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June 1, 1966 IN-R-QUAL-66-28

NftI

\l

AN EVALUATION OF TERMI-POINT

CONNECTORS

QUALITY AND RELIABILITY ASSURANCE LABORATORYGEORGE C. MARSHALL SPACE FLIGHT CENTER

Huntsville, Alabama

F O R I N T E R N A L U S E O N L Y

MSFC • Form 1094 (M«y 1961)

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June 1. 1966 IN-R-QUAL-66-28 ii

. jAN EVALUATION OF TERMI-POINT I

CONNECTORS

ABSTRACT

ADVANCED METHODS AND RESEARCH SECTIONELECTRICAL TEST AND ANALYSIS BRANCH

*

'

This report is a statistical evaluation of Termi-point con- >nectors and their adequacy for use in ground support equipment. ITests performed included vibration, physical shack, salt spray, .gas seal, thermal shock, and humidity. Suitability for the intended [purpose was demonstrated. . •'

TABLE OF CONTENTS

Section

I.

II.

.in.

IV.

V.

VI.

• VII.

SUMMARY

. INTRODUCTION

DESIGN OF EXPERIMENT

DESCRIPTION OF THE COMPONENT ....

EQUIPMENT USED IN TESTS ' ,

DETAILED TEST PROCEDURE ,

STATISTICAL ANALYSIS ,

TEST RESULTS AND DATA ANALYSIS

Page

1

2

2

3

5

6

678

. . . . . . 10 '

15

20

VIII. CONCLUSIONS AND RECOMMENPATIONS 24

APPENDIX A. THERMAL SHOCK TEST A-l

APPENDIX B. SALT SPRAY TEST B-l

APPENDIX C. GAS SEAL TEST . C-l

APPENDIX D. HUMIDITY TEST J D-l_7-

APPENDIX E. REFERENCES. . . . . . . . » . E-l

111

lN-R-QUAL-:66-28

LIST OF ILLUSTRATIONS

Figure Page,

1 Termi-Point Connection " . . . . . . 4

2 Contact Chatter 14

3 Contact Resistance . '. 14

4 Termi-Point Gas Seal Test Setup 16 i

5 Termi-Point Connections After the Gas LeakTest (Arrows Indicate the Location of the ;Termi-Points During the Test) 17 j

6 Typical Test Specimen 18 '*

.. 7 Distribution of Retention Force of Gold Clips • ',After Thermal Shock Conditioning 21 i

8 Distribution of Retention Force of Tinned Clips IAfter Thermal Shock Conditioning , 21

9 Distribution of Retention Force of Gold ClipsAfter Humidity Conditioning 22

10 Distribution of Retention Force of Tinned Clips. After Humidity Conditioning 22 k

11 Distribution of Retention Force of Gold Clips fAfter Salt Spray Conditioning 23 .

12 Distribution of Retention Force of Tinned Clips 'After Salt Spray Conditioning . . 23 t

i * -

I• LIST OF ^TABLES ' ." J

Table

1 Environmental Test - . . . - . « . « . < . . » o 8

2 Minimum Clip Retention » , ? . < > < > o o a o « o 9

3 Minimum Clip Stripping o <,„ 0 . = , < , < , 9

IV

June 1, 1966 IN-R-QUAL-66-28

AN EVALUATION OF TERMI-POINT !

. CONNECTORS !

SUMMARY

Termi-point connector-s-o£fer _a_n_ew technique for point-to-pointwiring. The wire and terminal are affixed to a terminal post by theuse of a pneumatic applicator that strips the wire and makes a contact.

This report covers a series of tests designed to ascertain the .adequacy of the Termi-point connectors for use in ground supportequipment.

Tests performed included vibration, physical shock, thermalshock, salt spray, gas seal, and humidity.

While suitability of Termi-point terminals for usage in groundsupport equipment was demonstrated, it was felt that in certaincritical areas and for flight conditions, that a more dynamic testprogram should be conducted.

IN-R-QUAL-66-28

I. INTRODUCTION

Termi-point connectors were introduced in 1963 by the AmpCorporation of Harrisburg, Pennsylvania. Possessing advantagesincluding the elimination of soldering, welding, and wrapping, Termi- f

point connections offer a new technique of point-~tb-point wiring.

