NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
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SPECIFICATION 80, ISSUE 1 Page 11
4.4.1 Sampling for Process Control Inspection
4.4.1.1 Conductor Material
Process control sample selection and inspection of uninsulated conductor shall be performed at
receiving inspection. The conductor lot size, for purposes of sampling, shall consist of the
num-ber of reels of a given type and size of conductor received at one time from one supplier
against a single purchase order. For lot sizes of 3 reels or less, one 15-foot (4.6-m) length of
conductor shall be selected from each reel. For lot sizes of not less than 4 and not more than 25
reels, a minimum of three 15-foot (4.6-m) lengths of conductor shall be selected at random, in
such a manner as to be representative of the material. For lot sizes in excess of 25 reels, the
inspection level shall be Level 1 and the AQL shall be 4.0 percent in accordance with MIL-
STD-105.
4.4.1.2 Insulation Flaws (Impulse Dielectric Test or Spark Test)
One hundred percent of the wire, after the application of the primary insulation, shall be tested
in accordance with the applicable specification sheet and MIL-W-22759.
4.4.2 Rejection and Retest in Process Control Inspection
When a sample selected from an inspection lot fails to meet the specified test (Table 2), except
the insulation flaws test (see 4.4.1.2), no items still on hand or later produced from that lot
shall be accepted until the extent and cause of the failure has been determined.
4.4.2.1 Effect of Process Control Failure on Quality Conformance Testing
Quality conformance testing may be continued during the investigation of a failure of a process
control sample, but final acceptance of the material shall not be made until it is determined that
the lot meets all the process control and quality conformance requirements of the specification.
4.5 PERIODIC QUALIFICATION RE-EVALUATION
Qualification re-evaluation shall be performed, at the manufacturer's discretion, whenever any
significant change is made to the materials or manufacturing process.
4.6 TEST METHODS
4.6.1 Bend Test (Post-Environmental)
At a temperature maintained between 20 and 25°C, one end of a finished wire specimen shall
be secured to the mandrel and the other end to the weight specified in the applicable
specification sheet. For finished cable specimens, the mandrel shall be as specified in Table 3
and sufficient weight shall be used to maintain contact with the mandrel. The mandrel shall be
rotated until the full length of the specimen is wrapped around the mandrel and is under the
specified tension with adjoining turns in contact. The mandrel shall then be rotated in the
reverse direction until the full length of the specimen which was outside during the first
wrapping is now next to the mandrel. This procedure shall be repeated until two bends in each
direction have been formed in the same section of the specimen. The specimen shall then be
examined for cracking of the insulation or jacket, as applicable.
