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Components
Buswire fracture due to nick in lead
This image shows a fractured bus wire caused a nick
in the lead. Historically, this criterion is one of
the areas NASA's workmanship standards have departed
from other standards - most of which allow nicks, cuts,
or scrapes as long as they don't exceed 10% of the diameter
of the conductor (a quick measurement will show this
nick to be somewhere between 5 and 10 percent of the
lead diameter). In NASA's vibration and thermal cyclic
environment, any lead damage other than smooth indentations,
usually caused by round nose pliers during lead forming,
can easily propagate through the entire lead.
Reference :
NASA-STD-8739.3, paragraph
8.1-6d:
Whether formed manually or by machine, part leads shall
not be mounted if they show evidence of nicks or deformations.
Smooth impression marks (base metal not exposed) resulting
from tool holding forces shall not be cause for rejection.
Secondary references:
NASA-STD-8739.2,
paragraph 8.7-4b:
There shall be no evidence of cracks, nicks, or chip-outs
in the part or substrate area.
NASA-STD-8739.4, paragraph
10.1-3:
After removal of the conductor insulation, the conductor
shall not be nicked, cut, or scraped to the point that
base metal is exposed. Conductors that were reduced
in cross-sectional area shall not be used.
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