September 21, 2023 | Original Notice

On Thursday, September 21, 2023, WireMasters received notice from TE Connectivity of a suspected escapement on the Shield Terminators Devices under MIL-SPEC SAE AS83519/2 as well as Crimp Splices under MIL-SPEC SAE AS81824/1 and AS81824/6. 

WireMasters immediately ceased all shipments, quarantined the impacted material, and is working to communicate with impacted customers. We will continue to monitor the situation and provide updates as needed.  

The complete communication from TE—as well as a full list of impacted part numbers—can be found below or please click here to download:  

Quality Alert / NOSP-23-023 / Notice of Suspect Product / Stop Shipment Notification 

Dear Valued Customer,  

We regret to send you this notice of a suspected escapement on the Shield Terminators Devices under MIL-SPEC SAE AS83519/2 as well as Crimp Splices under MIL-SPEC SAE AS81824/1 and AS81824/6, covering the TE part number families listed below. See Appendix A for a complete list of impacted part numbers.  

TE Part Number Families  

• M83519/2-1 through -20 S02-XX-R (-01 through -20)
• M81824/1-1 through -3 D-436-XX (36 thru 38)  
• M81824/6-1 through -3 D-436-XX (82 thru 84)  

There is the possibility that all supplied Shield Terminators supplied from March 15, 2019 to July 2023 and Crimp Splice Devices supplied from February 20, 2014 to July 2023 are non-conformant. Further investigation into the scope of this escape is underway, and the date range may be reduced once testing is complete.  

Description of Non-Compliance  

As a result of a material formulation change on heat shrink tubing and meltable sealing rings used in the manufacture of the listed Shield Terminators and Crimp Splice Devices, test articles were subjected to a qualification process consisting of testing to various test groups in accordance with SAE AS83519 and AS81824 specifications.  

The qualification of material change for Shield Terminators included test group VI (Temperature Cycling), VII (Moisture Resistance), and VIII (Fluid Immersion) in accordance with SAE AS83519. Although test articles successfully met the requirements outlined for test groups VI and VIII, failures were detected when tested for Insulation Resistance (M83519/2) after conditioned for Moisture Resistance.  

TE Connectivity is also qualified to other slash sheets within SAE AS83519 Specification. The construction and the materials used on these slash sheets are different. AS83519/1 does not contain a preinstalled wire lead. AS83519/3 and /5 contain a pre-installed un-insulated braid, which is not subjected to Insulation Resistance Test. Testing has shown these slash sheets products are not impacted, and performance is in accordance with the SAE AS83519 specification requirements.  

The qualification of material change for Crimp Splices was limited to Group B Inspection Testing (Altitude Immersion) in accordance with SAE AS81824. Although test articles successfully met the requirements outlined for Group B Inspection, based on failures detected during Shield Terminators testing, TE Connectivity decided to test for Moisture Resistance, followed by Altitude Immersion, Insulation Resistance, and Dielectric Withstanding Voltage, in accordance with SAE AS81824. te.com  

Failures have been detected when tested for Insulation Resistance after Moisture Resistance, and they were limited to the medium size of the crimp splices (AS81824/1-2). The smallest size (AS81824/1-1) and the largest size (AS81824/1-3) successfully met requirements. None of the tested articles have shown failures to Dielectric Withstanding Voltage.  

AS81824/1 and AS81824/6 contain the same Sealing Sleeve component; hence, failures also impact AS81824/6-1 through -3.  

TE Connectivity is also qualified to other slash sheets within SAE AS81824 Specification. The construction and the materials used on these slash sheets are different, based on the number of wires splices (/7 through /10), or the operating temperature requirements (/11). Additional testing has shown these products are not impacted and performance is in accordance to the SAE AS81824 specification requirements.  

Additional testing on control Shield Terminators and Crimp Splices test articles prior to the material formulation change confirmed the failure is not a consequence of the material formulation.  

Containment and Corrective Action 

TE Connectivity has notified the Qualifying Agency, NAVAIR, of the issue and voluntarily placed all affected part numbers, as listed in Appendix A, on ship hold. We are in the process of conducting a thorough investigation of the issue and will provide an update as soon as testing is completed. TE Connectivity has determined there is a potential impact to TE products already shipped to customers.  

Disposition of Non-conformity  

TE recommends that you conduct a risk assessment to determine what impact, if any, this NOE has on your end-applications. To assist you in completing this assessment, we will share Technical Risk Evaluation, Qualification Test Report, and QC Test Reports as they become available.  

Risk Assessment  

TE Connectivity is performing additional testing intended to determine the potential impact on the performance of Shield Terminators and Crimp Splices Devices in the field or final application. Testing will consist of the following:  

1. Voltage Drop and Tensile Strength. Test intended to determine the impact on electrical and mechanical performance.  
2. Insulation Resistance and Dielectric Withstanding Voltage between 2 adjacent spliced wires on cable bundles or 2 adjacent shield terminators to determine potential arcing or electrical connection.  
3. Vibration  
4. Heat Aging  
5. Voltage Drop and Tensile Strength  

When this evaluation is complete, TE will provide an updated risk assessment. As a next step, TE Connectivity advises that you quarantine the products listed in Appendix A at location and await further instructions from TE.  

Qualified Products List (QPL) Products are Affected  

Upon completion of your risk assessment, if your product is ultimately destined for the U.S. Government and you wish to use the existing inventory, TE can assist you with your waiver application to the Contracting Officer for the Program. te.com  

If your application does not require QPL Listed product, please contact your TE Customer Service representative to disposition the inventory and receive TE’s commercially equivalent product, listed in the table below.  

If neither option addresses your needs and you wish to return the impacted product, please contact your TE Customer Service representative.  

Future Communication  

If you need additional information or have any questions, please contact your TE account manager or the following TE team members:  

• Product Engineering Manager Luis E. Rodriguez [email protected]  
• Principal R&D/Product DVL Engineer Craig L. Reeder [email protected]  
• Product DVL Engineer Arnell Rey [email protected]  
• EPS Product Manager Chauvin Chhay [email protected]  
• Customer Quality Engineer Brent Diaz [email protected]  

We apologize for any inconvenience this issue may cause. TE is committed to providing our customers with high quality products and solutions, and we are grateful for your business.  

Sincerely,  

Ruben Ortega  
Tijuana Plant Quality Manager te.com  

 

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