' T h e purpose of this report is to evaluate a series of tests thatwere performed to determine the susceptibility of1 Termi-point connec-tions to anticipated ground support equipment environment.

The tests, selected to give a general appraisal of overall capa- fbilities, included vibration, physical shock, thermal shock, salt spray, Igas seal, and humidity. . j

. ~" Prior to use in critical areas and to meet flight conditions, a • Imore dynamic test program should be conducted on a sample of the [design configuration; acceptance being contingent upon satisfactory .jtest results.

II. DESIGN OF EXPERIMENT

Three factors were to be varied in the experiment:: wire type,wire size, and terminal -clip • plating material. The three wire sizesused were 22, 24, and 26. The two types of wire used were solid andstranded, and the two types of Termi-point clip and terminal postmaterials were gold and tin. This gave 11 degrees of freedom to theexperiment. .

A matrix, wherein all degrees of freedom were represented, wasused in designing the test sampled ThtB~ensured that all permutationsof the three factors were varied in such a way that statistical tests ofsignificance of variation could be made when the tests were completed.A gross sample size of 66 was planned, but for the thermal shock testa double sample was used to gain an extra measure of confidence*

The following diagram shows the approach used in developingthe matrix for the sample. •

IN-R-QUAL-66-28

Diagram for Matrix

1

WireType

StrandedSolid

2

2

WireSize

22'2426

3

3 -

Post and ClipPlating

GoldTin

2 Degrees ofFreedom

( 2 x 3 x 2 ) - 1 = 11 Degrees of freedom

The above diagram was expanded into the sample matrix by using6 specimens for each permutation except one wherein three specimenswere used. This exception was solid no. 26 wire where lack of materialrequired a reduction'of specimens.

The statistical analysis is found in section VI.

. DESCRIPTION OF THE COMPONENT

The Termi-point connector is an electrical wire clip which-consists of a web, crown, serrations, strain relief, and insulation ('support. (See figure 1.)

The web or body of the clip functions to press a stripped wireend against the terminal post.

The crown is the .embossing of the clip web. The function of thecrown is to control bundling of stranded wire during, application of clipand wire to the post.

The serrations are internal cross scorings located at the clip'scrown.' The function of the serrations is to prevent wire slippagerelative to the clip during clip application to the terminal.

3

IN-R-QUAL-66-28

Post

CarjryingStrip

Stripped' Wire

InsulationSupport

Crown ,_ Strain Relief

•A '^.","'' - ' <«•• .7O\^ ' <<S^P"

^Rlfts

Web

Curl(Retention Spring)

Cross-Section

Figure 1. Termi-point Connection

IN-R-QUAL-66-28

The strain relief, located at the outward flange on the end ofthe clip web, functions to eliminate wire nicking.

The insulation support is the preformed area of the clip. Thesupports hold the insulation secure to prevent movement of the wireduring flexing and vibration. . -~*

IV. EQUIPMENT USED IN TESTS

A brief description of the equipment used for the various testsis as follows:

1. Vibration System -

2. Physical Shock -

3. Thermal Shock -

4. Salt Spray

M. B. Manufacturing Company oilcooled vibration platform, ModelC-25HB.Rating - 5000 force pounds.Operating range - 5 to 3000 cps.Noise capability - 75 decibels (db)

per octave from 10 to 2000 cps±1/2 db.

Consolidated Electrodynamics Cor-poration shock test machine. •Capabilities - Imparts 1/2 sine wave

force impulse of 10 g to 130 gjvithin 8 to 13 milliseconds.Maximum force - 8000 poundsthrust with 100-pound specimen.

Tenney Engineering, Inc. Tempera-ture Chamber, Model 36T-90600.Range- -73. a°C to +315. 6°CChamber mounted on hydraulic lift —

capacity 0 to 56 inches-fo'r'combinedtemperature vibratib'n tests.

Industrial Filter and Pump Manu-facturing Co., Model CAS-1.Temperature range - + l . l °Cto

48.9°C.Simulates environments containing

25 percent salt by weight.

