Aviation Electrical Wire

Zhejiang IRONFLON Wire & Cable Co., Ltd. is one of the most professional manufacturers and suppliers of aviation electrical wire in China, also supports customized service. Please feel free to buy high quality aviation electrical wire for sale here from our factory. Also, free sample is available.

The product offers two models: AF-250 (basic version) and AFP-250 (shielded version). AFP-250 adds a tin plated round copper wire braided shielding layer, which has better electromagnetic interference resistance and can be flexibly selected according to scene requirements.

Our company provides customized services such as conductor materials, conductor structures, insulation materials (PTFE \ XLPE \ PFA \ FEP \ ETFE \ silicone), conductor specifications, shielding methods, outer diameters, wire colors, and more.

For product details or customized services, please feel free to consult our professional customer service team at any time( luna@ironflon.com )We will provide you with detailed product solutions and personalized service plans. Contact now to get exclusive discounts!

Lightweight design : Compared to traditional silicone rubber cables, AF250 significantly reduces weight, which is crucial for aircraft weight reduction and fuel efficiency improvement, helping to lower operating costs and optimize flight performance.

Excellent heat resistance : The wire can work stably in high temperature environments, effectively resist thermal stress, ensure safe operation in high-temperature areas such as engine compartments, and reduce the risk of faults caused by overheating.

Excellent flexibility and fatigue resistance : The AF250 wire is soft and easy to bend, suitable for complex wiring installation, and is not easily broken after long-term use, adapting to the harsh conditions of aircraft vibration and repeated movement.

Corrosion resistance and durability : It has strong resistance to chemical corrosion, can resist oil, moisture, and salt spray erosion, extend the life of the wire, reduce maintenance requirements, and performs exceptionally well in harsh weather environments.

Efficient electrical performance : high conductivity, low resistance, ensuring stable and reliable power transmission, reducing energy loss, and improving the overall response speed and reliability of aviation electronic systems.

Safe and reliable : Compliant with strict aviation standards, the insulation material is flame-retardant and resistant to voltage shocks, significantly reducing the risk of short circuits or fires and ensuring flight safety.

With its comprehensive performance advantages, AF250 aviation electrical wire have been widely used in high-end fields such as aerospace, weapons and ships, and industrial manufacturing, becoming the "lifeline" of key equipment.

1. Aerospace field
In aircraft systems, products are mainly used for high-temperature and high vibration parts such as engine control systems, avionics systems, fuel control systems, etc., such as signal transmission of sensors and controllers in the engine compartment, withstanding high-temperature radiation and mechanical vibration during engine operation, ensuring accurate feedback of flight parameters. In spacecraft, it can adapt to extreme temperature differences and radiation environments in space, and is used for power and signal transmission in environmental control systems and communication systems, providing stable support for spacecraft operation in orbit.

Wiring of aircraft engine compartment auxiliary system : The engine compartment is a typical high-temperature vibration area of the aircraft, which is exposed to a high temperature environment of 150 ℃~200 ℃ for a long time, accompanied by continuous mechanical vibration. The engine fuel control module and temperature monitoring sensor wiring of a certain civil aircraft (such as the Boeing 737NG series regional aircraft) uses AF250 wires. Its PTFE wire insulation layer can withstand fuel vapor corrosion, and tin plated conductors ensure low contact resistance in vibration environments, achieving stable transmission of fuel supply signals and temperature data. The application has passed the 5000V spark breakdown test and 2500V immersion voltage test in the aviation field, with a cumulative flight time of over 80000 hours and no insulation failure issues.

2. Weapons and ships field
In weapon equipment, it is applied to precision devices such as artillery control systems and missile guidance systems, which can withstand the impact, vibration, and chemical corrosion in complex battlefield environments, ensuring precise strikes of weapon systems. In the field of ships, it is used in ship power systems, navigation systems, and other parts to adapt to high humidity and high salt spray environments in the ocean, avoiding system failures caused by cable corrosion and aging.

Wiring of ship power cabin : The ship power cabin is exposed to high salt spray, high temperature (diesel engine operating temperature is about 220 ℃) and vibration environment for a long time, which requires strict requirements for the corrosion resistance and vibration resistance of the wires. In the diesel generator monitoring system of a certain frigate, AF250 wires are used as the connection lines between temperature and oil pressure sensors and controllers. The outer skin modified with UV resistant additives can resist the humid heat and salt spray erosion inside the cabin, and the outdoor service life is extended to 8 years, solving the frequent maintenance problem of traditional wires that need to be replaced every 3-5 years.

