AIRCRAFT
ELECTRICAL WIRE TYPES
associated
with
AIRCRAFT ELECTRICAL
FIRES
An aviation safety
article
by
http://www.vision.net.au/~apaterson/aviation/wire_types.htm
Last Updated: 8 March
2008
MASTER
INDEX of articles written, posted
online, or recommended by Alex Paterson
INTRODUCTION
This article provides a list of electrical wire types most
commonly used in jet transport aircraft. The articles lists both the
positive and negative characteristics of each wire type and the
aircraft that these wires have been installed in. It needs to be
understood that the article is by necessity incomplete because
aircraft manufacturers and airlines have historically given scant
regard to the potential dangers posed by different wire types when
installing them in their aircraft and therefore have not kept
accurate records of what types of wire have been installed in the
same. The complacency within the aviation industry
towards the dangers posed by electrical wire is endemic and is best
summed up by the comment of United States Federal Aviation Authority
(FAA) deputy head, Tom McSweeny, who is reported to have said before
a Congressional Committee in 19-- that "wire is wire". (more on Mr
McSweeny's alleged comment below)
NOTE: This is a draft web page only,
setup for discussion between contributors. It undoubtedly contains
omissions, and possibly some mistakes.
Alex Paterson (May 2007)
AIRCRAFT WIRE
TABLE
The following table relates to general purpose
aircraft electrical wire. All transport jet and turboprop aircraft
have a mixture of the following different wire types installed in
them. The wire types listed in the table relate to the predominant
type for each aircraft. It would appear that even aircraft
manufacturers themselves are not completely sure as to what wire is
installed in individual aircraft as their attitude towards electrical
wire in the past has been that "wire is wire".
Table Colour code:
|
UNSAFE WIRE
|
|
SAFE WIRE
|
|
PROBABLY SAFE
|
|
SAFETY UNKNOWN
|
NOTE: Wire is listed in the table by date of
introduction into aircraft, with the oldest wire typed listed at the
top.
|
WIRE
TYPE
|
DESCRIPTION
|
AIRCRAFT
INSTALLED IN
(some)
|
PVC/Nylon
(Polyvinyl-Chloride)
Introduced 1950s
Specification No: 5086
|
Fails Far
25
- Weight 6.8 lbs. per 1,000 ft
(Heaviest and thickest)
- Rated
temperature low:
105šC
- Flammable - burns readily creating
copious amounts of thick, toxic smoke rendering it
virtually impossible for pilots to see their flight
instruments or breathe. (e.g. Valujet 592)
- Insulation when burning turns to
hydrochloric acid when exposed to water.
- Outgasses
onto electrical & electronic contacts
- Soft - Susceptible to
chafing
- Susceptible to aging
in that it dries out and becomes brittle.
- Banned by US Air
Force.
- US Air Force had 800 autopilot
anomalies due to defective PVC in a 6 month study in
--?
- Still used as general purpose
replacement wire.
- Implicated in Valujet Flight 592
DC9 which crashed into the Florida Everglades on 11 May
1996
Dangerous
Wire
|
Installed in
- Early DC-9s up until 1979
(e.g. Valujet 592)
- Early B727s up until
1976
- Early B737s up until
1976
Still used as general purpose
replacement wire by sections
of the aviation industry.
|
Kynar
Introduced in 1964
Specification number:
|
Fails Far
25
- Thickness: 15 microns
- Weight 5.5 lbs per 1,000
ft.
- Rated Temperature: 150šC
(fails temperature spec)
- poor fluid
resistance
- No longer used
|
Installed in
- DC9s from 1970 until
1976
|
Kapton
(complex aromatic
polyamide)
Manufactured by Dupont Chemical
Co.
