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AEROSPACE AS4536™ REV. D
STANDARD Issued 1993-01
Reaffirmed 2012-11
Revised 2019-10
Superseding AS4536C
Safety Cable Kit Procurement Specification and Requirement for Use
RATIONALE
Revise tolerance for the 0.022 diameter cable from 0.006 to 0.004 (see [Link] and Table 1), update references, add
specification references for ferrules, correct typographical errors in Tables 4 and 5, general editorial revisions.
1. SCOPE
1.1 Purpose
This procurement specification covers aerospace quality safety cable kits consisting of safety cables and ferrules made
from the same corrosion and heat resistant steels and a nickel base alloy of the type identified under the Unified Numbering
System as follows:
a. UNS S30400 - Corrosion resistant steel (AMS5697, AMS5560)
b. UNS S32100 - Corrosion and heat resistant steel (AMS5689, AMS5570)
c. UNS N06600 - Nickel base alloy (AMS5687, AMS5580)
d. UNS N06625 - Nickel alloy, corrosion resistant (AMS5666, AMS5581)
The requirements for installation practices are also specified.
1.2 Field of Application
For use in aerospace systems for securing fasteners and other utility parts which may have the potential of coming loose
during operation.
2. REFERENCES
2.1 Applicable Documents
The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications
shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the
event of conflict between the text of this document and references cited herein, the text of this document takes precedence.
Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been
obtained.
__________________________________________________________________________________________________________________________________________
SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely
voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.”
SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and
suggestions.
Copyright © 2019 SAE International
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of SAE.
TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) SAE values your input. To provide feedback
Tel: +1 724-776-4970 (outside USA) on this Technical Report, please visit
Fax: 724-776-0790 [Link]
Email: CustomerService@[Link]
SAE WEB ADDRESS: [Link]
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SAE INTERNATIONAL AS4536™D Page 2 of 11
2.1.1 SAE Publications
Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA
and Canada) or +1 724-776-4970 (outside USA), [Link].
AMS5560 Steel, Corrosion Resistant, Seamless Tubing, 19Cr - 10Ni (304), Solution Heat Treated
AMS5570 Steel, Corrosion and Heat-Resistant, Seamless Tubing, 18Cr - 11Ni - 0.40Ti (321), Solution Heat Treated
AMS5580 Nickel Alloy, Corrosion and Heat-Resistant, Seamless Tubing, 74Ni - 15.5Cr - 8.0Fe, Annealed
AMS5581 Nickel Alloy, Corrosion and Heat-Resistant, Seamless or Welded Tubing, 62Ni - 21.5Cr - 9.0Mo - 3.7Cb
(Nb), Annealed
AMS5666 Nickel Alloy, Corrosion and Heat-Resistant, Bars, Forgings, Extrusions, and Rings, 62Ni - 21.5Cr - 9.0Mo
- 3.65 Cb (Nb), Annealed
AMS5687 Nickel Alloy, Corrosion and Heat-Resistant, Wire, 74Ni - 15.5Cr - 8.0Fe, Annealed
AMS5689 Steel, Corrosion and Heat Resistant, Wire, 18Cr - 10.5Ni - 0.40Ti (321), Solution Heat Treated
AMS5697 Steel, Corrosion-Resistant, Wire, 19Cr - 9.5Ni (304), Solution Heat Treated
AS567 Safety Cable, Safety Wire, Key Washers, and Cotter Pins for Propulsion Systems, General Practices for
Use of
AS3509 Cable, Safety, Kit, Nickel Alloy, UNS N06600
AS3510 Cable, Safety, Kit, Corrosion and Heat Resistant Steel, UNS S32100
AS3511 Cable, Safety, Kit, Corrosion Resistant Steel, UNS S30400
AS3618 Cable, Safety, Ferrule, Elongated, Corrosion and Heat Resistant Steel, UNS S32100
AS3619 Cable, Safety, Ferrule, Elongated and Kits, Nickel Alloy, UNS N06600
AS3655 Cable, Safety, Nickel Alloy, Corrosion Resistant (UNS N06625)
2.1.2 ASTM Publications
Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959,
Tel: 610-832-9585, [Link].