I IIN-R-QUAL-66-28 -. j

5. Gas Tightness - - HgS gas cylinder - Laboratory jdesiccator. • • * .

I6. Humidity - Tenney Engineering Inc., Model jCTTUFR-100350. ' f |

- ' Temperature range - -73. 3°C to+176.7°C.

" Humidity Control - 20 and 95 percent. over temperature range of +1«7°G

1 v to +82.2°C.

V. DETAILED TEST PROCEDURE il- A. REQUIREMENTS

1. Tolerance of Equipment. The maximum allowabletolerance on test conditions was as follows;

. ' ' a. Temperature ± 2°C

b. Vibration Amplitude ± 10 percent

c. Vibration Frequency ± 5 percent

d. Shock Duration ± 1 millisecond

' 2. Standard Conditions. Unless otherwise specified, alltests were Conducted under the following conditions:

a. Temperature 25° ± 3°C

b. Relative Humidity 70 percent maximum

c. Pressure 710-810 millimetersof mercury

3. Laboratory Equipment. The following major items ofequipment were required to perform the tests:

a. Vibration Table. Capable of imparting 0.06 inchdouble displacement from 10 to 80 cps and an acceleration of 20 g from8 0 t o 2000 cps. • . . - , . , t

i t

II

IN-R-QUAL-66-28 !t

' - -- [b. Shock Machine. Capable of imparting a one half

sine wave shock of 6 to 11 milliseconds duration and 125 g peak to !the test specimen and associated hardware.

•

c. Temperature Chamber. Controllable in the ranges; of 25 ± 5eOto-125 ±3°C; '• T '^ : -.

d. ' Temperature Chamber. Controllable in the ranges ',of *5+1j°cto,-65+joc. ;: . •:.. :.

e. Humidity Chamber. Capable of maintaining humidityper method 106B of Standard MIL-STD-202C.

f. Salt Spray Chamber. Capable of maintaining 20.percent salt spray environment per method 101B, Condition A, of

• Standard MIL.-STD-202C.•'•**•

4. Measuring and Recording Equipment. The followingmeasuring and recording equipment were required:

V a. Millivoltmeter •* 0-2000 millivolts dc, 1 percentt

b. Ammeter - 0-5 amps, 1/2 percent

' . • ' c. Voltohmmeter - multirange, 5 percent

d. Oscilloscope, camera, dc power supply, recorders,and other equipment as required.

B. EVALUATION TESTS

1. Examination of Product. The connectors and all com-ponent parts were required to be mechanically stable. There couldbe no evidence of misaligned clips or terminal posts or loose or brokenconnections. Visual inspections were performed in accordance withAMP GP-1920,"Quality Control Procedure for Termi-Point ClipApplication1.'o

2. Test Sequence. The connectors were subjected toenvironmental testing in accordance with and in the order shown intable 1. -Characteristic and mechanical tests were performed beforeand after each environmental test in accordance with paragraphs D. 1and D. 2.

IN-R-QUAL-66-28

Table 1. Environmental Test

Test Description

i

a. Vibration• .

*

b. Physical Shock

c. Thermal Shock

d. Salt Spray

e. Gas Seal

?.* Humidity . .

Test MethodPara. No.

D. 3. a andD. 3.b

D.3.c

D.3.d

D. 3.e

• D.3v£.

D. 3.£

Test FailurePara. No.

C. Z.h

C.Z.i

C. Z.j

C.Z.k

C. 2. 1

C. 2.mv

• i

C. DESCRIPTION OF SPECIMEN FAILURE

1. General. Visual inspection for any damage to theconnectors was performed following each environmental condition andfollowing each test phase of whenever any deviation from normal opera-tion was observed. Any deviation from the requirements of para-

" graphs'Bul and C.Zwas considered a failure.

2. Definition of Failure Points.

a. Physical Damage. Any physical damage or changewhich prevented satisfactory operation within tolerance under theenvironmental conditions specified constituted a failure.

ib. Irreparable Damage. Irreparable damage to

structural or principal parts was defined as catastrophic failure.

c. Contact Resistance. When the connector contactresistance was measured before and after each environmental con-dition, any contact resistance.which exceeded 800 microohms wasconsidered a failure. . . . . . .