3. High end industrial sector
In the steel smelting industry, it is used to connect temperature and pressure sensors around high-temperature furnaces, which can still stably transmit signals near the furnace body at temperatures above 300 ℃; In chemical production, the electrical connection of high-temperature reaction equipment should be adapted to withstand the corrosion of strong acid and alkali media; In the field of new energy vehicles, it is used for motor drive systems and battery management systems, which can withstand high temperatures during motor operation and reduce the failure rate by 62% compared to traditional solutions.

Technological advantages leading the industry

• Independent R&D capability : The company has a professional R&D team and invests no less than 5% of its annual revenue in R&D expenses. It has obtained more than 20 national patent technologies and maintains technological leadership in fields such as special cables and flame-retardant cables.
• Advanced testing system : equipped with a complete set of German imported testing equipment, such as partial discharge testing system, high-voltage testing equipment, material composition analyzer, aging test box, to ensure that each batch of products passes strict testing 100%.
• Breakthrough in Environmental Protection Technology : Leading the way in passing RoHS certification, we have developed a series of low smoke, halogen-free and flame-retardant products, with a smoke density lower than the national standard by more than 30% during combustion.

 

The production advantage of striving for excellence

• Raw material : Copper material with a purity of 99.99%.
• Production process : Automated production line with an automation rate of 85%.
• Quality control : Implement ISO9001 quality management system.
• The product line includes nine independent complete production lines, including copper wire drawing, winding and braiding of conductors, outer conductor coils, steel wire ropes and tapes, insulation and sheath extrusion, insulation coking and sintering, film packaging and sintering.
• Capacity scale : With an annual production capacity of over 200000 kilometers, it can meet the demand for small batch customization.

quality assurance
The company has successively passed ISO9001, IATF16949, UL, CUL, VDE, national level three safety production management system certification and product quality certification, and has obtained dozens of invention patents, utility model and software copyright patents. At the same time, it has obtained titles and certificates such as " National High tech Enterprise ",  " Yueqing Patent Demonstration Enterprise ",  " Yueqing Municipal Enterprise Technology Center ",  " Provincial Small and Medium sized Science and Technology Enterprise ",  " Ethylene Tetrafluoroethylene Polymer Group Standard for Wire, Cable and Optical Cable ",  " Group Standard for High Voltage Battery Cables for New Energy Vehicles ",  " Specialized and Innovative Enterprise ",  " Provincial New Product ",  etc. At the same time, it is promoting the introduction of projects such as " Tiefulong Information Management System ".

Comprehensive service advantage

• Pre sales service : Professional one-on-one consultation, providing free cable selection guidance, recommending the optimal product solution based on customer usage environment, load requirements and other parameters.
• Customized services : Provide specialized solutions for special application scenarios such as high temperature, high humidity, and corrosive environments, assist customers in optimizing cable layout, reducing overall usage costs, provide material substitution solutions, and help customers cope with fluctuations in raw material prices.
• After sales guarantee system :

1. 1. Quick response, providing initial solutions within 24 hours to ensure that issues of different levels of urgency can be promptly addressed.
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3. 2. The after-sales service team is composed of professional customer service personnel and engineers holding electrician certificates and cable testing qualifications. They not only have profound knowledge of cables, but also have rich practical experience.
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5. 3. A standardized and user-friendly after-sales service system ensures that every aspect is constantly improving. Customers can consult through phone, email, and other means.
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7. We have a professional, efficient, and thoughtful after-sales service system, which has won widespread praise from customers.

 

Certificate Informat

CERTIFICATIONS IN INTERNATIONAL AND DOMESTIC

UL AND CUL Certification ( Reference E252458)

VDE certification

QALITY CERTIFICATION:ISO9001:2005 AND IATF16949

All product can meet ROSH ,REACH

 

We've got a lot of certificates.

Awarded " WSF World Standard Certificate ".
Awarded " Growth oriented Technology Enterprise of YueQing ".
Awarded " Science and Technology Innovation Enterprise Certificate of YueQing ".
Awarded " Certificate of sci-tech enterprises in Zhejiang Province ".
Awarded " Integrity Business Enterprise Certificate ".
And so on.

In terms of product packaging, we usually use biodegradable plastic film packaging. It can protect the wires from damage and chaos. Degradable plastic materials will reduce environmental pollution.

We will first wrap the product with plastic film. Then pack it in cardboard boxes according to the customer's requirements. Prevent product damage.

After the wires are packaged, we will place them on a tray for easy transportation. Afterwards, contact the corresponding transportation personnel and arrange a suitable time to transport the pallets to the vehicle.

After the pallet is transported to the vehicle, it will be transported uniformly to the corresponding station. We will choose different transportation methods according to the customer's needs. Such as sea freight, air freight, express delivery, etc.

