How to Test the Durability of Coaxial Cable Assemblies - Micro Coaxial Cable factory-(FRS)

Coaxial cable assemblies (CCAs) are critical in industries like telecommunications, aerospace, and industrial automation, where they must withstand physical stress, harsh environments, and long-term use. Durability testing ensures CCAs maintain structural integrity and electrical performance over time—avoiding costly failures in applications like 5G base stations or medical equipment. Below is a step-by-step guide to rigorous, practical durability testing.

1. Mechanical Durability Testing: Resist Physical Wear

Mechanical stress (bending, twisting, pulling) is one of the most common causes of CCA failure. Tests in this category simulate real-world handling and installation conditions.

1.1 Bending Test

Purpose: Verify resistance to repeated bending (e.g., during cable routing or equipment movement).

Standards: Follow IEC 60794-1-2 (for fiber-optic coaxial hybrids) or UL 444 (for general CCAs).

Procedure:

• Secure one end of the CCA to a fixed mount; attach a 500g load to the free end (adjust load based on cable gauge).
• Set a bending angle (90° for industrial CCAs, 180° for flexible consumer-grade models) and radius (10× the cable diameter for standard cables, 5× for high-flex variants).
• Cycle the cable back and forth at 10 cycles per minute for 10,000–50,000 cycles (depending on application: aerospace may require 100,000+ cycles).

Pass Criteria: No visible cracks in the jacket, no conductor breakage, and electrical parameters (see Section 3) change by ≤5%.

1.2 Torsion Test

Purpose: Evaluate resistance to twisting (e.g., during installation in tight spaces).

Procedure:

• Clamp the CCA’s two ends 1m apart (or per cable length).
• Apply a torque of 0.5–2 N·m (based on cable size: 0.5 N·m for 3mm diameter, 2 N·m for 10mm diameter).
• Twist the cable 180° clockwise, hold for 30 seconds, then 180° counterclockwise—repeat 500 cycles.

Pass Criteria: No jacket separation, no shield fraying, and impedance variation ≤3Ω.

1.3 Tensile Test

Purpose: Ensure the assembly withstands pulling forces (e.g., accidental tugging or weight loading).

Procedure:

• Mount the CCA horizontally in a tensile tester, gripping 10cm of each end.
• Apply a gradual force (100N for small CCAs, 500N for heavy-duty industrial models) at 5mm/min until reaching the rated load. Hold for 1 minute.

Pass Criteria: No detachment of connectors from the cable, no conductor stretching beyond 1% of original length.

2. Environmental Durability Testing: Withstand Harsh Conditions

CCAs often operate in extreme temperatures, humidity, or corrosive environments. These tests validate performance under such stress.

2.1 High-Low Temperature Cycling

Purpose: Simulate temperature fluctuations (e.g., outdoor CCAs exposed to day-night changes or aerospace conditions).

Standards: Refer to MIL-STD-810H (military-grade) or IEC 60068-2-14.

Procedure:

• Place the CCA in a temperature chamber.
• Cycle between -40°C (low) and 85°C (high), holding each temperature for 2 hours. Repeat 50 cycles.
• After cycling, let the CCA return to room temperature (25°C) for 4 hours.

Pass Criteria: No jacket hardening/cracking, no electrical performance degradation (see Section 3).

2.2 Humidity Testing

Purpose: Test resistance to moisture (e.g., CCAs in marine or tropical environments).

Procedure:

• Store the CCA in a humidity chamber at 85% relative humidity (RH) and 60°C for 1000 hours.
• Remove and inspect for moisture ingress (e.g., fogging inside connectors) or jacket swelling.

Pass Criteria: No moisture inside the assembly, and electrical loss (insertion loss) increases by ≤0.5 dB.

2.3 Salt Spray Testing

Purpose: Evaluate corrosion resistance (e.g., coastal or industrial CCAs exposed to salt-laden air).

Procedure:

• Expose the CCA to a 5% NaCl (salt) solution spray at 35°C for 480 hours (per ASTM B117).
• After testing, clean the CCA with deionized water and dry.

Pass Criteria: No rust on connectors (e.g., brass or stainless-steel parts), no shield corrosion, and electrical continuity remains intact.

3. Electrical Performance Stability Testing

Durability is not just physical—CCAs must maintain consistent electrical performance (e.g., signal transmission) after stress. Key tests include:

3.1 Impedance Measurement

Purpose: Ensure the CCA’s characteristic impedance (e.g., 50Ω or 75Ω) stays within specs (critical for signal integrity).

Procedure: Use a vector network analyzer (VNA) to measure impedance at 100 MHz–6 GHz (common for high-frequency CCAs) before and after mechanical/environmental tests.

Pass Criteria: Impedance variation ≤5% of the rated value (e.g., 50Ω CCAs must stay between 47.5Ω and 52.5Ω).

3.2 Insertion Loss (IL) and Return Loss (RL) Testing

Purpose: IL measures signal loss through the CCA; RL measures signal reflection (both critical for low-noise transmission).

Procedure:

• Use a VNA to test IL (target: ≤0.3 dB/m at 1 GHz) and RL (target: ≥20 dB at 1 GHz) before testing.
• Repeat after mechanical/environmental cycles.

Pass Criteria: IL increases by ≤0.1 dB/m; RL decreases by ≤3 dB.

3.3 Electrical Continuity Test

Purpose: Confirm no conductor breaks or connector failures.

Procedure: Use a multimeter to check continuity between the center conductor and connector pins, and between the shield and connector shells.

Pass Criteria: Zero resistance (full continuity) in all paths.

4. Critical Considerations for Accurate Testing

To ensure reliable results, follow these best practices:

• Sample Preparation: Test 3–5 identical CCAs (not just one) to account for manufacturing variability.
• Equipment Calibration: Calibrate testers (e.g., VNA, tensile tester, temperature chamber) monthly per manufacturer specs.
• Data Logging: Record test parameters (e.g., cycle count, temperature, impedance values) for traceability—critical for quality audits or troubleshooting.

Conclusion

Durability testing of coaxial cable assemblies requires a holistic approach, combining mechanical, environmental, and electrical evaluations to mimic real-world use. By following the methods outlined above—from 10,000-cycle bending tests to salt spray exposure—you can validate a CCA’s long-term reliability.

For manufacturers and buyers seeking CCAs that meet these rigorous durability standards, FRS brand factory is a trusted partner. FRS integrates all the testing protocols detailed here into its production process: every CCA undergoes 10,000-cycle bending tests, 50 temperature cycles (-40°C to 85°C), and full electrical performance checks (impedance, IL, RL) using calibrated VNA equipment. With a dedicated team of engineers monitoring each test step and adherence to MIL-STD-810H and IEC standards, FRS ensures its CCAs deliver consistent durability in telecommunications, industrial, and aerospace applications. Choose FRS for coaxial cable assemblies you can test—and trust—for the long haul.