IN-R-QUAL-66-Z8

d. Contact Chatter. When the connector contactswere monitored during any physical test, any contact chatter which

• caused a change in the connector contact resistance of one ohm for• one microsecond was considered a failure.

e. Low Level Conductivity Test. When 1 microvoltwas applied across the connector contact in an open circuit, theconnector was considered a failure if less than 1 milliampere ofcurrent flow was measured.

f. Connector Retention. When the connectors;were'tested in accordance with parag-raph D.2.a, any measurement thatdid not meet the requirements of the following table was considereda failure.

Table 2. Minimum Clip Retention

Wire, AWG :

.SizeStr'anded, Solid

26 AWG,24 AWG22 AWG

Post Finish

Electrotinned, ReheatedAfter Tinned or Rolled

Finish

3.0 Ibs3. 0 Ibs3. 0 Ibs

Rolled Tin Plated, Gold OverNickel, Gold Plate, Smooth

Nickel, or Tin Nickel

2. 25 Ibs2.25 Ibs2.25 Ibs

g, Connector Stripping. When the connectors were'testediin accordance with paragraph D.2.b, any measurement thatdid not meet the requirements of the following table was considereda failure.

Table 3. Minimum Clip Stripping

Stranded Wire Size

26 AWG24 AWG22 AW(S

Method A(Second Part ofthe Appendix)

5.0 Ibs7. 0 Ibs7. 0 Ibs

Method B(Second Part of .the 'Appendix)

5.0 Ibs7.0 Ibs7.0 Ibs

IN-R-QUAL-66-28

h. Vibration. Any connector that loosened, cracked,or broke, or any contact claaiter which caused the contact resistanceto exceed I ohm for I microsecond during test was considered afailure.

1 i. Physical Shock. Any connector that was physicallydamaged or any contact chatter which exceeded 1 ohm for 1 micro-second during test was considered a failure.

j. Thermal Shock. Any connector physical damagethat resulted from the effects of the test conditions was considereda failure.

k.. Salt Spray. Any visible or injurious effect to theconnector finish or materials resulting from the effects of the testconditions was considered a failure.

1. Gas Seal. Any visible or injurious effects to the, contact surface resulting from exposure to hydrogen sulfide fumes

/ was considered a failure.

• r \m. Humidity.. Any evidence of damage to the connector

was considered a failure.

D. DESCRIPTION OF TESTS

1. Characteristics Tests. Except as indicated below,the tests described in the following paragraphs were performed beforeand after subjecting the test specimen to each of the environmental

.. tests listed in table 1.

a. Visual Inspection. The test specimen was sub-jected to visual examination in accordance with the requirements ofparagraph B. 1.

i1 -

b. Contact resistance applicable to thermal shock,salt spray, gas seal, and humidity tests was determined by measuring

: the voltage drop across each connector contact at a test current of0.1 ampere.

c. Contact Chatter. (Applicable to vibration andphysical shock tests only.) Connector contacts were wired in series,.and the connector contact chatter was monitored with 0.1 ampereflowing through the test circuit* " •

t

10

IN-R-QUAL-66-28

2. . Mechanical Tests. Except'for the gas seal test, thefollowing tests were performed after each environmental test listedin table 1. i

- ' ' . Ia. ' Connector Retention. An axial force was applied '

to the connector. The force was applied to the connector in the 'direction opposite to the force originally applied to clip the connector ito the terminal post. The rate of pull was approximately 0. 5 inch jper second.

b. Connector Stripping. A force was applied to the ;

!• Connector perpendicular to the terminal post. The force was jincreased until the connector stripped from the terminal post. The !stripping force was recorded* . i

3. Test Methods.

J • • a. Sinusoidal Vibration. The test specimen was. subjected to sinusoidal'vibration in each of three mutually perpendi-

1 cular axes i The axes were defined as follows iI • :. . - . - i i . • • • - • -

• ., X-Axis - Passes through arid parallel to the connectorslongest axis. . — - — . - _ - • '

'• • > Y-Axis - Passes through and parallel to the connectors... ---- -• shortest axis.

Z-Axis - Passes through and perpendicular to the X• . v •' and Y axis.

