... .2 .84E+64

I AN?- .. *.. . .

.... .... ... - .. . . .

11-94 SIC /DIV --- )HUIC-UJI CONNIE! : PEARSON PROBE

63

m11 To ggx RISE TinE

I AN-. . . .. . .

11-64 SEC /Div -

INK-DPI COWif MASON30 PROD

- ft NOT OUNDI HT:Nl

00*is.fie SHOTS: NMIS

+41+83) . . . . . . .. . . ..

LE-H4 SIC/DIV--HURC-RF CommY PEARSON PROBE

................. ...........6 4

lox: NOT fOMKNo.RISE fiNe I. SHOT#: 9663

4440 .. . . .lxNTPU

. . ..... .....

11-64 SIC pig ---

IN: lNOT SHOS 900

PEAK CURRENT2.061E46

-41+03) ..

11-64 SKC Dig --

HUUCt-UT CONmD(! PEMON P101K

[in HOT#899 65

S. S: ,NOT FOU ,

PEAK lUME

-8+81 ...................

Il-H SIC / DIVJ --- )

HIUK-If CONNf : (UTIWt POIK)

66

CERTIFICATE OF CALIBRATION

A Lightning Test was performed at the Naval Air Test Center during - to 12October 1991. Test was performed for the Naval Research Lab. The followingequipment was used during test for measurements.

a. Pearson Model 1330 Current Probe, Calibration date: 16 Sep 1991,Accuracy ±1%, 3db points at .9Hz and 1.SMHz.

b. Biddle Digital Low Resistance Ohmmeter, Calibration date: 7 Jan 1991,Accuracy of ranges 0.000 to 5.999 milliohm and 00.00 to 59.99 milliohm is±.25% plus 1 LSD (Least Significant Digit).

c. IWATSU Digitizing Oscilloscope, Model TS-8123, Calibration Date: 3 May1991, Vertical Accuracy ±2%, Horizontal Accuracy ±2%.

Test Director Date

67

CERTIFICATION OF CALIBRATION

Lightning strike tests were performed at the Naval Air TestCenter during the period 7 through 12 October 1991. Thesetests were performed for the Naval Research Laboratory inconnection with the V-22/NAC composite connector tests.

An independent check on the Biddle Digital Low ResistanceOhmmeter used by NATC was conducted by NRL by using acalibrate 1.00 milliohm (0.001 ohm ) resistor (i.e.,200 x 10- volts @ 200 amps.) The resistance measured by theBiddle instrument in the milliohm range was 0.991 to 1.001milliohms.

NRL Test Director DaCte

68

LIST OF CONNECTOR COMPONENTSAND ASSOCIATED FITTINGS

The specific MIL-C-38999 shell size 9 connectors and components were provide bythe Naval Avionics Center form the following suppliers:

Part Mfg. Part No.

Aluminum Connector / All aluminumReceptacle Bendix TVPOORW935PPlug Bendix TV06RW935SBackshell Sunbank SPL3202BF6400-12A-1

Composite Connector / Plastic resin with metal overplatingReceptacle Bendix CTVPSOORF935SPlug Bendix CTVS06RF935PBackshell Glenair 440HS035XM0903-31931

Receptacle Deutsch ATD ATD060RA35PNPlug Deutsch ATD ATD066RA35SNBackshell Glenair 440HS035XM0903-31931

Hybrid Connector / Metal sleeve overmolded with plasticReceptacle ITT-Cannon KJAH7T9W35SNPlug ITT-Cannon KJAH6T9W35PNBackshell ITT-Cannon KJAM-9 Test Sample 9121

Associated fittingsAdapter Electro Adapter In. N AStainless Bands Band It z AL0089Banding Tool Glenair S/N 3081Std. Braid 0.5" wide N A

69