1、_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 theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this publication ma
3、y 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) Tel: +1 724-776-4970 (outside US
4、A) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS81044AAEROSPACESTANDARDAS81044 REV. A Issued 1998-07 Revised 2011-08Superseding AS81044 Wire,
5、 Electrical, Crosslinked Polyalkene, Crosslinked Alkane-Imide Polymer,or Polyarlyene Insulated, Copper or Copper Alloy RATIONALERevised to incorporate all outstanding amendments. NOTICEThis document has been taken directly from U.S. Military Specification MIL-W-81044B, Supplement 1A, Amendment 3 and
6、 contains only minor editorial and format changes required to bring it into conformance with the publishing requirements of SAE technical standards. The initial release of this document is intended to replace MIL-W-81044B, Supplement 1A, Amendment 3. Any part numbers established by the original spec
7、ification remain unchanged. The original Military Specification was adopted as an SAE standard under the provisions of the SAE Technical Standards Board (TSB) Rules and Regulations (TSB 001) pertaining to accelerated adoption of government specifications and standards. TSB rules provide for (a) the
8、publication of portions of unrevised government specifications and standards without consensus voting at the SAE Committee level, and (b) the use of the existing government specification or standard format. Under Department of Defense policies and procedures, any qualification requirements and assoc
9、iated qualified products lists are mandatory for DOD contracts. Any requirement relating to qualified products lists (QPLs) has not been adopted by SAE and is not part of this technical report. SAE AS81044A Page 2 of 281. SCOPE 1.1 Scope This specification covers single conductor electric wires made
10、 as specified in the applicable specification sheet with tin-coated, silver-coated, or nickel-coated copper or copper alloy conductors insulated with crosslinked polyalkene, crosslinked alkane-imide polymer, or polyarylene. The crosslinked polyalkene, crosslinked alkane-imide polymer, or polyarylene
11、 may be used alone or in combination with other insulation materials as specified in the specification sheet. 1.2 Classification The wires shall be as described in the applicable military specification sheet. 1.2.1 Part numbers: Part numbers under this specification are coded as in the following exa
12、mple: M81044/1 - 22 - 9Applicable speci- fication sheet Wire size Insulation color designator or designators1.2.2 Temperature rating of finished wire: The maximum conductor temperature of the finished wire for continuous use shall be as specified in the applicable military specification sheet (6.1.1
13、). 2. 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 the other publications shall be the issue in effect on the date of the purchase order. In the event of conflict
14、 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. 2.1 U.S. Government Publications Available from the Document Automa
15、tion and Production Service (DAPS), Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-9495, https:/assist.daps.dla.mil/quicksearch/.SPECIFICATIONSFederalTT-I-735 Isopropyl Alcohol MilitaryMIL-PRF-5606 Hydraulic Fluid, Petroleum Base; Aircraft, Missile, and Ordnance MIL-DTL-5
16、624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-DTL-12000 Cable, Cord, and Wire, Electric; Packaging of MIL-PRF-23699 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base MIL-DTL-29606 Wire, Electrical, Stranded, Uninsulated Copper, Copper Alloy, or Aluminum, or Thermocouple Extension, Gene
17、ral Specification For MIL-DTL-83133 Turbine Fuel, Aviation, Kerosene Types, NATO F-34 (JP-8) and NATO F-35 SAE AS81044A Page 3 of 28P-D-410 Type I, Dishwashing Compound, Hand SD-6 Provisions Governing Qualification STANDARDSFederalFED-STD-228 Cable and Wire, Insulated; Methods of Testing MilitaryMIL
18、-STD-104 Limits for Electrical Insulation Color MIL-STD-129 Marking for Shipment and Storage MIL-STD-202 Test Methods for Electronic and Electrical Component Parts MIL-STD-681 Identification Coding and Application of Hookup and Lead Wire PUBLICATIONSDefense Logistics Information Service Available at
19、 http:/www.dlis.dla.mil/hseries.asp.H4/H8 Commercial And Government Entity (Copies of specifications, standards, drawings, and publications required by suppliers in connection with specific procurement functions should be obtained from the procuring activity or as directed by the contracting officer