* " * "

• • ' • _ „ The vibration cycle consisted of simple harmonic motion overa range from 10 to 2000.to 10 cps in approximately 20 minutes. Thiscycle was performed three times in each major axis. The rate of

I- . change of frequency was varied logarithmically. The vibration levelswere as follows:

10 to 80 cps at . 06 inch double amplitude (da) displacement80 to 2000 cps at 20 g

• • . fcb. Random Vibration. The connectors were subjected

to 2 minutes of random vibration on each of the test specimen's three: mutually perpendicular axes (paragraph D. 3. a). An average 21. 1

root mean square (rme) g force was maintained during testing in eachaxis. The random noise broadband power density pattern, was as follows:

0 OQ^crZFrom 16 cps to 64 cps @ U 'U*JK-

cps

• • ' • 11-

IN-R-QUAL-66-28

From 64 cps to 500 cps @ 0.36

to

From 500 cps t 2000 cps @

0.029cps

cps

0.36cps

linearly decreasing

Pattern equalization was ± 3 db.

c. Physical Shock. The connectors were subjectedto impact shock tests in accordance with Standard MIL-STD-202C,method. 202B.

Initially, the connectors were subjected to three shocks, eachont-half sine wave of 30 g peak for 11 milliseconds, parallel to eachconnector axis.

After the initial shock tests, the test specimen was subjectedto three shocks, each one-half sine wave of 125 g peak for 6 milli-seconds, parallel to each connector axis.

During each shock test, the connectors were wired in series, anda current of 0. 1 ampere flowed through the test circuit. The connectorcontact chatter was monitored.

d. Thermal Shock. The connectors" were subjectedto thermal shock conditions in accordance with Standard MIL/-STD-202C,method 102A, condition A, except for low temperature extrem.e wasminus 20° C instead of minus 55° C. Cbndition A is defined as follows: .

Stej Temperature °C

..+3

Time (Minutes)

. : so

- 3 .

4

10 to 15

! ' ', • * ' '

r- ,30

10 to 15i '»'*

;in

IN-R-QUAL-66-28 |

After the above test, the specimen was subjected to five continu-ous cycles of temperature change in accordance with Standard MIL-STD-202C, method 102A, condition C. Condition C is defined. as follows:

Step Temperature °C Time (Minutes), • •

1 . ' -65*° , . v ' - 30-5 -

- 2 25g 10 to \5'., '

• '3 : 125+0 v 30

4 25+*° 10 to 15-o

The contact resistance of the connectors was measored beforeand after each thermal shock test in accordance with the 'requirementsof paragraph D. l.b. (See figure 3. ) Results of the thermal shocktest are outlined in appendix A. j

e. Salt Spray. The connectors were subjected toa 20 percent salt spray test for 96 hours in accordance with StandardMIL-STD-202C, method 101 B, condition A. The test was conductedas follows:

"The specimen, was supported from the bottom of the chamberand positioned to ensure a uniform exposure. • Temperature in theexposure zone was maintained at 95 t?j0F (35+j' | °C). A 20 percentatomized salt solution was introduced into the chamber with atomi-zation of approximately 3 quarts of solution- per. 10 "cubic feet of boxvolume. Exposure to these conditions was 96 hours. '

1

The contact resistance of the connectors was measured before sand after submission to the testconditions in accordance with proce-dure paragraph D. l.b. See figure 3 and appendix B for test schematicand test results, respectively.

i

f. Gas Seal Test. The sample was suspended in adesiccator (corrosion chamber). The desiccator and sanpple assembly

•

• • 1 3

IN-R-QUAL-66-28

PowerSupply

TektronixType 531Serial No. 5849

To Oscilloscope

Termi-point

Weston A. C. & D. C.Milliampere MeterModel 370No, 12267

figure 2. ContacVehatter

H&wlett-Packard ,Model 42SAMicrW Volt- 'Ohmm&ter

V J MicrovoltMeter

Weston'A. C. & E\C,'Milliampere MeteModel 370No,12267

DC J-powerSupply

Figure 31 Contact Resistance

IN-R-QUAL-66-28

were purged thoroughly with hydrogen sulfide.f^S) bottled gas forfive minutes. The flow of hydrogen sulfide was then regulated to 15

..bubbles per minute for the remainder of 24 hours. See figure 4.Figure 5 shows the Termi-point connectors after the test. Seeappendix C for the results of the gas seal test.