Introduced 1966
Specification Numbers:
|
Fails Far
25
- Thickness: 8.4 microns
(Very thin)
- Weight: 4.6 lbs per 1,000 ft
(Very light weight)
- Rated temperature:
200šC
- 'Explodes'
and burns fiercely at flash-over
during an arc
tracking event due to the
production of free hydrogen, severely damaging adjacent
wires and igniting surrounding structure. (i.e. behaves
like detonator fuse.) 1
- High ignition temperature to start
burning (usually associated with an electrical short
circuit of 5000šC), but when it does finally ignite it
burns very fiercely (explodes) creating virtually no
smoke.
- Fumes are clear and fairly
benign.
- Susceptible to wet and dry
Arc
Tracking.
- Susceptible to aging
in that it dries out forming hairline cracks which can
lead to micro current leakage (i.e. electrical 'ticking'
faults ) which in turn can eventually culminate in an
explosive arc tracking event. (i.e. short circuit)
1
- Stiffness (straight line memory)
makes it prone to vibration chafing, (rubbing) and
stressed by bending.
- Abrasive to other wires. (due to
its hardness)
- Hygroscopic
(i.e. absorbs water ) rendering it susceptible to wet arc
tracking.
- Installation difficulties
(difficult to strip and mark)
- Banned by
* US Air Force
* US Navy
* Canadian military
* Boeing in 1992
* Bombardier?
VERY
DANGEROUS WIRE
|
Installed in
- Airbus A310 (all)
- Airbus A320 (currently)
2
- Airbus A330
(currently)
- Airbus A340
(currently)
- B727 (after 1979, EB)
- B737 (after 1979 to
1990)
- B747-400 (some from 1989 -
1991)
- B757 (up until 1990)
- B767 (up until 1991)
- BAe 146 (unconfirmed
reports)
- DC-10
- MD-8x (all)
- MD-11 (up until early
1992)
- A300 -600 (with Teflon
top-coat)
- L-1011 Tristar
- Concorde SST
- B-707 (but not according to
EB)
- Dassault Mercure
- CL 600 Series (but not
RJ/CL604 or Global Express (Challenger)
- Shorts SD-330
- Gulfstream G-II, G-III
- HS125-700
- Bell 212, 214
- Sikorsky S-61, S-70B,
S-76
- Westland 606
- Plus 31 military types such as
P-3, C130, F-14, F-18, Hawkeye, etc
Still used by AIRBUS
in A319, A320, A330, A340
until about 2005
(see footnote
2 below)
|
Teflon
(Polytetrafluoroethylene -
PTFE)
Introduced in 1969
Specification Numbers:
|
Fails Far
25
- Thickness: 10 microns
- Weight 5.43 lbs/1,000
ft.
- Rated temperature:
200šC
- Longitudinal splitting problem due
to manufacturing process.
- Susceptible to cold-flow (creeping
of conductor).
- Type of insulation found as
ignition source on Apollo 13
- Type of insulation found split in
TWA 800-fuel tank wires [Fuel Quantity Indicating
System] (FQIS)
- Banned by major manufacturers in
1983
|
Installed in
|
Poly-X
(alkane-imide)
an Aliphatic polyimide
Manufactured by Raychem
Introduced in 1970
Specification Numbers:
|
Fails Far
25
- The first exotic blend of
insulation (due to oil embargo)
- Thickness: 10 microns
- Weight: 4.7 lbs. per 1,000 ft
(Light weight)
- Rated temperature:
150šC
- Susceptible to
solvents
- Susceptible to radial
cracking. Projected service
life 60,000 hrs/but circumferential cracks found after
just 2000 hrs by US Navy.
- Susceptible to premature aging.
Banned by US Navy in 1978 due to premature aging of
insulation after 4000 hrs
- Brittle. Due to brittleness, 1"
bare spots not uncommon.
- Susceptible to
chafing.
- Fails FAR 25 (airworthiness
testing standards)
- Caused 323 USN F-14s to be
re-wired
- Banned by US Navy.
