AS9120B, ISO 9001:2015, and FAA AC 0056B Accredited
Posted on October 8, 2025 Jack Daniel manufacturer
Cables are vital components of any aircraft flight control system, such components serving to reliably transmit pilot inputs from the cockpit to various control surfaces. As these cables are subject to constant tension, friction, and environmental stressors during flight, their ability to uphold integrity and dependable signal transfer is paramount for safe operations. When wear begins to develop, it can compromise both the responsiveness and reliability of the aircraft’s flight controls, making it necessary that professionals understand the basics of addressing common cable issues.
In this blog, we will explore some of the most common signs of wear that aircraft control cables may exhibit over time, discussing the causes behind such issues, the risks of neglecting them, and best practices for managing maintenance and extending service life.
Control cables are typically made of high-strength steel or stainless-steel wire strands that are woven into flexible structures. During flight, these assemblies are subject to considerable loads and must be able to endure vibration, temperature fluctuations, and exposure to contaminants without failing. This is why monitoring for wear and properly handling such issues in a timely manner is very important, preventing a range of setbacks and potential hazards.
Recognizing wear early is key to preventing malfunctions and ensuring airworthiness, the following being the most prevalent signs of deterioration that may be observed during inspection.
As individual wire strands face repeated bending, vibration, and stress concentrations, they can begin to snap and break. This often occurs at pulleys and terminals, where fatigue, corrosion, and overloading is common. Even a few broken wires can significantly weaken a given cable, reducing its tensile strength and increasing the risk of full failure under load.
Corrosion and rusting are concerning issues that cause the oxidation of steel cables, often appearing as discoloration, pitting, or surface flaking. Corrosion reduces cross-sectional strength and increases susceptibility to strand breakage, as well as accelerates wear as corroded surfaces abrade adjacent strands. Generally speaking, moisture, humidity, de-icing chemicals, and inadequate lubrication levels can all be culprits, making it important that such issues are looked out for on a regular basis.
Pulleys and fairleads are susceptible to issues where cable surfaces become flattened or face abrasion at contact points with pulleys, guides, or fairleads. Typically, this is due to the misalignment of pulleys, insufficient lubrication, or excessive tension, causing uneven strand stress and eventual breakage as localized wear weakens the cable.
Kinking and distortion comes in the form of visible bends, twists, or permanent deformation in cable geometry. Kinks tend to create stress concentrations that accelerate fatigue and prevent smooth cable movement through pulleys, making it undesirable. To avoid such issues, operators should prevent cables from being mishandled during installation, improperly tensioned, or subject to excessive side loads.
If cable strands begin to separate and fray, they may cause a “birdcage” effect, where wires begin to bulge outward. This is usually the fault of a cable facing sudden overload conditions, being improperly installed, or facing cable slippage under stress. Frayed cables are prone to complete failure, and birdcaging indicates severe structural compromise requiring immediate replacement.
As cables are stretched beyond acceptable tolerances, they will face wear from elongation. Oftentimes, repeated load cycles, thermal effects, and gradual material fatigue are primary drivers of stretching, with resulting issues ranging from reduced control responsiveness to a lower range of motion.
Surface wear and polishing issues tend to come in the form of shiny, flattened, or smoothed areas along cable strands, caused by continuous rubbing against pulleys, guides, and other cables. While subtle at first, polished surfaces indicate ongoing abrasion that will eventually thin the cable structure.
Proper maintenance is critical for guaranteeing that all control cables of an aircraft remain safe and effective throughout their service lives. While exact practices will vary based on the type of aircraft one operates, how often it is flown, and other factors, the following are the most basic tasks that one will need to be familiar with.
Following manufacturer-recommended intervals, control cables should be visually inspected to check for any potential signs of fraying, corrosion, breakage, etc. As a general recommendation, such practices should be carried out in proper lighting and with suitable tools, allowing technicians to optimally detect any early-stage damage before it worsens.
For any control cables that require lubrication for rust and friction reduction, it is important that approved substances are used. Additionally, humid or salt-laden environments may benefit from corrosion inhibitors, while proper protection from dust, de-icing, and other contaminants is a must.
Proper tensioning and alignment will ensure that cables perform as expected, with manufacturers regularly specifying recommended levels. During normal servicing, one should verify pulley alignment to minimize side loads and uneven wear, avoiding over-tightening to deter fatigue.
If one detects broken strands, corrosion, or distortion, affected cables should be replaced as soon as possible with approved items that meet all necessary aviation standards. During installation, ensure that qualified personnel carry out all tasks in accordance with strict safety policies.
For those seeking dependable fulfillment options on aircraft control cables, look to Simplified Purchasing and our expansive selection. Here, we connect customers with top-quality hardware, electronics, and avionics for civil and military aircraft, all of our stock being strictly sourced from leading manufacturers and suppliers across the globe. Explore our curated catalogs today, and once you narrow down items of interest, our team will be just a call or email away from providing hands-on support.
Share