ASTM D3951 Packaging, Commercial
ASTM E4 Standard Practices for Force Verification of Testing Machines
ASTM E8/E8M Standard Test Methods for Tension Testing of Metallic Materials
2.2 Definitions
STRAND: A group of wires helically wound around a core wire in a left-hand direction or a right-hand direction.
CABLE: A group of strands helically twisted together in a right-hand direction without a core.
DEFECTIVE: A defective is a unit of product which contains one or more defects.
DIAMETER: The diameter of wire strand and cable is the diameter of the circumscribing circle, or across diametrically
opposite wires.
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SAE INTERNATIONAL AS4536™D Page 3 of 11
FERRULE/END FITTING: Metal sleeve used for crimping onto the cable to maintain tension in the cable.
LAY: The helical form taken by the wires in the strand and by the strands in the cable is characterized as the lay (or twist)
of the wires in a strand, or strands in a cable, respectively. In a right-hand lay, the wires of the strand are the same direction
as the thread on a right-hand screw, and a left-hand lay the strands or wires lay in the opposite direction.
LENGTH OF LAY (OR PITCH): The distance parallel to the axis of the strand, in which a wire makes one complete turn
about the axis.
PING: Ping is an audible sound given off as a result of an individual wire breaking in the wire strand.
PRODUCTION INSPECTION LOT: Shall be all finished parts of the same part number, made from a single heat of alloy,
heat treated at the same time to the same specified condition, produced as one continuous run, and submitted for vendor’s
inspection at the same time.
PULL-OFF LOAD: The force required to pull the cable out of either the ferrule or cable end fitting.
SAFETY CABLE: An inseparable assembly consisting of a length of cable and an end fitting affixed to one end of the cable.
SAFETY CABLE ASSEMBLY: An assembly consisting of a ferrule affixed to the safety cable.
TERMINATION POINT: The point at which the cable end fitting or ferrule attach to the cable.
WIRE: Each individual cylindrical element is designated as a wire.
3. TECHNICAL REQUIREMENTS
3.1 Material
Material requirements for cable, end fitting, and ferrule shall be as specified on the part standards.
3.2 Design
3.2.1 Finished safety cable shall conform to AS3509, AS3510, AS3511, or AS3655.
3.2.2 Corresponding finished safety cable ferrules shall conform to AS3509, AS3510, AS3511, AS3618, AS3619, or
AS3655.
3.3 Construction
3.3.1 Wire Properties
Tensile strength of wire and wire sizes shall be such that the cable will be capable of meeting the requirements of this
specification.
[Link] Preforming of Wires
The individual wires comprising a strand shall be shaped into the exact helical position they will have in the finished strand
or cable, so that if the strand or cable is cut, the measured diameter of the cable at the cut ends shall not increase by more
than 0.004 inch (0.10 mm) for nominal cable diameter 0.022 inch (0.56 mm), shall not increase by more than 0.006 inch
(0.15 mm) for nominal cable diameter 0.032 inch (0.81 mm), shall not increase more than 0.008 inch (0.20 mm) for nominal
cable diameter 0.040 inch (1.02 mm), and shall not increase by more than 0.009 inch (0.23 mm) for nominal cable diameter
0.062 inch (1.57 mm).
[Link] Splicing and Joining
There shall be no wire splices in the finished strand or cable.
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SAE INTERNATIONAL AS4536™D Page 4 of 11
3.3.2 Type of Construction
[Link] 0.022 inch (0.56 mm) diameter safety cable shall be 1 x 7 construction.
[Link].1 Strand 1 x 7
The 0.022 inch (0.56 mm) nominal diameter cable shall be a strand of wires having 1 x 7 construction, consisting of a lay of
six wires laid around a center core wire in a left-hand, or right hand direction. The length of lay shall be not more than
0.25 inch (6.35 mm) nor less than 0.20 inch (0.51 mm).