- No longer used in civilian
aircraft
|
Installed in
- Early 747s (e.g. TWA
800)
- Early DC-10s
|
Stilan
Introduced 1972
Specification Numbers:
|
Fails Far
25
- Thickness: 10 microns
- Weight 4.7 lbs. per 1,000 ft
(Light weight)
- Rated Temperature:
150šC
- Insulation breaks down in
hydraulic and de-icing fluid
- Microscopic crazing problem seen
under microscope
- Cracks under stress
- Found to arc over
- Susceptible to spurious signal
generation (EMI
hazard)
- Absorbs water (i.e.
hygroscopic)
- No longer used
|
Installed in
- B-747s built in mid-to-late
1970s
- DC-10s built in mid-to-late
1970s
|
Tefzel
(ETFE)
Introduced 1972
Specification numbers
|
Fails Far
25
- Rated temperature 150š
C
- Soft at rated
temperature
- Used as general installation wire
but should never be mixed in bundle with other
wire types due to its softness.
|
Installed in
Arcturus
Tefzel was found in Swiss Air flight
SR111's Inflight Entertainment System (IFEN) which was
suspected as being the cause of the inflight fire and
subsequent crash of the aircraft off Nova Scotia in November
1998.
|
Cross Linked Tefzel
(XL-ETFE)
Manufactured by Judd Wire and
Raychem.
Known by some sections of the aviation
industry as "Spec 55" wire. Apparently the name "Spec 55"
has been trademarked by Raychem.
Introduced 1977
Specification numbers
- MIL-W-22759/34
- Spec 55
- Spec 55A
- BMS 13-48 (Boeing)
|
Fails Far
25
- Thickness: 10 microns
- Weight: 5.0 lbs/1000' (light
weight)
- Rated temperature:
150šC
- Wet arc tracks
- Flammable producing copious
amount of Dense toxic smoke (96%+ density) when it
burns rendering it virtually impossible for flight crew
to see their flight instruments.
- NASA states will fail flammability
requirements in 30% oxygen.
- Toxicity - the worst of all
wires, banned for manned aerospace use by major
manufacturer. (Grumman Corporation banned it in 1982 and
NASA followed suit in 1983 due to its
toxicity)
- Soft at rated
temperature
- Loses mechanical strength
properties at rated temperature
- Fails FAR 25 (airworthiness
standards test)
- Projected life 50,000
hrs
- Notch
propagation
problems
Dangerous
Wire
|
Installed in
- B747 (currently)
- B757 (currently)
- B767 (currently)
- B777 (currently)
- BAe146
- Airbus A320
- Airbus A330
- Airbus A340
Still used by BOEING in
B747, B757, B767, B777
and Airbus
|
TKT Boeing
(Teflon/Kapton/Teflon)
Introduced 1992
Boeing Specification No:
- MIL-W-22759
- BMS 13-60 (Boeing)
Tufflite brand manufactured by
Tensolite
http://www.tensolite.com
|
Passes FAR 25
- Weight: 5.0 lbs. per 1,000 ft
(Light weight)
- Arc-track resistant
- Abrasion resistant
- Superb insulation
protection
- High heat tolerance
- Resists smoking when burning (less
than 2% density)
- Displays all the positive aspects
of Kapton (i.e. lightweight, resistance to burning, no
fumes when burning etc) without any of Kapton's
negatives.
- No known problems
SAFE
WIRE
|
Installed in
- B737s built after 1992
- B757s built after 1992
NOTE: Airbus Industries now use their
own version of TKT (See
below)
|
KKF BAe
Two layers of Kapton within a FEP laquer topcoat.
Installed within the pressure cabin of BAe 146
aircraft.
Source of info:
BAe Statement dated 7 July 1999
|
FAR 25 attributes unknown
Undoubtedly safer than Kapton if only because it reduces
Kaptons propensity to dry out and form cracks.
Resistance to Arc Tracking
unknown.
|
Installed in
|
KT BAe
Single layer of Kapton overlaid by single wrap of PTFE
(i.e. Teflon)
Installed outside the pressure cabin of BAe 146
aircraft.
