Overview

In today’s military aircraft and future fleets, higher frequency mmWave components are being added to electronic warfare (EW) and aircraft survivability equipment (ASE). These components and systems require microwave/RF assemblies to operate within Ka-band frequencies from 26 to 40 GHz and V-band frequencies from 40 to 75 GHz. Microwave/RF assemblies are also susceptible to electrical challenges and mechanical stresses due to damage from installation and harsh environmental conditions. These conditions can cause interference in the signal transmission and errors within the aircraft systems. Small, rugged GORE-FLIGHT Microwave Assemblies, Type 6G, is proven to perform reliably up to 40 GHz over the aircraft’s lifetime, ensuring mission-critical success and peace of mind.

Maintaining signal integrity under difficult aerospace environments is essential to the reliability of mission-critical systems in aircraft. Starting with continuous flexing during routing through flight conditions, like repeated shock/vibration during flight, extreme altitude/temperature changes, and harsh contaminants. At the same time, airframe assemblies must be both lightweight and durable to improve fuel efficiency and reduce operating costs.

In fact, we conducted independent studies and research showing that globally more than 75% of microwave/RF assemblies are frequently replaced due to damage during installation or operation. So, costs can quickly add up with replacing assemblies, extra labor, and more maintenance and downtime!

LIGHTWEIGHT SOLUTION WITH THE LOWEST INSERTION LOSS

Award-wining GORE-FLIGHT Microwave Assemblies are proven to deliver the lowest insertion loss and more reliable VSWR after installation compared to leading competitor assemblies. Our rugged yet flexible airframe assemblies can easily withstand rigorous routing, maintenance activities, and flight conditions for lifetime performance. They’re also lighter weight compared to leading competitor designs, which improves fuel efficiency and increases payload.

Our assemblies have been thoroughly tested and qualified to meet stringent defense specifications and requirements for current and future generation fixed-wing and rotary-wing aircraft. With this high level of performance, our assemblies reduce costly production delays, field service frequency, and the need for purchasing replacement assemblies.

Aircraft manufacturers no longer have to accept the practice of replacing microwave/RF assemblies because they get damaged during installation. A fit-and-forget philosophy is now a reality because GORE-FLIGHT Microwave Assemblies provide the most cost-effective, lightweight solution that ensures mission-critical system performance for pilots.

Image of cable construction of GORE-FLIGHT Microwave Assemblies, Types 65 and 6E
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Abrasion-resistant braided jacket

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Liquid barrier

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Crush member

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Vapor barrier

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Torque-resistant braid

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Helically wrapped, silver-plated outer conductor

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Silver-plated conductor

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ePTFE dielectric

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Rugged construction of GORE-FLIGHT Microwave Assemblies, Types 65 and 6E.

Applications

GORE-FLIGHT Microwave Assemblies are engineered to perform reliably in a variety of aircraft applications, including:

Innovators Awards

GORE-FLIGHT Microwave Assemblies earned a platinum award for product innovation from Military & Aerospace Electronics.

Find out more

  • C5ISR
  • airborne electronic surveillance / countermeasures / jamming
  • EW (Electronic Warfare) systems
  • RWR (Radar Warning Receiver) systems
  • radar interconnects
  • electronic / signal intelligence
  • navigation / communication systems
  • Millimeter wave technologies

If you have any questions or to discuss your specific application needs, please contact a Gore representative.

Benefits

GORE-FLIGHT Microwave Assemblies provide aircraft system architects and engineers with many benefits that improve electrical and mechanical performance such as:

  • Outstanding signal integrity with lowest insertion loss up to 40 GHz before/after installation
  • lower installation costs due to fewer failures and reduced aircraft production delays
  • improved fuel efficiency and increased payload with lightweight assembly
  • longer system life and reduced downtime due to mechanically robust construction
  • less RF interference among electronic systems due to superior shielding effectiveness
  • proven compliance with stringent industry requirements

For more information about the benefits of our assemblies, please contact a Gore representative.

Properties

These values demonstrate the electrical, mechanical and environmental performance of GORE-FLIGHT Microwave Assemblies.

Download the data sheet for more technical information — including qualifications, performance data, torque values, connector options, and ordering information.

