MIL-DTL-24231E(SH)
3.4.2.3 Wire identification (inserts and receptacles). Ends of wires extending from inserts and receptacles shall
be marked with the pin number to which they are attached.
3.4.2.4 Wire identification (plugs). Wires of cables molded to plugs shall be marked at ends according to the
sockets to which they are attached.
3.4.2.5 Shields. Where shielded cables are molded in inserts, each shield shall be insulated from other shields
in the cable, except where shields are connected to a common pin.
3.4.3 Molded plugs and inserts. Molded plugs and inserts shall be free of flash, blow holes, or other
imperfections. Small gas bubbles that form on the face and top surface shall not be cause for rejection provided the
molded parts are in accordance with the requirements specified (see 3.1). The flash shall be removed and the width
of the flash edges shall be not greater than 1/32 inch. Flash edges shall then be buffed smooth.
3.4.3.1 Plugs. The termination of the mold at the cable may be a featheredge or may be terminated short of a
featheredge at the option of the contractor, provided the mold meets the requirements specified herein. Metal areas
of plug sleeves in contact with polyurethane or epoxy compounds shall be sandblasted and cleaned in accordance
with S9320-AM-PRO-020 to obtain the best possible bond. The molding compound shall be bonded to metal parts
and cured in accordance with S9320-AM-PRO-020. Surfaces in contact with O-rings shall be protected from
sandblasting.
3.4.3.2 Inserts. Inserts shall be of a one-piece construction. Split inserts shall not be allowed. Pre-pot inserts
subsequently molded into a complete one-piece insert assembly are acceptable. Pre-pots can be used in high density
count connectors thus permitting contact insertion and soldering of wires prior to final molding of the complete
insert.
3.4.4 Caps. Cable connectors, receptacles, and adapter fittings shall be provided with caps in place to prevent
damage to threads and entrance of water or dust into the receptacle. Caps shall remain in place until final assembly
with plugs.
3.4.4.1 Pressure-proof caps. When specified (see 6.2), pressure-proof caps (see 3.1) consisting of a cover and
O-ring shall be furnished with single cable and multi-pin receptacles, and molded plug adapters. The number of
caps furnished shall be as specified (see 3.1). When pressure-proof caps are not specified, plastic caps shall be
furnished (see 3.3.7).
3.4.4.2 Sealing plugs. When specified (see 6.2), sealing plugs consisting of a cover and O-ring shall be
furnished with molded plugs.
3.4.4.3 Protective caps. Protective caps shall be furnished with molded plugs when sealing plugs are not
specified (see 3.4.4.2). Where protective caps are not specified on the applicable specification sheet, plastic caps
shall be furnished (see 3.3.7).
3.4.5 Welding. Welding shall be in accordance with S9074-AR-GIB-010/278.
3.4.5.1 Welders. Welders shall be qualified in accordance with S9074-AQ-GIB-010/248.
3.4.5.2 Electrodes. In welding nickel-copper (Ni-Cu) alloy to Ni-Cu-Al alloy, the following electrodes shall be
used:
a.
8N12 or 9N10 covered electrode in accordance with MIL-E-22200/3 (manual metal arc).
b.
MIL-EN60 or MIL-RN60 electrode in accordance with MIL-E-21562 (tungsten inert gas).
c.
See Requirement 16 of MIL-DTL-24231/11.
3.4.5.3 Weld repair. There shall be no weld repair on any portion of a hull fitting body, nut, washer, or plug
for hull inserts.
3.4.6 Stress relieving. Metals used in fabrication and assembly shall be treated or heat-treated to prevent
deterioration or failure due to stresses or other conditions resulting from working, forming, welding, brazing, and so
forth during the fabrication process. Final condition shall be in accordance with the applicable specification sheet.
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