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Common Test Requirements for Harsh Environment Connectors

When connectors are used in harsh environments, it’s not enough to assume that these products will be strong enough to withstand the impact of external stresses. It has to be proven.

While the application and industry-specific environmental conditions vary, test validation for harsh environments is a critical indicator you have the right connector for your project. Beyond certified lab testing, Amerline insists on submitting samples for first article approvals before proceeding with production runs for new customers. That’s because no one is more knowledgeable with performance expectations than the end customer. Successful test results provide assurance that the connector will meet and exceed the standards it was designed for.

So what kind of testing do our harsh environment connectors undergo? We’ll use our AEC 26482 series to walk through the tests our connectors have passed.

Testing Data for Our AEC 26482 Connector Series

Thermal Shock Test


How resistant are your connectors to sudden shifts in temperature — high or low?

The circular connectors in our AEC 26482 series are compliant with the EIA-364-32 (MIL-DTL-26482 J 3.6.12) standard. This temperature cycling compliance test is meant to simulate extreme conditions encountered during connector storage, transportation and use. By passing this test, our connectors are proven to have no physical abnormalities in very extreme cases of thermal shock.

High Temperature Test


How resistant are your connectors to heat?

Adhering to the MIL-DTL-26482 J standard, our AEC 26482 connectors are proven to operate in temperatures that reach up to 125℃ (257℉). Whether a result of natural or industrial causes, the heat simulated in this connector compliance test ensures proper performance in the field.

Vibration Test


How resistant are your connectors to varying levels of vibrations?

Another layer of testing our AEC 26482 connectors undergo pertains to the EIA-364-28 (MIL-DTL-26482 J 3.6.21 Test condition number III) standard. The goal of this test is to mimic the ranges of frequencies that a connector could encounter during its life through the use of a vibration machine. This frequency range extends from 10 to 2,000 Hz.

Salt Spray Test


How resistant are your connectors to corrosion?

Our AEC 26482 series connectors are subjected to salt spray testing according to method ASTM B 117. Results confirm that our OR (Electro-Deposited Olive Drab RoHS) and BR (Electro-Deposited Black RoHS) finishes have no rust after 500 hours in a sodium chloride 5% salt spray fog. This compares to the military (QPL) cadmium specification that requires 48 hours of testing with no rust. That is a 942% improvement in corrosion protection that separates our connectors from the competition. Military requirements are met and surpassed for commercial and industrial applications. This is the confidence you will have when you select Amerline’s AEC® series connectors. 

Connector Quality You Can Trust


At Amerline, we’re passionate about providing our customers with top-quality solutions for their connector needs. Part of that means performing a series of tests to ensure the connectors we ship to our customers not only meet but exceed industry standards.

While we provide this baseline of test data for your application, we can also jump in to help when applications require additional protection to operate in their environment. As part of our value-added services, we offer overmolding and potting services for our AEC connectors that further defend connectors and cables from sources of strain and stress.

Talk to us about your connector solution needs. Request a quote to get started.

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