Source of info:
BAe Statement dated 7 July 1999
|
FAR 25 attributes unknown
Undoubtedly safer than Kapton if only because
it reduces Kaptons propensity to dry out and form
cracks. However, similar to Airbus' KTT
(see below) which according to the America's foremost
independent aircraft wire expert, Edward Block, "this type
of wire is just Kapton with a cosmetic coating of Teflon
which is used for marking purposes only and does little to
reduce Kapton's propensity to explosively arc
track".
Safety Unknown
|
Installed in
|
KTT Airbus
Kapton with two very thin outer layers of
Teflon.
Called by Airbus
Polimide/PTFE/PTFE
Airbus Specification No:
|
FAR 25 attributes unknown
Undoubtedly safer than Kapton, but Airbus refuses to
disclose performance attributes or specifications of this
wire to independent researchers.
According to specifications available, this wire is made
up of 25µm Kapton, sandwiched between two layers of
2.5µm FEP.
Safety Unknown
|
Used by Airbus to replace Kapton as a general purpose
wire.
Installed in Airbus FBW aircraft up until mid 2006 when
it was replaced by Airbus' TKT specification EN2267-008
listed below. See footnote 3 below.
|
TKT
Airbus
Called by Airbus
PTFE/Polimide/PTFE
Note: PTFE/Polimide/PTFE is just another name for
TKT as
Teflon is a PTFE and
Kapton is a Polimide
Airbus Specification No:
|
Probably meets FAR 25
Airbus refuses to fully disclose the performance
attributes or specifications of this wire to independent
researchers.
- No known specifications released by Airbus although
suspected to be very similar to Boeing's TKT wire listed
above.
- Allegedly has a much thicker outer layer of PTFE
(i.e. Teflon) than the KTT wire used earlier by Airbus.
(see below)
Probably Safe
|
Reportedly now installed in Airbus Aircraft as from mid
2006 as a general purpose wire.
|
Sources:
- Edward Block (IASA)
- Captain John Sampson (IASA)
- Michael Murphy
- Patrick Price (deceased)
NOTES
Only
Boeing's TKT wire has no known problems and meets FAR 25
requirements. Airbus' version of TKT probably meets FAR 25
requirements.
No
specific standards spelt out by aircraft regulatory authorities such
as US FAA or European JAR regarding aircraft electrical wire.
Specifically no standards defined or any requirement to test wire
for:
- Propensity of wire to wet or dry arc
track.
- Propensity of wire to burn.
- the density of smoke and toxicity of fumes
when wire burns.
Modern
jet transport aircraft are required by law (FAA 25 & JAR 25) to
ensure all safety of flight items and aircraft systems have
adequate backup systems installed in the event of a failure of the
main system, (and that includes aircraft electrical systems), yet no
thought was given to the failure of the aircraft wiring system
itself.
Wire
is deemed by most in the aviation industry (i.e. aircraft
manufacturers, pilots, airline management and regulatory authorities)
as an "install and forget" item. This attitude is best summed up by
the comment of United States Federal Aviation Authority (FAA) deputy
head, Tom McSweeny, who is reported to have said before a
Congressional Committee that "Wire is wire". This attitude ignores
the fact that:
- Modern jet transport aircraft contain
literally hundreds of kilometres of wire.
- Wire is often damaged during manufacture
and/or installation.
- Wire is often incorrectly installed in
aircraft. (i.e. incorrectly routed near hot equipment and/or
bundled together with other incompatible wire types such as soft
wire laying adjacent hard wire etc)
- Wire (both the wire and its insulation)
deteriorates with age. With regard to the insulation, it dries
out, becomes brittle forming cracks exposing the conductor (i.e.
wire) . Wire itself, oxidises especially associated with the
widespread electrolysis that occurs in aircraft leading to poor
contacts and the generation of local hot spots in the wire which
has the potential to melt the surrounding insulation
material.