[Link] 0.032 inch (0.81 mm) diameter safety cable shall be 3 x 7 construction.
[Link].1 Cable 3 x 7
The 0.032 inch (0.81 mm) nominal diameter cable shall consist of three strands of seven wires each, laid together without
a core. Each strand shall consist of a layer of six wires laid around a center core wire in a left-hand direction. The three
strands shall be laid together in a right-hand direction. The length of the lay of the six outer wires in each strand shall not
exceed 70% of the lay of the finished cable. The length of lay of the finished cable shall be not more than 0.25 inch (6.35 mm)
nor less than 0.18 inch (4.57 mm).
[Link] 0.040 inch (1.02 mm) diameter safety cable shall be 7 x 7 construction.
[Link].1 Cable 7 x 7
The 0.040 inch (1.02 mm) nominal diameter cable shall consist of six outer strands of seven wires each laid around a core
of seven wires. The six outer strands shall consist of six wires laid around a center wire in a left-hand direction. The core
strand shall consist of six wires laid around a center wire in a right-hand direction. The six outer strands shall be laid around
a core in a right-hand direction. The length of lay of the outside six wires in each of the six outside strands, and the outside
six wires of the core strand shall not exceed 60% of the length of lay of the finished cable. The length of lay of the finished
cable shall be not more than 0.37 inch (9.40 mm) not less than 0.24 inch (6.10 mm).
[Link] 0.062 inch (1.57 mm) diameter safety cable shall be 7 x 19 construction.
[Link].1 Cable 7 x 19
The 0.062 inch (1.57 mm) nominal diameter cable shall consist of six outer strands of 19 wires each laid around a strand
core of 19 wires. The six outer strands shall each consist of a layer of six wires laid around a center wire in a left-hand
direction and a layer of 12 wires laid over the seven-wire strand in a left-hand direction. The strand core shall consist of a
layer of six wires laid around a center wire in a right-hand direction. The six outer strands shall be laid around the core in a
right-hand direction. The length of lay of the inside layer of six wires in each of the six outer strands and the one strand core
shall not exceed 60% of the outside layer of 12 wires in each strand. The length of lay of the outside layer of 12 wires in
each of the six outside strands and the strand core shall not exceed 50% of the lay of the finished cable. The length of lay
of the finished cable shall be not more than 0.54 inch (13.72 mm), not less than 0.40 inch (10.16 mm).
3.3.3 Safety Cable
[Link] The 0.022 inch (0.56 mm) nominal diameter safety cable comprises the following:
a. One strand of wires, 1 x 7 construction as in [Link].1.
b. Fitting end, as specified on part drawing, crimped onto strand at one end.
c. Free end of strand is fused by brazing or welding.
d. Ferrule, as specified on part drawing, to be crimped onto the free end of the strand at installation.
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[Link] The 0.032 inch (0.81 mm) nominal diameter safety cable comprises in the following:
a. Three strands of wires, 3 x 7 construction as in [Link].1.
b. Fitting end, as specified on part drawing, crimped onto cable at one end.
c. Free end of cable is fused by brazing or welding.
d. Ferrule, as specified on part drawing, to be crimped onto the free end of the cable at installation.
[Link] The 0.040 inch (1.02 mm) nominal diameter safety cable comprises the following:
a. Seven strands of wire, 7 x 7 construction as in [Link].1.
b. Fitting end, as specified on part drawing, crimped onto cable at one end.
c. Free end of cable is fused by brazing or welding.
d. Ferrule, as specified on part drawing, to be crimped onto the free end of the cable at installation.
[Link] The 0.062 inch (1.57 mm) nominal diameter safety cable comprises the following:
a. Seven strands of wire, 7 x 19 construction as in [Link].1.
b. Fitting end, as specified on part drawing, crimped onto cable at one end.
c. Free end of cable is fused by brazing or welding.
d. Ferrule, as specified on part drawing, to be crimped onto the free end of the cable at installation.
