Gore-Flight Microwave Assemblies, 6 Series designed to deliver lowest insertion loss before and after install

FARNBOROUGH, England, 15 July 2014. W. L. Gore & Associates Inc. has introduced new GORE-FLIGHT Microwave Assemblies, 6 Series lightweight cable solutions, designed to deliver low insertion loss before and after installation and help to ensure 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, officials say. The lightweight assemblies also help to 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," says Jim Foreman, product manager at Gore.

Gore's Cable Installation Simulator uses a series of mandrels, mounting 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. 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 navigation/communication systems.

Gore controls the entire GORE-FLIGHT Microwave Assembly, Series 6 manufacturing process from purchasing raw materials, to creating and applying the proprietary dielectric material, through testing and shipping the final cable assembly. This vertical integration allows Gore the complete control necessary to achieve tight specifications consistently, officials say. 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.