g. Humidity. The connectors were subjected to tendays of humidity conditions in accordance with Standard MIL-STD-202C,method 106B, figure 106-1 conditions. A typical cycle was as follows:

The sample was initially conditioned in an ovan at 50°C with un-controlled humidity for a 24-hour period, then lowered to room tempera-ture (25°C) and maintained for 2 hours. Initial measurements weremade on the sample at the end of this conditioning period. The sampletemperature was then increased from room temperature to 65°C with90 to 98 percent relative humidity over a period of 2 1/2 hours andmaintained at that point for a period of 3 hours. From this point thesample was cycled to room temperature and 80 to 98 percent relativehumidity, then to 65°C, 90 to 98 percent relative humidity and main-tained for 3 hours, this portion of the test requiring 8 hours. Thesample was then lowered to room temperature and 80 to 98 percentrelative humidity over a period of 2 1/2 hours and maintained at 25°Cfor 1 1 / 2 hours, after which final measurements were made. Thesample was then taken to minus 10°C, held there for 3 hours, andreturned to room ambient temperature and uncontrolled humidity. <The specimen was then vibrated at room temperature for 15 minutesusing simple harmonic motion having an amplitude of 0. 03 inch, the fre-quency being varied uniformly between the approximate limits of 10and 55 cps. The, specimen was then returned to 25°C and 90 to 98percent relative humidity and maintained at these controlled conditionsbetween cycles. Ten such cycles were performed. Figure 6 shows aiypical test specimen, appendix D provides the test results.

VI. STATISTICAL. ANALYSIS

The statistical analysis applies only to the following tests:

li. Thermal Shock. . ' v

' '• ' •

2. Salt Spray.

IN-R-QUAL-66-28

' . - ' I ' - : ;'"•/' : < • • ; . - V ' ' - : - -

• ( ' - 3 4 J \ " B < '

!,•* -• -'J ' - J l " ' - '' ;' ^-' >' ' • VI '"

' - '

.;;•• "-.,;.- W,

!*"•'" ;!: •''•' ; • / ' • '"• \:: '• * . i . * . . . ' • • • * ' - ' • *

!' i'. ' ' '•'-;''./•'•,.'•• •' '••" '•'"' l' ..' . -• ' - , ' . '

.§•*J<uto4->CO

(4Vwco

•Moi

|VH

4)

9bo

IN-R-QUAL-66-28

GOLD No. 20 STRANDED GOLD No. 22 SOLID

It1

TIN No. 22 STRANDED TIN No. 22 SOLID

Figure 5. Termi-Point Connections After the Gas Leak Test. (ArrowsIndicate the Location of the Termi-points-During the Test)

17

IN-R-QUAL-66-Z8

c

• o0)a

Ma)H

*rtu'a,EH"

d00

18

IN-R-QUAL-66-28

3. Humidity.

4. Gas Seal.

In these tests three parameters were measured:

1. Contact Resistance.

2. Retention Force.

3. Clip Stripping Force.

The first parameter, contact resistance; was measured beforeand after each of the tests. Retention force and clip stripping forcewere measured after the tests.

As indicated in Section II, "Design of Experiment", the overallsample was designed so it was possible to .o'btain comparative datafrom subsamples within the overall sample. The data sheets showthe breakdown of the samples. For each sample thejpean of thetest characteristic_was computed and entered under X. The signifi-cance between the'X's was then computed.

The hypothesis: used was:

Null hypothesis) Xj = X£ where Xj and X£ are different permuta-tions of the same characteristic. For example, Xi could be theaverage contact resistance of a sample before a certain test and X£the average contact resistance after the test. By accepting the nullhypothesis we are saying there is no significant difference betweenthe two averages. The level of significance used was 5 percent.

In addition to pretest and posttest comparisons, comparisonswere made between other parameters such as wire size, platingmaterial, and wire type -- both pretest and posttest measurementsbeing compared. The data sheets indicate the comparisons andresults of significance tests.

19

IN-R-QUAL-66-28

VII. TEST RESULTS AND DATA ANALYSIS

The test results and subsequent data analysis are tabulated inappendices A through D. In most cases, the "Z" statistic was usedto determine if a significant difference between conditions existed.