[Link] The length of the safety cable shall be as specified on the part drawing.
3.4 Performance
3.4.1 Breaking Strength
Strength of 0.022 inch (0.56 mm) nominal diameter cable as in [Link], of 0.032 inch (0.81 mm) nominal diameter cable as
in [Link], of 0.040 inch (1.02 mm) nominal diameter cable as in [Link], and of 0.062 inch (1.57 mm) nominal diameter
cable as in [Link] shall be not less than the minimum breaking strength specified in Table 1, for the applicable material,
and determined in accordance with ASTM E8/E8M.
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Table 1 - Construction and physical property of cables
Nominal Cable Tolerance Diameter Breaking Strength
Diameter Plus Only Minimum
Material Inch (mm) Inch (mm) Construction lbf (N) /1/
AMS5687 0.022 (0.56) 0.004 (0.10) 1x7 60 ( 266.9)
AMS5689 0.022 (0.56) 0.004 (0.10) 1x7 60 ( 266.9)
AMS5697 0.022 (0.56) 0.004 (0.10) 1x7 60 ( 266.9)
AMS5666 0.022 (0.56) 0.004 (0.10) 1x7 60 ( 266.9)
AMS5687 0.032 (0.81) 0.006 (0.15) 3x7 100 ( 444.8)
AMS5689 0.032 (0.81) 0.006 (0.15) 3x7 100 ( 444.8)
AMS5697 0.032 (0.81) 0.006 (0.15) 3x7 100 ( 444.8)
AMS5666 0.032 (0.81) 0.006 (0.15) 3x7 100 ( 444.8)
AMS5687 0.040 (1.02) 0.006 (0.15) 7x7 180 ( 800.6)
AMS5689 0.040 (1.02) 0.006 (0.15) 7x7 180 ( 800.6)
AMS5697 0.040 (1.02) 0.006 (0.15) 7x7 180 ( 800.6)
AMS5666 0.040 (1.02) 0.006 (0.15) 7x7 180 ( 800.6)
AMS5689 0.062 (1.57) 0.010 (0.25) 7 x 19 400 (1778.8)
/1/ Breaking strength applies to the cable strength only. For pull-off load test for crimped safety cable ends, see
Table 2.
3.4.2 Stretch Limits
When tested in accordance with [Link], the stretch limit in the cable shall be as follows:
a. The 0.022 inch (0.56 mm) nominal diameter cable as in [Link] shall not exceed 1% when it is loaded to 60% of the
minimum breaking strength as specified in Table 1.
b. The 0.032 inch (0.81 mm) nominal diameter cable as in [Link] shall not exceed 1.5% when it is loaded to 60% of the
minimum breaking strength as specified in Table 1.
c. The 0.040 inch (1.02 mm) nominal diameter cable as in [Link] shall not exceed 1.5% when it is loaded to 60% of the
minimum breaking strength as specified in Table 1.
d. The 0.062 inch (1.57 mm) nominal diameter cable as in [Link] shall not exceed 1.5% when it is loaded to 60% of the
minimum breaking strength as specified in Table 1.
[Link] Stretch Test
For each size and material, one specimen from each sample of wire strand or cable, taken from the production inspection
lot, shall be tested to determine the percent stretch. The length of the wire strand or cable specimen to be tested shall not
be less than 24 inches (609.60 mm). The amount of stretch shall be determined on a tension testing machine in accordance
with ASTM E8/E8M. The specimen shall be loaded to 1% of the minimum breaking strength specified in Table 1 to straighten
the wire strand or cable. While the specimen is under tension, a gage length not less than 10 inches (254.00 mm) shall be
marked on the specimen between the end fittings of the testing machine. The specimen shall then be leaded to 60% of the
minimum breaking strength and measured for elongation under load. From this data, the percent stretch can be read directly
or calculated using Equation 1:
% stretch = (100)(elongation under load)/(original length) (Eq. 1)
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SAE INTERNATIONAL AS4536™D Page 7 of 11
3.4.3 Test Load
Each wire strand or cable shall carry 80% of its respective minimum breaking load. As specified in Table 1, without any
failures. The test loading shall be made using the same specimen used in the stretch test. Load the specimen to 1% of the
breaking strength, then increase the loading to 80% of the minimum breaking strength of the wire strand or cable and apply
for 5 seconds. At the end of the test, the specimen shall be removed, the entire specimen be completely unwound, and
each individual wire inspected. A suitable electronic device capable of detecting the breaking of individual wires during
testing may be used instead of unwinding the wires from the specimen. The failure of any wire shall be cause for rejection.