20、.) 2.2 Other Publications The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on date of invitation for bids or request for proposal shall apply: 2.2.1 ASQ Publications Available from American Society for Quality,
21、600 North Plankinton Avenue, Milwaukee, WI 53203, Tel: 800-248-1946 (United States or Canada) or +1-414-272-8575 (International), www.asq.org.ASQC Z1.4 Sampling Procedures and Tables for Inspection by Attributes 2.2.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. B
22、ox C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.B33-71 Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes B298-70a Standard Specification for Silver-Coated Soft or Annealed Copper Wire B355-69 Standard Specification for Nickel-Coated Sof
23、t or Annealed Copper Wire ANSI/ASTM D 3032 Standard Test Methods for Hookup Wire Insulation SAE AS81044A Page 4 of 283. REQUIREMENTS 3.1 Specification Sheets The requirements for the individual wires under this specification shall be as specified herein and in accordance with the applicable specific
24、ation sheet. In the event of any conflict between the requirements of this specification and those of the specification sheet, the requirements of the specification sheet shall govern except as follows: a. All specification sheet references to tape abrasion or resistance to propellants shall be cons
25、idered as cancelled. b. All specification sheet requirements for blocking shall be at the rated temperature of the wire of that specification sheet (for example: the blocking test temperature of MIL-W-81044/12 shall be 150C in lieu of 225C). 3.2 Classification of Requirements The applicable requirem
26、ents are classified herein as follows: Requirement ParagraphQualification 3.3 Materials 3.4 Construction 3.5 Finished Wire 3.6 3.3 Qualification The wire furnished under this specification shall be a product which is qualified for listing on the applicable qualified products list at the time set for
27、 opening of bids (see 4.3 and 6.3). The provisions of 4.6 for retention of qualification are included in this requirement. 3.4 Materials 3.4.1 Conductor Material: All strands used in the manufacture of the conductors shall be tin-coated, silver-coated, or nickel-coated soft annealed copper conformin
28、g to ANSI/ASTM B33-71, B298-70a, or B355-69, as applicable, or shall be silver-coated or nickel-coated high strength copper alloy. Strands shall be free from lumps, kinks, splits, scraped or corroded surfaces and skin impurities. In addition, the strands shall conform to the following requirements a
29、s applicable. 3.4.1.1 Tin-coated Copper Strands: No additional requirements. The tin coating shall be as specified in ANSI/ASTM B33-71.3.4.1.2 Silver-coated Copper Strands: The strands shall have a coating thickness of not less than 40 micro-inches of silver when tested in accordance with ANSI/ASTM
30、B298-70a. 3.4.1.3 Nickel-coated Copper Strands: The strands shall have a coating thickness of not less than 50 micro-inches of nickel when tested in accordance with ANSI/ASTM B355-69. Adhesion of the nickel coating shall be such that, after subjection to the procedures of 4.7.2.1, the strands shall
31、still pass the continuity of coating test in ANSI/ASTM B355-69. 3.4.1.4 High Strength Copper Alloy: The strands shall be of the applicable AWG gage specified in Table 1 and of such tensile properties that the conductor from the finished wire conforms to the requirements of 3.5.1.3.2 for elongation a
32、nd tensile strength. The strands shall be silver-coated or nickel-coated in accordance with 3.4.1.2 or 3.4.1.3 as applicable. SAE AS81044A Page 5 of 28TABLE 1 DETAILS OF CONDUCTORS SAE AS81044A Page 6 of 283.4.2 Insulating Material: All primary insulation shall be crosslinked polyalkene, crosslinked
33、 alkane-imide polymer, or polyarylene, as specified in the applicable specification sheet. Insulation coatings or jackets, if present, shall also be of the material specified in the specification sheet. All insulating materials, including primary insulation and coating or jacket, shall be certified
34、virgin material (3.4.2.1) containing no additives except those required as pigmentation for colors, lubricants used in extrusion and stabilizers. The physical properties of the materials shall be such that, when tested in accordance with 4.7.5.7 after extrusion on the finished wire, the insulation w
