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ASTM B794-97(2015)

ASTM B794-97(2015)

Standard Test Method for Durability Wear Testing of Separable Electrical Connector Systems Using Electrical Resistance Measurements

2020-10-22 /Historical
Superseeded by:
Significance and Use:

4.1 Materials for electrical connector contacts must satisfy a number of requirements in the areas of electrical, mechanical, and economic characteristics. The stability of electrical properties is one of the most important of these characteristics. Wear of contact surfaces may adversely affect these electrical properties, especially in designs where the contact surfaces are relatively thin coatings. This test method provides a means to compare various material systems on a basis relevant to their application in electrical connector contacts.

4.2 Repeated insertion and withdrawal of a connector may cause wear or other mechanical damage to the electrical contact surfaces, rendering those surfaces more susceptible to environmental degradation. This test method is intended to detect degradation of the electrical properties of the connector by such processes.

4.3 This test method describes procedures for conducting wear and durability testing of electrical connectors; the procedures produce quantitative results. These results may be used to compare the performance of different connector designs so that meaningful design choices can be made. Such results may also be used to compare the performance of a connector to a previously established standard to evaluate the quality of the samples under test.

4.4 The test results obtained from this test method are limited in their applicability to connector combinations that are equivalent in design and manufacture to those actually tested.

4.5 The user is cautioned that the conditions in this test should be compared to the conditions that the connector will experience in the intended application in order to determine the relevance of this test method to the particular needs of the user. For example, the environmental stress in this test method is less severe than certain industrial and marine environments and therefore test results are not directly applicable to predict the performance of product intended for use in such areas.

4.6 It is recommended that this test method be used in one of two ways. First, it may be used to evaluate and report the performance of a particular connector system. In such a case, it is appropriate to report the results in a table in the format shown in Fig. 1 and to state “The results shown in the table were obtained for (insert connector designation or description) when tested in accordance with ASTM Standard B794, Method __ , Procedure __ .” Second, it may be used to impose requirements for acceptance of product. In this case, limits for the values shown in Fig. 1 must be established prior to product acceptance testing. Such limits may be established by various methods such as by evaluation of product which is known to be acceptable or by application of appropriate experience. These limits must be documented in a manner that the entity performing the product test can refer to the limits to determine if the test product conforms to such limits. A purchaser may wish to supply a table of limits and include on the purchase order a statement similar to: “The product, when tested in accordance with ASTM Standard B794, Method __ , Procedure __ , shall meet the limits in the supplied table.” This table supplied by the purchaser may set limits on all of the values in Fig. 1, or only on a subset of those values that the purchaser deems adequate to ensure the performance of the product.


1.1 This test method covers the effects of repeated insertion and withdrawal of separable electrical connectors which are harmful to the electrical performance of the connector.

1.2 This test method is limited to electrical connectors designed for use in applications where the current through any one connection in the connector does not exceed 5 A, and where the connector may be separated a number of times during the life of the connector.

1.3 This test method is limited to electrical connectors intended for use in air ambients where the operating temperature is less than 65°C.

1.4 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.

1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to become familiar with all hazards including those identified in the appropriate Material Safety Data Sheet (MSDS) for this product/material as provided by the manufacturer, to establish appropriate safety and health practices, and determine the applicability of regulatory limitations prior to use.

contact resistance; electrical connectors; electrical contacts; temperature and humidity cycling test; wear; wear tracks;
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