[Link] Use of Electronic Device for First Wire Break Test
The load shall be increased to 80% on the test specimen. If no ping is heard, the specimen has passed the test. If one or
more pings are heard, the specimen will be unraveled, and the broken wires shall confirm failure of the specimen. If no
broken wires are found, the specimen has passed the test.
3.4.4 Pull-Off Test
The crimped fitting end on the safety cable shall withstand a pull-off load not less than that specified in Table 2, determined
in accordance with ASTM E8/E8M.
Table 2 - Safety cable minimum crimp requirements (pull-off load)
Nominal Cable
Diameter Safety Cable Minimum Pull-Off Load
Inch (mm) Construction lbf (N)
0.022 (0.56) 1x7 30 ( 133.4)
0.032 (0.81) 3x7 70 ( 311.4)
0.040 (1.02) 7x7 110 ( 489.3)
0.062 (1.57) 7 x 19 280 (1245.5)
3.5 Installation
Install safety cable in accordance with the installation and process instructions in AS567.
3.6 Quality
Kits of safety cables, individual safety cables, and individual ferrules as received by purchaser shall be uniform in quality
and condition, free from foreign materials, and free from imperfections detrimental to usage of the parts. The cut end of the
safety cable shall not contain frayed strands of wire.
4. QUALITY ASSURANCE PROVISIONS
4.1 Responsibility for Inspection
The manufacturer of parts shall supply all samples for manufacturer’s test and shall be responsible for performing all
required tests. Purchaser reserves the right to sample, and to perform any confirmatory testing deemed necessary to ensure
that the parts conform to the requirements of this specification.
4.2 Responsibility for Compliance
The manufacturer’s system for parts production shall be based on preventing product defects, rather than detecting the
defects at final inspection and then requiring corrective action to be invoked. An effective manufacturing in-process control
system shall be established, subject to the approval of the purchaser, and used during the production of parts.
4.3 Production Acceptance Tests
The purpose of production acceptance tests is to check, as simply as possible, using a method which is inexpensive and
representative of the part usage, with the uncertainty inherent in random sampling, that the parts comprising a production
inspection lot satisfy the requirements of this specification.
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4.3.1 Tests to determine the conformance to all technical requirements of this specification are classified as acceptance
tests and shall be performed on each production inspection lot. A summary of acceptance tests is specific in
Tables 3 and 3A.
Table 3 - Summary of acceptance tests
Req Sample
Characteristics Para Size Test Method
Design & Dimension 3.2 Table 4 Conventional measuring methods
Construction 3.3 Table 4 Visual
Quality 3.6 Table 4 Visual
Table 3A - Destructive tests
Sample
Characteristics Para Size Test Method
Material Per material
Composition 3.1 4.4.1 specifications
Breaking Strength 3.4.1 Table 5 ASTM E8/E8M
Stretch Limits 3.4.2 [Link] ASTM E8/E8M
Test Load 3.4.3 [Link] ASTM E8/E8M
Pull-Off Test 3.4.4 Table 5 ASTM E8/E8M
4.4 Acceptance Tests Sampling
4.4.1 Material
One sample of wire, from which safety cable kit was made, from each heat of alloy.
4.4.2 Nondestructive Tests - Visual and Dimensional
A simple random sample shall be selected from each production inspection lot in accordance with Table 4.
