MIL-DTL-642E
3.6.3 Contact resistance. When plugs are tested as specified in 4.6.4, the contact resistance shall not
exceed 0.02 ohm, except following the salt spray test, the contact resistance shall not exceed 0.10 ohm.
3.6.4 Insulation resistance. When plugs are tested as specified in 4.6.5, the insulation resistance shall be
1,000 megohms or greater.
3.6.5 Moisture resistance. When plugs are tested as specified in 4.6.6, the initial insulation resistance
shall be not less than 1,000 megohms, and the initial dielectric withstanding voltage shall be as specified
in 3.6.2. Following step 6 of the final cycle, at a relative humidity of 90 to 95 percent, the insulation
resistance shall be not less than 5 megohm. Following the 24-hour conditioning period, the insulation
resistance shall be not less than 1,000 megohms, the dielectric withstanding voltage and contact
resistance shall be as specified in 3.6.2 and 3.6.3 respectively. Shells and other insulation shall not be
cracked, warped, or delaminated. There shall be no excessive corrosion (see 3.6.9) of metal parts. All
marking shall remain legible and it shall be possible to remove and replace screw-on shells (where used)
without the use of tools. The outside diameter of the insulating spacer(s) between the tip and sleeve shall
be as specified (see 3.1).
3.6.6 Thermal shock. When plugs are tested as specified in 4.6.7, shells and other insulation shall not be
cracked, warped, or delaminated. The electrical continuity shall not be affected. All marking shall remain
legible and it shall be possible to remove and replace screw-on shells (where used) without the use of
tools.
3.6.7 Vibration, high frequency. When plugs are tested as specified in 4.6.8, there shall be no damage or
loosening of parts, the mating jack shall not separate from the plug, and the contact resistance shall be as
specified in 3.6.3.
3.6.8 Shock (specified pulse). When plugs are tested as specified in 4.6.9, there shall be no visual
evidence of mechanical damage, rupture of dielectric materials, or loosening of parts.
3.6.9 Salt spray (corrosion). When plugs are tested as specified in 4.6.10, there shall be no excessive
corrosion of metal parts. The insulation shall not be cracked, warped, or delaminated and the contact
resistance shall be as specified in 3.6.3. Excessive corrosion shall be construed as any corrosion which
interferes with electrical or mechanical performance or, in the case of plated metals, when the corrosive
action has passed through the plating and attacked the basis metal. Exposed screw threads may be
protected with a suitable coating.
3.6.10 Insertion and withdrawal forces. When plugs are tested as specified in 4.6.11, the insertion and
withdrawal forces shall be as specified (see 3.1).
3.6.11 Strain relief (see 3.1). When tested in accordance with 4.6.12, there shall be no evidence of
damage or cutting of the conductors or stay cord.
3.6.12 Longitudinal pull (see 3.1). When tested in accordance with 4.6.13, there shall be no damage or
loosening of parts, loss of electrical continuity for more than a period of ten microseconds with a current of
100 ± 2 milliamperes dc, the mating jack shall not separate from the plug, and the contact resistance shall
be as specified in 3.6.3.
3.6.13 Static load (see 3.1). When plugs are tested as specified in 4.6.14, there shall be no damage or
loosening of parts.
3.6.14 Stack assembly strength (see 3.1). When plugs are tested as specified in 4.6.15, there shall be no
damage or loosening of parts.
3.6.15 Controlled drop (see 3.1). When plugs are tested as specified in 4.6.16, there shall be no damage
or loosening of parts.
3.7 Marking. Plugs shall be marked in accordance with method I of MIL-STD-1285, and shall include the
manufacturer's name, trademark, or source code and the part number (see 3.1).
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