35、ill meet the elongation and tensile strength requirements set forth in the specification sheet. 3.4.2.1 Virgin Material: For purposes of this specification, virgin material shall be 100 percent new material which has been through only the processes essential to its manufacture and its application to
36、 the wire and has been through these essential processes one time only. Any material which has previously been processed in any other manner is considered nonvirgin material. This requirement shall apply to the manufacture of all ingredients and components used. 3.5 Construction Construction of the
37、wire shall be as specified herein and in the applicable military specification sheet. 3.5.1 Conductor 3.5.1.1 Stranding 3.5.1.1.1 Concentric Lay Stranding: The conductors of wire sizes 30 through 10 shall be concentric-lay conductors constructed as specified in Table 1. Concentric lay shall be inter
38、preted to be a central strand surrounded by one or more layers of helically wound strands. It is optional for the direction of lay of the successive layers to be alternately reversed (true concentric lay) or to be in the same direction (unidirectional lay). The strands shall be assembled in a geomet
39、ric arrangement of concentric layers, so as to produce a smooth and uniform conductor, circular in cross-section and free of any crossovers, high strands, or other irregularities. The direction of lay of the individual strands in the outer layer of the concentrically stranded conductors of finished
40、wire shall be left hand. The length of lay of the outer layer shall not be less than 8 nor more than 16 times the maximum conductor diameter as specified in the applicable military specification sheet. 3.5.1.1.2 Rope Lay Stranding: The conductors of wire sizes 8 through 0000 shall be rope-lay as spe
41、cified in Table 1 and in (a) and (b) below. a. Rope-lay stranded conductors shall be laid up concentrically with a central member surrounded by one or more layers of helically wound members. It is optional for the direction of lay of successive layers to be alternately reversed (true concentric lay)
42、, or to be in the same direction (unidirectional lay). The length of lay of the outer layer of rope-lay stranded members forming the conductor shall not be less than 10 or more than 14 times the outside diameter of the completed conductor. The direction of lay of the outside layer shall be either le
43、ft or right hand. b. Members of rope-lay stranded conductors: The length of lay of the wires composing the stranded members shall be not greater than 16 times the outside diameter of the member. Stranding of the individual members may be either concentric or bunch. 3.5.1.2 Splices: Splices in indivi
44、dual strands or members shall be butt brazed. There shall not be more than one strand-splice in any two lay lengths of a stranded concentric-lay conductor or in any two lay lengths of any member in a rope lay conductor, except that not more than one splice of an entire member shall be permitted in a
45、ny two lay lengths of a rope lay conductor. Splices in members of a rope lay construction shall be so finished that the conductor diameter is not increased at the point of brazing. In no case shall the whole conductor be spliced at one point. SAE AS81044A Page 7 of 283.5.1.3 Elongation and Tensile S
46、trength of Conductor 3.5.1.3.1 Soft or Annealed Copper: The individual strands removed from finished wires with soft or annealed copper conductors, wire sizes 20 and larger, or the whole soft or annealed copper conductor removed from finished wire, sizes 22 and smaller, shall have the following mini
47、mum elongation when tested in accordance with 4.7.5.6.1:Sizes 24 and smaller - 6 percent (minimum) Sizes 22 and larger - 10 percent (minimum) There shall be no tensile strength requirements for soft or annealed copper conductors. 3.5.1.3.2 High Strength Copper Alloy: The whole conductor removed from
48、 finished wires with high strength copper alloy conductors shall exhibit elongation of 6 percent, minimum, and a tensile breaking strength conforming with Table 1, when tested in accordance with 4.7.5.6.2. 3.5.1.4 Conductor Diameter: The diameter of the conductor shall be as specified in Table 1. Ap
49、plicability of the “general purpose” or of the “small diameter” Table 1 requirements for maximum conductor diameter shall be as indicated in the military specification sheet. 3.5.2 Insulation: The insulation shall be constructed as specified in the applicable specification sheet. All insulation shall be readily removable by conventional wire stripping devices without damage to the conductor. 3.5.3 Flaws Test of Primary Insulation: One