Table 4 - Sampling data
Non-Destructive Tests, Visual
and Dimensional Production Nondestructive Tests, Visual
Inspection Lot Size and Dimensional Sample Size
2 to 15 2
16 to 50 3
51 to 150 5
151 to 500 8
501 to 3200 13
3201 to 35000 20
35001 to 500000 32
500001 and over 50
4.4.3 Destructive Tests
A simple random sample shall be selected from each production inspection lot; the size of the sample shall be as specified
in Table 5, except the sample for the stretch test as in [Link] and the test load as in 3.4.3 shall be a specimen as specified
in [Link].
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Table 5 - Sampling data
Destructive Tests,
Performance Tests Destructive Tests,
Production Inspection Performance Tests
Lot Size Sample Size
Up to 500 3
501 to 3200 5
3201 to 3500 8
3501 and over 13
4.4.4 Acceptance Quality
Of simple random samples tested, acceptance quality shall be based on zero defects.
4.5 Reports
The vendor of safety cable kits, individual safety cables, and individual ferrules shall furnish with each shipment a report
stating that the chemical composition of the kits, or individual safety cables and ferrules, conforms to the applicable material
specification, and stating that the kits, or individual safety cables and ferrules conform to the other technical requirements.
This report shall include the purchase order number, AS4536 (Revision Letter), lot number, part number, nominal size, and
quantity.
4.6 Rejected Lots
If a production inspection lot is rejected (on the basis of an acceptance test defined by Table 4), the vendor of the parts
shall perform corrective action to screen out or rework the defective parts, and resubmit for acceptance tests inspection as
in Table 5.
5. PREPARATION FOR DELIVERY
5.1 Packaging and Identification
5.1.1 Kits, individual safety cables, and ferrules (standard and elongated) having different part numbers shall be packed
in separate containers (each package containing 50 units or kits).
5.1.2 Each container of parts shall be marked to show not less than the following information:
KIT, SAFETY CABLE, OR SAFETY CABLE, OR FERRULES, NICKEL ALLOY (or CRES, as applicable)
AS4536D
PART NUMBER
LOT NUMBER
PURCHASE ORDER NUMBER
QUANTITY
MANUFACTURER’S IDENTIFICATION
5.1.3 Safety cable kits, or safety cable, or ferrules shall be suitably protected from abrasion and chafing during handling,
transportation, and storage.
5.1.4 Containers of kits, or safety cable, or ferrules which are to be delivered to the U.S. government shall be packaged
in accordance with ASTM D3951.
5.1.5 Ferrules shall be packaged in a spring-loaded magazine. Each magazine shall contain 50 ferrules, and shall be
designed so as to permit the free end of the safety cable to pass through one ferrule, and to allow that only one
ferrule shall exit from the magazine without disturbing the remaining ferrules in the magazine.
6. ACKNOWLEDGEMENT
There are no acknowledgements.
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7. REJECTIONS
Parts not conforming to this specification, or to modifications authorized by purchaser, shall be subject to rejection.
8. NOTES
8.1 Revision Indicator
A change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions, not
editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document title
indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original
publications nor in documents that contain editorial changes only.
8.2 Patents
When the cable of a safety cable is passed through holes in two or more fasteners or other utility parts and a ferrule or end
fitting is affixed to the free end of the cable, the assembly is a safety cable system (apparatus) which may be covered by
U.S. Patent 5, 116, 178 to GE Aircraft Engines of General Electric Company (CAGE Code 07482) (see Figures 1 and 2).
Corresponding patent applications have been filed in various foreign countries. Currently, the following providers of safety
cable kits are licensed under the U.S. Patent:
a. Bergen Cable Technology (Fairfield, NJ) (CAGE Code 70958)
b. Daniels Manufacturing Corporation (Orlando, FL) (CAGE Code 11851)
Figure 1 - Standard hardware
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SAE INTERNATIONAL AS4536™D Page 11 of 11
Figure 2 - Tube couplings
PREPARED BY SAE COMMITTEE E-25, GENERAL STANDARDS FOR AEROSPACE AND PROPULSION SYSTEMS