The data are arranged such t'hat Z values in the right handcolumn represent the calculated Z for a comparison between testconditions, i.e., pretest and posftest values. Immediately beneaththe items being compared is another Z, the value of which is locatedby reading horizontally across the table. This is a Z value for a com-parison between test items, i. e. , gold clips versus tinned clips, etc.The calculated Z values listed in the data tables are compared witha Z value for a one-tailed test of significance obtained from a standardtable. The Z value used in this report is_ 1.645, which is the criticalvalue of-Z for a one-tailed test at the 95 percent confidence level. Ifthe calculated value exceeds this value (Z = 1.645), then there is saidto be a significant difference between the items being compared.

The experiment plan was set up to allow a determination of whichclip surface treatment, gold-plated or tinned, was superior. Obser-vation of appendices A through D reveals that there is a significantdifference between the two treatments at a five percent level. Inalmost every case there is a significant difference between gold-platedand tinned clips. In general, the tinned clips exhibited a higher contactresistance, which would normally be undesirable, but they also exhib-ited significantly higher characteristic clip retention forces as shownin figures 7 through 12. This is desirable from a mechanical stabilitystandpoint. This attribute, however, is offset somewhat by a largervariance, which is objectionable* Environmental "conditioning did notappear to affect one type of surface treatment more than the other,although all terminations exhibited reduced clip retention forces afterthermal shock conditioning. This is probably due to annealing of thematerials and a consequent stress relaxation resulting in lowercompression of the wire by the clip. Note that after exposure to thermalshock, 12 of a sample of 33 gold clip terminations did not meet minimumrequirements as established by the manufacturer. In addition, 3 of asample of 33 tinned clips did not meet minimum requirements.

A comparison of the solid and stranded wires used in these testsshowed that both humidity and salt spray conditioning caused significant

20

IN-R-QUAL-66-28

ug3CT0>

141312I I109876543

I

0

MINIMUMACCEPTABLEFORCE=2.25LB.

10 II 12 13 14

Retention Force - PoundsFigure 7. Distribution of Retention Force of Gold Clips

AfterThermal Shock Conditioning

U

0)3iro>

MINIMUMACCEPTABLEFORCE-3LB.

Retention Force - PoundsFigure 8. Distribution of Retention Force of Tinned Clips

After Thermal Shock Conditioning

21

IN-R-QUAL-66-28

uti<Uacr<ut*

14..13-12.If •

ID-S'8-7-6-5 -4-3 -

MINIMUMACCEPTABLEFORCE-2.25 LB.

I . I10 II 12 13 14

Retention Force - PoundsFigure 9. Distribution of Retention Force of Gold Clips

After Humidity Conditioning

o<L>3cr<u

I4r13.12-I I109676543

MINIMUMACCEPTABLEFORCE°3La


After Humidity Conditioning

22

IN-R-QtfAL-66-28

>sOc3

4)Ki

ClJ>*H

1413

12

II

10

9

8

7

5

4

3

2

1o

•

MINIMUM .ACCEPTABLEFORCE-2.25 LB.

1 '

1 [331 r~*~X •111

1

1

1

1

kn R-

vA/voo ,,^x ^^ )^ *

x>xLA/OOOC

, • , r\l , (VvYVwri rxn ,._..,.. , .,._ » — • ,

Figure 11.

10 II 12 13 14

Retention Force - PoundsDistribution of Retention Force of Gold Clips

After Salt Spray Conditioning

udo>3crv

141312I I1098765432I0

MINIMUM 'ACCEPTABLE •FORCE-3LB.


After Salt Spray Conditioning

23

IN-R-QUAL-66-28

increases in the contact resistance of connections made with solidwire. The stranded wire, in general, appeared to be somewhat moredesirable cue to less coniact resistance change.

As cited by the manufacturer of Termi-points, stranded wireis usually more vibration resistant than solid wire. However, nofailures of either solid or stranded wire were detected duringvibration testing.