- All wire deteriorates in service due to
environmental factors such as:
- extremes of heat & cold experienced
by aircraft on the ground and in the air. (i.e. wire can
experience plus +200šC down to minus -70šC),
- water damage, (hydrolysis
and the fact that some wire types exhibit hygroscopic
tendencies)
- salt damage associated with marine
environments. (all aircraft operate into airfields
adjacent marine environments at least some time in their
operational lives)
- contamination by aircraft fluids such as
fuel, oil, hydraulic fluid, deicing fluid, cleaning chemicals,
toilet residue, galley spillage etc.
- inflight vibration causing chafing of
wires rubbing against other wires or the structure of the
aircraft. This is especially a problem with hard wire such as
Kapton laying adjacent a soft wire like Tefzel.
- All wire products display differing
properties with regard to aging, but practically all
wire insulation material dries out, goes hard and then develops
hairline fractures which allow the ingress of water and other
aviation fluids leading to micro-discharges of current through
the cracks to surrounding wires or the aircraft structure.
('ticking'
faults)
- All aircraft use their airframe as their
electrical earth return pathway resulting in significant
constraints in the operation of protection devices such as
circuit breakers located in the cockpit. (see separate paper on
this issue)
FAR
25 states: "that insulation material
can not be used that is hazardous, unreliable, or contributes
smoke/fire."
COMMENT by Ed Block: "No particular uses of
insulation were further specified so insulation material includes;
seat insulation, insulation blankets, rug insulation, acoustic and
wire insulation. They are all types of insulation materials. Unless
they are tested with an electrical fire (2,000 degrees) igniter to
prove flammability proof, the material can not meet FAR 25
requirements. By their own (limited) standards, the FAA has said, in
fact, that most types of wire cannot be used!"
"Only TKT
wire insulation (BMS 13-60) meets FAR 25
Standards."
(Ed Block)
RECOMMENDATIONS
The aviation industry as a whole needs to
acknowledge that the shortcomings associated with different
electrical wire types are a serious issue and potentially very
dangerous as evidenced by the information presented in this paper.
The notion held by many with in the aviation industry that "wire is
just wire" is irresponsible.
Practical steps that the industry should take
to begin to address the situation include:
- Aviation regulatory authorities need to
specify rigorous performance standards for electrical wire so that
they conform to FAR 25 in that "insulation material is not used
that is hazardous, unreliable, or contributes smoke/fire". Any
promulgated standards for electrical wire would need to be
rigorously enforced.
- Acknowledge that Kapton wire is a
particularly dangerous hazard to aircraft and insist upon its its
removal from aircraft where practical. (this statement
acknowledges the fact that the complete removal of Kapton wire
will be in many cases an impossibility)
- Insist that electronic 'Fly by Wire' (FBW)
aircraft be fitted with a completely separate 'virgin' emergency
electrical bus to allow pilots to remove all electrical
current from all 'normal' electrical wire circuits in the event of
an electrical fire. For more on this subject see 'Virgin
Electrical Bus'
GLOSSARY
- Aging is the
deterioration of wiring insulation with the passage of time. To
certain extent aging is a natural process associated with the
propensity of most materials to breakdown into their constituent
parts over time. (e.g. rust) Most electrical insulation compounds
tend to dry out over time, become brittle and crack. Aging of
wiring insulation is exacerbated by aircraft vibration causing
chaffing (see below) and exposure to a whole raft of chemicals
within the aircraft such as hydraulic fluid, engine oil, toilet
chemicals, salt spray and moisture etc. Fluorination and other
treatments (such as top-coating) may accelerate the aging
process.