Electrical Property Value
Type 04 Type 65 Type 6E Type 6G
Maximum Frequency (GHz) 18 18 18 40
Typical VSWR through 18 GHz (straight connector) 1.25:1 1.25:1 1.25:1 1.30:1
Guaranteed VSWR through 18 GHz (straight connector) 1.40:1 1.40:1 1.40:1 1.45:1
Typical Insertion Loss at 18 GHz (dB/ft) 0.633 0.342 0.198 0.795
Guaranteed Insertion Loss at 18 GHz (dB/ft) 0.673 0.384 0.208 0.870
Standard Impedance (Ohms) 50 ± 1 50 ± 1 50 ± 1 50 ± 1
Nominal Dielectric Constant 1.4 1.35 1.35 1.40
Nominal Velocity of Propagation (%) 85 86 86 85
Nominal Time Delay ns/in (ns/cm) 0.103 (0.04) 0.0984 (0.0387) 0.0984 (0.0387) 0.103 (0.04)
Shielding Effectiveness through 18 GHz (dB) > 90 > 90 > 90 > 90
Mechanical / Environmental Property Value
Type 04 Type 65 Type 6E Type 6G
Overall Diameter in (mm) 0.18 (4.55) 0.24 (6.1) 0.35 (8.9) 0.195 (4.95)
Nominal Weight lb/ft (g/m) 0.027 (41) 0.040 (60) 0.084 (125) 0.033 (49)
Minimum Bend Radius in (mm) 0.5 (12.5) 1.0 (25.4) 1.9 (48.3) 0.75 (19.0)
Temperature Rangea (°C) -55 to +125 -55 to +125 -55 to +125 -55 to +125
Concentrated Load per MIL-T-81490 paragraph 4.7.18 (lb) > 150 > 150 > 150 > 150

a For applications outside of these temperatures, please contact a Gore representative.

Installation Simulator

Gore has long been a proponent of showing accurately how its products and technologies function in real-world environments before bringing them to market. Because nearly one-third of cable failures occur during installation, this is a crucial risk factor that shouldn't be minimized. Damaged airframe assemblies can lead to compromised signal integrity and failures over time, additional testing, and maintenance and replacement costs.

Installation Simulator With our installation simulator, aircraft manufacturers can be confident they are getting a reliable microwave/RF assembly solution that withstands the rigors of installation and reduces the total cost of ownership.

"Aircraft manufacturers need reliable solutions that can be installed deep within an aircraft and left there for the life of the platform. Therefore, we want to create 'fit-and-forget' solutions that will survive the demanding environments within an aircraft," said Jim Foreman, Gore Associate.

Gore is committed to designing next-generation products that solve key challenges and mitigate risk for aircraft. To do this, we test and simulate real-world conditions to ensure that our products do what we say they will do, consistently and reliably even in harsh conditions.

For more information about our Installation Simulator, download the white paper, 
Proving Installed Performance of Airframe Microwave Assemblies.

Also, download the white paper, Reducing Life Cycle Costs with Reliable Airframe Microwave Assemblies.

Videos

Watch these videos and more on YouTube to learn why our cables survive and perform when others do not.

Online Tools

Easy to Use, Fast Results

Gore’s online resources are designed specifically to make it easy for you to select the right microwave/RF assembly for your specific application requirements.

GORE Online Cable Builder Tool

Microwave/RF Cable Assembly Builder allows you to design an assembly with ease from your desktop, tablet or mobile phone. Whether you’re working in aerospace and defense, spaceflight or test and measurement environments, you can design an assembly to meet your specific needs. Once you design your assembly, you can quickly download custom data sheets for your builds. You can also submit your builds for a quote, and our specialists will review your designs and application requirements.

Microwave/RF Cable Assembly Calculator allows you to calculate insertion loss, VSWR and other parameters of Gore’s assemblies for different cable types. Select and compare up to three assemblies at a time.

If you have questions about our assemblies and want to discuss your specific application needs, please contact a Gore representative.

Resources

Recent News

W. L. Gore & Associates High Performance Aerospace Wires Set Gold Standard With Industry Award

Posted November 5, 2021

W. L. Gore & Associates (Gore) announced today that its GORE® High Performance Aerospace Wires, GWN3000 Series, were recognized among the 2021 Military & Aerospace Electronics Technology Innovators Awards. An independent panel of esteemed judges from the aerospace and defense community recognized Gore as a gold honoree for the second consecutive year. The company’s PHASEFLEX® Microwave/RF Test Assemblies were recognized in 2020.

Press Release

GORE® Jolts Emerging Electric Aviation Market with New High-Performance Aerospace Wires

Posted October 15, 2020

W. L. Gore & Associates announced today a new solution that meets higher voltages as the trend continues towards aircraft electrification to reduce the impact of air transport on our environment. GORE® High Performance Aerospace Wires, GWN3000 Series, deliver the best combination of superior mechanical strength and outstanding electrical reliability without increasing wire bundle size or weight.

Event

Gore at 2019 New Space Show

October 17, 2019 - October 18, 2019

Learn more about GORE® Space Cables and Assemblies engineered for the future of the space industry. Also, listen to our expert speak at the show on Thursday, October 17 at 11:00 am CEST.

Press Release

Gore Premiering New Portfolio of Qualified Solutions at 2019 NewSpace Show

Posted October 8, 2019

Gore will be showcasing a new portfolio of qualified GORE® Space Cables and Assemblies at the 2019 NewSpace Show in Monaco on October 17-18.

View all News & Events

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