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This standard provides a test method for determining the torque-tension relationship of a fastener finish as applied to a surrogate screw for the purpose of measuring the frictional characteristic of the fastener finish. The results obtained by this test shall be used as a process control attribute of the fastener finish and shall not be utilized for specific applications.

This standard provides a test method for determining the torque-tension relationship of a fastener finish as applied to a surrogate screw for the purpose of measuring the frictional characteristic of the fastener finish. The results obtained by this test shall be used as a process control attribute of the fastener finish and shall not be utilized for specific applications.

This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to ≤ (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for “Temperature Class Ratings”.

This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to ≤ (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for “Temperature Class Ratings”.

IMPORTANT NOTICE: In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. The Authorized Person is the final authority as to what tests are to be performed on his or her parts and for what purpose these tests are required. He or she is also the final authority for resolving any questions related to testing to this specification and to authorizing any deviations to the equipment or procedures contained in this specification.

SAE/USCAR-45 defines test methods and performance requirements for ultrasonically-welded wire-to-wire splices for automotive applications. Face-to-face, butt splice, and center strip configurations per Figure 1 can be tested. The tests defined in this specification subject samples on test to stresses that simulate a lifetime of exposure for a road vehicle. Stresses called out in this specification include thermal shock, temperature/humidity cycling and mechanical stress from different directions.

This specification defines test methods and performance criteria for evaluating ultrasonically welded wire-to-terminal metallurgical bonds. The examples used are specific to the linear weld type of process equipment. USCAR-38 is not applicable for “Splice Welding”. The specification is applicable to wire-on-pad configurations with a typical weld shown in Figure 1. This test specification subjects parts under test to environmental exposures to simulate a lifetime of field exposure for a road vehicle. Exposures called-out in this specification include Thermal Shock, Temperature Humidity Cycling and mechanical abuse. This test specification is intended to evaluate the strength and performance of the interface between wires to an electrical terminal. Validation of the performance of the Terminal is a separate task and can be accomplished using a component validation test such as SAE/USCAR-2, which evaluates whether the entire connection system is acceptable.

This specification defines test methods and requirements for validation of solderless crimped connections. The purpose of this test is to simulate in the lab the stress seen in a typical life (15 years and 150000 miles) for a crimp connection and assure the crimp is mechanically strong and electrically stable. This specification was developed for use with stranded automotive copper wire. Only where specifically mentioned are other constructions or other core materials (aluminum, clad, steel core, etc.) applicable. This specification does not apply to wire types not mentioned, such as coaxial cable crimps, unless a USCAR-21 test is specifically referenced in the test specification for that wire type. This specification is based on accepted levels of environmental exposure for automotive applications.

This specification defines test methods and requirements for validation of solderless crimped connections. The purpose of this test is to simulate in the lab the stress seen in a typical life (15 years and 150,000 miles) for a crimp connection and assure the crimp is mechanically strong and electrically stable. This specification was developed for use with stranded automotive copper wire. Only where specifically mentioned are other constructions or other core materials (aluminum, clad, steel core, etc.) applicable. This specification does not apply to wire types not mentioned. This specification is based on accepted levels of environmental exposure for automotive applications.

In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. The Authorized Person is the final authority as to what tests are to be performed on his or her parts and for what purpose these tests are required. He or she is also the final authority for resolving any questions related to testing to this specification and to authorizing any deviations to the equipment or procedures contained in this specification.

This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises a) from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray and different thicknesses of the holes that the clip is inserted into.

This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray, and different thicknesses of the holes that the clip is inserted into.

This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray, and different thicknesses of the holes that the clip is inserted into.

Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors and components for coaxial cable connection systems (hereafter referred to as RF connectors) in road vehicle applications. The intent of this specification is to qualify RF connectors that operate at frequencies greater than 200 MHz. This specification does not apply to single conductor wire or twisted pair connection systems. The RF connection system will be qualified for specific coaxial cable; the qualified coaxial cable and frequency range of interest must be listed on the connector drawing. Changing coaxial cable necessitates re-qualification. This specification is a supplement to the SAE/USCAR-2 Performance Standard for Automotive Electrical Connector Systems and all requirements herein must be met in addition to all requirements of SAE/USCAR-2, unless otherwise specified.

This document contains procedures for testing performance of SMB-style electrical terminals, connectors and components for coaxial cable connection systems intended for road vehicle applications. These are often called FAKRA II designs. This specification does not apply to the Non RF portion of a Hybrid RF connection system. The intent of this specification is to qualify sealed and unsealed RF connectors that operate at frequencies from DC to 6 GHz. The characteristic impedance of the SMB/FAKRA connection system is 50 ohms however this specification does not exclude the use of these RF connectors on non-50 ohm cables or systems. This specification does not apply to single conductor wire or twisted pair connection systems. This specification (along with SAE/USCAR 18) is designed to provide the mechanical and electrical data required to insure that assemblies from various manufacturers will perform reliably in actual conditions.

Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors and components for coaxial cable connection systems (hereafter referred to as RF connectors) in road vehicle applications. The intent of this specification is to qualify RF connectors that operate at frequencies greater than 200 MHz. This specification does not apply to single conductor wire or twisted pair connection systems. The RF connection system will be qualified for a specific coaxial cable; the qualified coaxial cable and frequency range of interest must be listed on the connector drawing. Changing coaxial cable necessitates re-qualification.

This standard lists variables that shall be investigated and reported as an initial investigation into new or revised surface finishes intended for use on fasteners. This standard provides instruction for producing a final report that will be used to determine if further investigation of a surface finish is justified. Further investigation may include tests and evaluations specific to an individual OEM prior to introduction/approval of the surface finish. The final report shall include the results, observations, and conclusions for all of the variables. The final report may be made up of several individual reports covering each variable. In all cases the laboratory performing the test, the test date and the report approver shall be included in the final report.