Design of Optimal Outboard Electrical Cables

Outboard electrical cable arrays, particularly those in the Vertical Launch System (VLS), have had numerous failures which have led to the loss of weapon readiness and high maintenance/replacement costs. The failures can be attributed to the extremely aggressive environment in which the cables reside. Cables are housed in a free flooded zone, and routinely undergo hydrostatic, thermal, and mechanical stresses. When surfaced, the cables are exposed to air, and experience wet-dry cycles which tend to degrade jacket materials. Cable runs frequently come into contact with sharp metal objects such as angle iron and pass-through holes, which cause abrasion damage to the outer jacket. An improved cabling system with physical properties that meet the demands of this environment with a service life of 20+ years would result in substantial cost savings and improved weapon readiness. Texas Research Institute Austin, (TRI/Austin, Inc.) proposes the development and evaluation of two parallel approaches to solve these problems: 1. An innovative over-coating system for post-manufactured VLS cables 2. A new cable design using modern materials and CY 2000 manufacturing technology The Phase I effort includes development of innovative life testing procedures for comparing cost and performance effectiveness of the two approaches.