W. L. Gore & Associates, Inc. (Gore) has introduced new GORE-FLIGHT™ Microwave Assemblies, 6 Series – lightweight cable solutions that deliver the lowest insertion loss before and after installation, ensuring reliable performance for the life of the system. The robust construction of these assemblies reduces total costs by withstanding the challenges of installation, reducing costly production delays, field service frequency, and the need for purchasing replacement assemblies. These lightweight assemblies improve fuel efficiency and increase payload.
Physical damage to the cable assembly during installation can result in impedance changes. Compared to alternative airframe assemblies, GORE-FLIGHT™ Microwave Assemblies, 6 Series maintain a consistent impedance of 50 ± 1 ohms, providing excellent VSWR characteristics and eliminating insertion loss stack-up issues when assemblies are cascaded or routed through airframe bulkheads.
The 6 Series has been qualified to the most stringent specifications for airframe assemblies, with proven compliance with MIL-T-81490 requirements. In addition, Gore has designed a Cable Installation Simulator to evaluate the stress of installation on microwave airframe assemblies. The simulator enables Gore to evaluate the electrical performance of various cable assemblies after installation. “With GORE-FLIGHT™ Microwave Assemblies, 6 Series, a fit-and-forget philosophy is now a reality — providing the most cost-effective solution that ensures mission-critical system performance for military and civil applications,” said Jim Foreman, product manager at Gore.
Gore’s Cable Installation Simulator uses a series of mandrels, routing guides and an abrasion bar to replicate the conditions a cable assembly experiences while being routed during installation in an aircraft. Use of the Installation Simulator gives aircraft manufacturers and installers evidence that their assemblies will provide the highest possible level of electrical performance after installation. And they can be assured that the assemblies will continue to perform reliably throughout the service life of the aircraft.
Typical applications for GORE-FLIGHT™ Microwave Assemblies, 6 Series include: airborne electronic surveillance/counter measures; radar warning (electronic defense) systems; missile approach warning systems; radar interconnects; electronic/signal intelligence; and GORE-FLIGHT™ MICROWAVE ASSEMBLIES navigation/communication systems. Gore controls the entire GORE-FLIGHT™ Microwave Assemblies, 6 Series manufacturing process from purchasing raw materials, to creating and applying the proprietary dielectric material, through testing and shipping the final cable assembly. This unsurpassed vertical integration allows Gore the complete control necessary to consistently achieve tight specifications consistently. This process includes testing 100 percent of the assemblies for vapor leakage, dielectric withstanding voltage, VSWR, insertion loss, impedance, and velocity of propagation — ensuring that every assembly will
deliver the highest-quality performance required for today’s civil and military aircraft.