Wire rope

Testing wire rope. Testing terminals. Testing rigging.

Terminals

Tools

Inspection

Care: log use, moisture, special stresses, inspections

How to inspect the condition of wire rope and rigged wire rope?

Inspection of tools used in rigging?

Notes from marine world. Open discussion on what applies and does not apply to HG flying wires:
Lift@HangGliderMagazine.com

• http://www.bosunsupplies.com/nicopressswage.cfm
• Check tools
• swage sleeves
• stainless steel, aluminum, copper, or zinc-covered copper
• hand tool
• hydraulic swager
• oval swages      (cold-rolled into an hour-glass shape)  The tube had to have met the ASTM-B75 standard.
• eye, eye splieces
• thimble
• Nicopress fitting
• crimp
• full rated strength
• stainless steel thimble
• standing rigging
• lifelines
• crimped wire fittings
• anhydrous lanolin
• just slightly beyond
• finishes
• cavity tool
• wire splicing sleeve
• economy Nicopress swaging tool
• swage gauge
• things that can go wrong; inspecting for those events.
  • Did the sleeve mash into the thimble?
  • Does the final set fit the Go/NoGo tool properly?
  • Is the sleeve the correct one for the wire?
  •  
• http://www.nicopress.com/
  • Oval sleeves for steel aircraft cable and wire rope
  • finished eye splice
  • Nicopress oval sleeve
  • HG flying wire:   Discuss plan copper versus zinc plated copper
  • Cable size
  • Number of grooves
  • hand tool, bench tool heads, hydraulic tool die
• http://www.aircraftspruce.com/catalog/appages/nicopress.php
  • Sleeve:  18 series are plain copper
  • Sleeve: 28 series are zinc plated copper
  • Nicopress stop sleeve
  • cable assemblies
  • AN100 cable thimbles. Distinguish between cadmium plated steel and the stainless steel thinble
  •  

Load Lab Test Results - Comparison of Swages with Sleeves and Tools from Different Manufacturers  SEE DISCLAIMER.
 

• Locoloc®       Loos & Co.
• Proving one's tools?
• Types of finishing?
• MS51844 specifications  for swaging sleeves
• Match sleeve source with swaging tool source. Avoid mixing.
• standards for nominal breaking strengths
• performance criteria
• MS83420 (Mil. Spec.) compliant GAC
• “properly assembled using the manufacturer’s recommended tools and splicing instructions.”
• What sleeves and what tools were used to swaged the sleeves on your flying cables? Do you have a check tool to verify the swage result?
• BS   breaking strength
• Mil. Spec. GAC  Galvanized Aircraft Cable
• 7x19 galvanized aircraft cable GAC is one of the most common, versatile and cost effective wire ropes but is not to be used for control cables or any other aircraft use. So, why is it then called "aircraft" cable, if it is not to be used for aircraft cable.    The ungalvanized wirerope is bright.
• "Wire rope is categorized by it's construction of strands. 6x36, 6x25, 7x19, 6x19, 19x7 and more. Each construction of wire rope can be galvanized or ungalvanized and comes in many different diameters. Refer to the product information chart for breaking strengths to help you determine the best wire rope for your project."
• "Rotation resistant 19x7 wire rope consists of an inner layer of strand laid in one direction covered by a layer of strand in the opposite direction which effectively counteracts torque and reducing rotation. A hanging or lifted object resists the tendency to spin."

  "Stainless steel wire rope is used for applications that require corrosion resistant material. Stainless steel wire rope is a staple in the maritime, food processing and water treatment industries. Our material is either type 320/304 or type 316. Type 316 is less magnetic than 302/304 and is more corrosion resistant but costs more and is not available in all sizes and constructions."
   

  
   

What is the effect of using a flying cable?  Thermal bumps, stall recoveries, gust bumps? Size of bumps, number of bumps of various sizes, etc.

Discussions:

• http://www.hanggliding.org/viewtopic.php?p=117179
• To well respond to replacement practices, one needs to well-know what is the use and stress history of one's cables and parts.
• What about Spectra?        Verify: [ ]  "most fraying of spectra fiber occurs internal to the weave from internal abrading"
• Sleeve slippage?
• Consider study of second sleeve set good distance and with slight looseness. Consider fatigue inside the first main sleeve. Consider have the loose section as an indicator: looseness lost might mean slippage in first sleeve. This needs full testing.
• Protecting one's glider from mysterious influences and strangers.
• Buying a used glider? One cannot know the actual history; you were not there!
• ball swage inside downtube?  Inspection?  How are those holding?
• Galvanized versus stainless steel?   What did Avia Hang Gliders find?
• http://www.hanglide.com/news/?page_id=76
• Shock load history of your glider?
• Use, abuse, transport coverage, storage environment
• Red: "Young cables are cheap life insurance."
• Front, side, rear, pull-back wires
• Detecting wire defects?  Difficulty.
  • http://flyatos.com/nose_cross_wire.html
  • fatigue?
  •  
• http://www.hanggliding.org/viewtopic.php?t=11019
• http://www.hanggliding.org/wiki/Checking_NICO_sleeves_on_cables

Some links

• http://www.hubbell-gleason.com/Parts/Festoons/618046.pdf