lightweight qualities in high-heat applications. Plated steel shells can be used, but the long-term durability of plated surfaces can be compromised by heat and by the physical effects of scratches and abrasions. A simple scratch in a plated surface will expose the bare base material to corrosive environments. In contrast, a scratch in a titanium component is a minimal concern due to the corrosion-resistant qualities throughout the base material. The core of the high-temperature connector is typically a ceramic insert which provides heat resistance and stability. However, ceramic materials are vulnerable to cracking due to vibration or shock loading and may have limitations when used in a high vibration or shake load environment. The most successful high-temperature connectors use exotic high-specification composite ceramic materials which balance vibration resilience and high-temperature performance. Ultimately, high-temperature connectors must provide reliable, high-speed data transfer between the launch signal and receiving signal devices. Connecting cables that can sustain high data transfer rates over long wire run lengths is important to the equation, but the connectors are critical components at the launch signal and receiving signal connection. Overall, the entirety of the connector design (temperature limits, termination features, and resistance to EMI and environmental factors) defines the connector, not just one specification. 38999 HARSH-DUTY CONNECTORS The MIL-DTL-38999 specification is the most common harsh-duty connector and is found in
virtually all aerospace and military applications and a number of industrial applications. A tried- and-true design, the MIL-DTL-38999 has roots in designs and specifications implemented 75 years ago. It is safe to say that MIL-DTL-38999 specification connectors will remain in mainline production throughout and beyond the lifetime of anyone who is reading this now. The 38999 is successful in that the common features, such as physical interface, mounting, technical specifications for conductivity, EMI, and environmental factors, are the same over a range of connector diameter sizes, small to large. Base materials of steel, aluminum, or composite materials are common, as well as specialty surface finishes for cosmetic and environmental purposes for all manner of harsh environments and rugged duty applications. In short, the 38999 connector offers no surprises and is an industry standard due to its wide range of proven characteristics.
Octax® connector shown with MIL-DTL-38999 configuration
The features that make the 38999 connector an outstanding choice for harsh, rugged duty may result in some compromises and limitations for applications. However, engineered solutions ensure this connector’s ongoing viability.
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