AF250aviation electrical wire, as the core wiring component of the aviation industry, adopts tin plated soft round copper wire core and PTFE wire insulation structure. It is suitable for aircraft wiring and instrument lines with AC rated voltage of 600V and below. It can work stably for a long time in an environment of -60 ℃~250 ℃, and has excellent insulation and corrosion resistance. To ensure its performance, the following usage guidelines are formulated.

1. Selection and pre-processing specifications
Selection needs to match scenario parameters: Select a single core specification with a nominal cross-sectional area of 0.6-6.0mm ² based on the load current, and choose the AFP-250 model with shielding for anti-interference scenarios. Before pre-processing, it is necessary to verify the integrity of the identification, confirm that the model, rated voltage, factory name, and other information are clear, and that there are no insulation layer bubbles, cracks, or loose wire cores on the appearance. Before using the new line, it is necessary to clean the surface with a dry cloth to avoid oil stains and dust affecting the insulation performance.

2. Core requirements for installation operation
Laying should follow the principle of mechanical protection: priority should be given to using cable trays or conduit laying, avoiding high-temperature radiation areas of the engine, fuel pipelines, and high-frequency vibration parts. The distance between strong and weak electrical lines should not be less than 15cm. When bending, the radius should not be less than 8-10 times the outer diameter of the wire to avoid repeated bending and damage to the insulation layer. Fixed with aviation specific clamps, with a spacing of 30cm between straight sections and increased to 15cm at turns to prevent shaking and wear.
The connection process determines reliability: special crimping pliers are required for conductor connections, and the crimping depth of tin plated core wires is controlled at 0.3-0.5mm to ensure a contact resistance of less than 5m Ω. The joint insulation treatment uses heat shrink tubing that can withstand temperatures above 250 ℃, and the temperature is uniformly raised to 300 ℃ during heating to ensure no bubbles after shrinkage. The shielding layer needs to be grounded at one end, with a grounding resistance not exceeding 1 Ω, to avoid electromagnetic interference.

3.  Testing and Maintenance Standards
After installation, double testing is required: use a multimeter to check the continuity in the on/off range to ensure there are no open circuits or virtual connections. Before use in extreme environments, temperature resistance sampling tests must be conducted in accordance with GJB 1916-2015 standards.
Daily maintenance needs to be carried out regularly: inspect the appearance every week, focusing on the aging and discoloration of the insulation layer and the oxidation of the wire core; Use a milliohmmeter to check the joint resistance every month. If it exceeds 10m Ω, it needs to be re crimped; Conduct comprehensive insulation resistance testing every quarter, and replace it promptly if it falls below the specified value. Storage should be placed in a dry and ventilated environment, avoiding contact with oil and chemicals, and stacking height should not exceed 1.5m.

4.  Safety Warning
Overloading is strictly prohibited and must be matched with the rated current carrying capacity of the wire; Do not apply electricity when the insulation layer is damaged; When repairing, the power must be disconnected first and a warning sign must be hung. This product is only suitable for designated scenarios in the aviation and electronics industries and cannot be used for civilian low-voltage wiring.

Q: Are you a manufacturer or trading company?
A: We are a professional manufacturer. We can control your order from the first begining to the last.

Q: Is there a standard for the aviation maintenance cycle of AF250? What are the key points for testing different parts?
A: According to CCAR-145 maintenance specifications: 1 AF250 avionics system: visual inspection every 100 hours of flight, insulation resistance testing every 500 hours; 2. Engine compartment AF250: Appearance inspection every 50 hours of flight, insulation and joint resistance testing every 300 hours; 3. AF250 near the fuel system: visual inspection every 20 hours of flight and fuel penetration test every 200 hours.

Q: Will AF250 produce toxic gases when it fails at high temperatures above 250 ℃? Does it affect the cabin?
A: When the temperature exceeds 300 ℃, PTFE insulation will decompose and produce trace amounts of hydrogen fluoride, but its content is much lower than the HB 5469-1991 smoke toxicity standard; When AF250 is installed, it needs to be equipped with a cabin ventilation system that can quickly discharge trace gases. Under normal operating conditions (≤ 250 ℃), no gas is produced, and its safety meets aviation requirements.

Q: what services can we provide?

A: Accepted Delivery Terms: FOB;

Accepted Payment Currency:USD,EUR,CNY;

Accepted Payment Type: T/T,L/C;

Language Spoken:English,Chinese.

Q: How Long Is Your Delivery Time?

A: The general delivery time is 10-15 days after order confirmation. In addition, if you need this product, we have it in stock and the delivery time is 1-2 days after order confirmation. You can consult our salesperson for specific details.

Q: Do You Have After-Sale Service?

A: Yes, Good after-sale service, handling the customer complaint and solve problem for customers.

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