Utilization of TGA Flynn-Wall and Arrhenius Analysis for Rapid Prediction of Automotive PVC Cable Performance Robert Alan Smith, Allison Ward, and Daniel D. Brintnall Delphi Electrical/Electronic Architecture 4551 Research Parkway Warren, Ohio 44483 Poly(vinylchloride), PVC, insulated cable was first used in automobiles in the 1940’s when the average vehicle contained 40 meters of wiring. Presently, the Bentley Bentayga has a wiring harness that weighs 110 lbs! Indeed, the electrical systems of automobiles have become much more complicated than just provision of lighting, signaling, and heat with the evolution of climate control, infotainment and data delivery systems. Due to low cost and light weight, PVC insulated cable is still the most widely used cable in automobiles and is found predominantly in non-engine compartment applications limited by an upper use temperature of 80◦ C. Cumbersome heat aging testing of PVC for automotive applications involves heating the samples for at least 3000 hours at 80◦ C and performing comparative physical testing. Thermogravimetric Analysis, using the Flynn-Wall method, provided comparative heat aging testing on three automotive PVC cable grades in less than 1 day and only requiring approx. 100 milligrams of sample. Assignment of a sample weight loss correlated with performance failure was obtained from both literature and mandrel-wrap testing. Arrhenius relationships were used to predict performance at 80-100◦ C from rapid isothermal weight loss at 200◦C. Dynamic Mechanical Analysis was performed on virgin and samples heated to both the literature and experimentally-determined failure weight losses.