SIST EN 2591-220:2006

Overview

EN 2591-220:2005 - "Aerospace series - Elements of electrical and optical connection - Test methods - Part 220: Contact/conductor joint ageing by current and temperature cycling" is a CEN/AECMA-STAN test standard that defines a reproducible method to demonstrate the long‑term electrical stability of conductor-to-contact joints used in aerospace connectors. The method uses a combination of conductor current and controlled ambient heating to reach the maximum rated operating temperature and evaluates joint ageing by monitoring voltage drop and contact resistance over repeated thermal/current cycles. This part is intended to be used together with EN 2591-100.

Key Topics and Requirements

• Scope: Verifies electrical stability of joints referenced in the EN 3155 product standards (electrical contacts).
• Specimen preparation:
  • Wired male contact mated to corresponding female contact and barrel/bucket.
  • Cable per EN 3155-001; temperature rating equal or higher than contact rating.
  • Test points attached to contact body and conductor (≤1 mm from barrel end) for voltage-drop measurement.
• Test population: 10 specimens per barrel/bucket size - 50% with maximum gauge cable, 50% minimum gauge.
• Load & temperature cycling:
  • Specimens linked in series; thermocouple attached to monitor contact temperature.
  • Enclosure ambient heated plus conductor current applied to reach target contact temperature.
  • Cycles comprise a “heat-on” period (±5 °C tolerance for ≤1 min) and a “heat-off” cool to (25 ±5) °C (fan-assisted cooling allowed).
  • Cycle counts: 1 000 cycles for parts rated below 150 °C; 1 500 cycles for parts rated at 150 °C and above.
• Measurements & acceptance:
  • Voltage drop measured initially and after every 100 cycles at (25 ±5) °C.
  • During final 500 cycles, voltage-drop variation per joint must be ≤20% from the first value of that period.
  • Final voltage drop must not exceed 150% of the initial value.

Applications and Users

• Intended users:
  • Aerospace manufacturers, connector and contact designers, test laboratories, quality assurance and procurement teams, and suppliers of aerospace wiring and crimp systems.
• Practical uses:
  • Qualification of contact/crimp processes and materials for long-term electrical reliability.
  • Supplier acceptance testing, product development, failure analysis, and compliance evidence for aerospace electrical interconnects.

Related Standards

• EN 2591-100 (General test methods)
• EN 2591-202 (Contact resistance at rated current)
• EN 2591-417 (Tensile strength - crimped connections)
• EN 3155 (Electrical contacts - product standards)

Keywords: EN 2591-220:2005, contact/conductor joint ageing, thermal cycling test, aerospace connectors, contact resistance, conductor current, EN 2591 series, EN 3155.