- Arc
tracking is the process by which electrical conductance can
occur through and along the insulating coating, rather than just
the wire conductor. This is made possible by the formation of
carbon along cracks within the insulation material and because
carbon is an electrical conductor, once formed the carbon track
tends to grow associated with the localised heat that is generated
along the track by the electricity leaking through it. The heat
generated by the current flow leakage causes a chemical breakdown
of the insulating material adjacent to the carbon track, forming
more carbon along the track. In other words once initiated the
formation of a carbon track becomes self propagating and therefore
continues to grow with the passage of time. In other words, once
started, arc tracking is capable of self propagation through the
virtual instant creation of its own combustion-induced carbon char
leading to a massive leakage of electrical current through the
carbon track so formed and the damage of adjacent wires in the
same wire-bundle. This process is called 'flash-over'. (see
next)
The initiator of arc tracking can be a flaw in the insulation
caused by imprint labeling, radial cracking, chafing between wires
or contact between a wire conductor and the airframe, hygroscopic
absorption of water, salt and other contaminants or an electrical
short circuit. It can also be precipitated by undetected shorting
damage in inaccessible areas or by use of inappropriate types of
insulation in SWAMP areas (severe weather and moisture-prone areas
such as wheel-wells).
NOTE: See also 'Ticking Faults' listed below
- Flash-over
is the self propagation and catastrophic escalation of an arc
tracking event through the instant creation of a major carbon char
pathway associated with the heat that is generated during the
initial arc track event (i.e. carbon is produced when the
insulation material starts to burn) The resulting escalation of
the arc track event associated with flashover can be explosive
(especially with Kapton wire) and the naked flames can cause
damage to adjacent wire-bundles and thermal-acoustic insulation
within the airframe. (e.g. Mylar) Vertical wire runs are more
susceptible to flash-over (because naked flames naturally rise
vertically). However flash-over can also occur horizontally or,
less explosively, in a downward vertical sense. Unlike a straight
electrical short, the conductor's temperature itself may not rise
high enough to trip the circuit protective device (CPD) meaning
the arcing phenomena may not necessarily cause a thermal
circuit-breaker to trip. The arc tracking phenomenon is based upon
the ability of the conductive carbon char to heat adjacent wiring
and self-propagate, particularly along a wire bundle more so than
an individual wire. Note that the phenomena induced in the
presence of significant moisture is called "Wet Arc Propagation"
(as against "Dry Arc Propagation"). Wet arcing is more likely to
produce the flash-over end-result.
- Chafing occurs
when wires vibrate and rub against each other (or the structure of
the aircraft) causing the insulation layer surrounding the wire to
be rubbed away exposing the electrical. The vibration causing the
chafing is usually the cumulative effect of the high-frequency
vibration which naturally occurs in flight associated with
aerodynamic and engine vibrations. The tendency for wire to chaff
is exacerbated by insufficient tensioning, insufficient offset or
the tightening of a wire against an airframe component (especially
around corners). Over-tensioning of wires and/or insufficient
support intervals can lead to "strumming" of wires (causing them
to contact other surfaces). Scraping caused by pulling wire
through narrow areas during installation can cause a similar
effect to chafing.
- Cold-flow
(creeping of the conductor) is any permanent deformation due to
pressure or mechanical force, without the aid of heat
softening.
- EMI: Electromagnetic
Interference. Wiring that is unshielded is susceptible to strong
electromagnetic fields stemming from systems and modules that are
natural emitters such as GPS, DME (Distant Measuring Equipment),
radios, weather radars, radar altimeters etc (plus cell-phones and
Gameboys etc)
- FBW: Fly By Wire. In
conventional aircraft, flight control is actuated by pushrods and
cables to hydraulic actuators driving the primary control surfaces
(i.e. ailerons, rudders, spoilers, canards, elevons and
elevators). In FBW aircraft the physical connections of cables and
pushrods are replaced by proportionate computer-generated
digitized signals.
- Fluid
resistance: Resistance to a wide range of commonly used
solvents, fluids and lubricants used in aircraft.
- Hydrolysis:
(noun) the chemical reaction of a substance with water, usually
resulting in decomposition of the said substance. (Source: Oxford
Dictionary)
- Hygroscopic:
(adjective): A hygroscopic substance is one that tends to absorb
moisture from the air (Source: Oxford Dictionary)
- Notch Propagation:
The tendency of a wire insulation to propagate a crack through to
the conductor with on going bending cycles. Usual requirement is
expressed as an acceptable limit. e.g. The wire shall not
propagate a crack to the conductor following a minimum of ten bend
cycles of the v-notched area.