- -Although the larger wire sizes of both stranded and solid wirepossessed similar slip retention forces, for fhe smallest gauge (AWG26) tested, the stranded wire exhibited a. conersteritly higher strippingforce. From the appendices and data .charts it can be seen that, ing'eneral, the clip retention force of all three wire sizes tested isapproximately the same. However, there is a'definite decrease in

.clip stripping force as the wire size decreases, i. e, , from 22 AWGto 26 AWG. This is to be expected since lower compressive forcesare-exerted with smaller diameter wires.

Environmental conditioning results were not consistent, due inpart to the use of small sample sizes. The effects of the conditioning,discussed in previous paragraph, can be summed up as follows:

In general, the contact resistance increased as a result ofconditioning. The effect of conditioning was statistically significantat the 95 percent level in several cases, the most notable of which issalt spray. Thermal shock reduced the retention force of the clipsconsiderably. This is characteristic of terminations which dependupon compression and tension forces for their stability. No cata-strophic failures were noted during vibration nor were any inter-mittent failure's.detected by the.monitoring instrumentation.

VIII. CONCLUSIONS AND RECOMMENDATIONS

Evaluation of the test results indicates that the Termi-pointconnections are capable of withstanding the adverse 'environmentsto which they were subjected:—Th-e-s-e-environments however did notsimulate all ground support equipment environments. Therefore, eachparticular proposed application of Termi-point should-be reviewedcarefully with regard to use environment.

24

•IN-R-QUAL-66-28

In general, each individual application should be studied sepa-rately.

"the low value of stripping strength, when compared with com-petitive interconnection techniques, is certainly a major disadvantageof the-Termi-point. However, the maintainability aspects of theTermi-point offers an advantage unattainable in competing devices and •should be considered in preprototype and prototype models whereextensive engineering changes are contemplated. In'dense connectionareas the maintainability attribute is also lost due to the inaccessibilityof the individual terminals.

• Although Termi-points were designed to serve as connections fora whole spectrum of wire types and uses, this is virtually impossible.Based on the tests performed it is recommended that:

(a)' Tinned clips'be used as opposed to gold-plated clips

(b) No. 24 gauge stranded wire be used.

The results of this report should not be construed as an approvalof the use of Termi-point connections as a reliable interconnectionmethod.

25

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APPENDIX E

REFERENCES

; '1. Termi-Point Handbook, AMP 5070, AMP,Incorporated,Harrisburg, Pennsylvania.

*

2. Freund & Williams, Modern Business Statistics, Prentice -; " Hall, Inc., Englewood Cliffs, New Jersey, 1958.I ' - 'i - 3. Arthur E. Mace, Sample Size Determination, Keinhold; - Publishing Corporation, New York, 1964.I ""-; 4. MIL.-STD-202C, Test Methods for Electronic and Electrical; ' Component Parts.i

i 5. AMP GP-1918, Customer Manual for Termi-Point Air Tools,i " " AMP,Incorporated,-Harrisburg, Pennsylvania.

i •i . 6. AMPGP-1920, Quality Control Procedures for Termi-Point

Clip Application, AMP.Incorporated, Harrisburg, Pennsylanvia.

E-l

June 1, 1966 IN-R-QUAL-66-28

APPROVAL

AN EVALUATION OF TERMI-POINTCONNECTORS

The information in this report has been reviewed for securityclassification. Review of any information concerning Department ofDefense or Atomic Energy Commission programs has been made bythe MSFC Security Classification Officer. This report, in itsentirety, has been determined to be unclassified.

This document has also been reviewed and approved fortechnical accuracy.

'M.^Jerkebile, ChiefAdvanced Methods and Research Section

E. PennyT Chieflectrical Test and Analysis Branch

R. Henritze, ChiefAnalytical Operations Division

Directorand Reliability Assurance Laboratory

. IN-R-QUAL-66-28

DISTRIBUTION

R-QUAJL-QO/NEO, Mr. B. MontyR-QUAL-J, Mr. KlaussR-QUAL-OCP, Mr. Krone (3)R-QUAL-OT, Mr. bendyR-QUAL-RE, Mr. BrownR-QUAJL-Q, Mr. Br.ien (2)R-QUAJL-A, Mr. HenritzeR-QUAL-AE, Mr. SmithR-QUAL-AA, All Section ChiefsR-QUAL-J/NAA, Mr. H. GoetzR-QUAJL-AAR, Mr. Berkebile (5)

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