- Outgasses:
Some insulation materials are volatile. In many critical aerospace
and semiconductor applications, low-outgassing materials must be
specified in order to prevent contamination in high vacuum
environments. Outgassing occurs when a material is placed into a
vacuum (very low atmospheric pressure) environment, subjected to
heat, and some of the material's constituents are volatilized
(evaporated or "outgassed"). Outgassing is related to conductor
temperatures (i.e. load carrying capabilities).
- Radial
cracking: This can occur around a wire's circumference and
expose the conductor and cause 'ticking faults'. (see below)
Causes of radial cracking can be natural deterioration,
insufficient bend radii or damage at installation. Over
significant stretches of wire runs, the cause will normally be the
degradations due to aging, coupled with top-coat flaking. This
latter phenomenon is the natural breakdown of a shellac-like
substance applied to protect aromatic polyamide (i.e. Kapton
types) in particular from hygroscopic activity. Radial cracking
can be initiators of ticking faults.
- Rated
temperature: The maximum temperature at which a given
insulation or jacket may be safely maintained during continuous
use, without incurring any thermally-induced deterioration. Rated
temperature of a wiring insulation/conductor gage may not remain
constant for the life of an installation due to the aging
process.
- 'Ticking'
faults. This is an intermediate process of wiring insulation
breakdown where sufficient conductor exposure (perhaps due to
radial cracking) coupled with the early phase of outer carbon
charring allows "arcing in miniature" (i.e. "ticking") to occur.
Think of it as sparkling along the outer sheath. Once sufficiently
advanced, this process will have built up a sufficient carbon char
for full-blown self-propagating arc-tracking to occur. If wetted
(by say a galley or toilet leak or ramp moisture ingress), the
condition may allow an earlier 'flash-over'
event.
FOOTNOTES
1. Kapton Arc Tracking and
Flashover: According to Dr Armin Bruning of the Lectromechanical
Design Company of Dulles, Virginia USA - a company which has been
contracted by the US Navy amongst others to investigate Kapton arc
tracking - the reason Kapton explodes during an arc tracking event
and 'flashover' is because "the arc will cause a temperature of 5000
degrees Celsius ... and in this condition carbon is vaporized and
free hydrogen is liberated."
Source: email from Armin M. Bruning Lectromechanical Design Co to
Alex Paterson dated 5 May 2001
It would appear that encapsulating Kapton
between layers of Teflon [i.e. Teflon - Kapton - Teflon
(TKT)] prevents the Kapton layer from drying out and cracking, as
well suppressing the production of hydrogen during a short circuit,
rendering the Teflon coated Kapton (i.e. TKT) relatively benign from
an arc tracking point of view.
___________________________
2. Airbus Industries
began using a hybrid version of Kapton comprising Kapton coated with
Teflon (TK) made by Dupont in some parts of its Fly by Wire aircraft
in the late 1990s. However, according to the America's foremost
independent aircraft wire expert, Edward Block, this type of wire is
"just Kapton with a cosmetic coating of Teflon which is used for
marking purposes only and does little to reduce Kapton's propensity
to explosively arc track".
However, see note 3 below.
___________________________
3. As of mid 2006 Airbus
Industries have started to install their own version of Boeing's
TKT in their new Airbus aircraft. This wire is designated
Airbus Specification No: EN2267-008. This wire would almost
certainly be much safer than bare Kapton, but Airbus Industries
refuses to disclose the performance attributes of this wire so it is
difficult to determine for certain how safe this wire actually is.
See main wire table above for more details about this wire.
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ABOUT
ALEX PATERSON 
Alex PATERSON is an Australian airline pilot. He writes
articles and advises on issues pertaining to aviation, politics,
sociology, the environment, sustainable farming, history, computers,
natural health therapies and
spirituality.
He can be contacted
at:

Photograph
of Alex Paterson 
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