1、 AMSC N/A FSC 6145 INCH-POUND MIL-DTL-25038J 10 January 2012 SUPERSEDING MIL-DTL-25038H 9 September 2005 DETAIL SPECIFICATION WIRE, ELECTRICAL, HIGH TEMPERATURE, FIRE RESISTANT, AND FLIGHT CRITICAL This specification is approved for use by all Departments and Agencies of the Department of Defense. 1
2、. SCOPE 1.1 Scope. This specification covers insulated single wire for electrical use in flight critical circuits and under short-time emergency conditions involving exposure to flames with temperatures up to 2,000 F (see 6.1). 1.2 Part or Identifying Number (PIN). The PIN (see 6.2) consists of the
3、letter “M”, which indicates a defense specification item; the basic number of the specification sheet; and a coded number, as shown in the following example: M25038/1 - 22 1/- 9 - A2/Defense specification Wire size Color - Flight critical sheet (see 1.2.1) (see 1.2.2) 1/ For MIL-DTL-25038/3, the hea
4、vier wall construction has an “H” designator added to the PIN. 2/ Only for flight critical applications. 1.2.1 Wire size. The wire size is identified by a number indicating the conductor wire size (AWG). Comments, suggestions, or questions on this document should be addressed to DLA Land and Maritim
5、e, ATTN: VAI, P.O. Box 3990, Columbus, OH 43218-3990, or email to WireCabledla.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https:/assist.daps.dla.mil. Provided by IHSNot for ResaleNo reproduction or ne
6、tworking permitted without license from IHS-,-,-MIL-DTL-25038J 2 1.2.2 Color. The insulation color is identified by a series of numbers. The first number is the color of the insulation; the second number represents the color of the first stripe or band; the third number, the color of the second stri
7、pe or band, and so on. The colors and their corresponding numbers are shown in table I. TABLE I. Color code. Number designator Color Number designator Color 0 Black 5 Green 1 Brown 6 Blue 2 Red 7 Violet (purple) 3 Orange 8 Gray (slate) 4 Yellow 9 White 2. APPLICABLE DOCUMENTS 2.1 General. The docume
8、nts listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this l
9、ist, document users are cautioned that they must meet all specified requirements documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed. 2.2 Government documents. 2.2.1 Specifications, standards and handbooks. The following specifications, standards and handbook
10、s form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.2). FEDERAL STANDARD FED-STD-228 - Cable and Wire, Insulated; Methods of Testing DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-PR
11、F-5606 - Hydraulic Fluid, Petroleum Base: Aircraft, Missile, and Ordnance MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-PRF-7808 - Lubricating Oil, Aircraft Turbine Engine, Synthetic Base MIL-DTL-12468 - Decontaminating Agent, STB MIL-PRF-23699 - Lubricating Oil, Aircraft Turbine E
12、ngine, Synthetic Base, NATO Code O-156 MIL-DTL-25038/1 - Wire, Electrical, High Temperature, Fire Resistant, Flight Critical, Normal Weight MIL-DTL-25038/3 - Wire, Electrical, High Temperature, Fire Resistant, Flight Critical, Light Weight, Small Diameter Provided by IHSNot for ResaleNo reproduction
13、 or networking permitted without license from IHS-,-,-MIL-DTL-25038J 3 MIL-DTL-83133 - Turbine Fuels, Aviation, Kerosene Types, NATO F-34(JP-8), NATO F-35, and JP-8 + 100 DEPARTMENT OF DEFENSE STANDARDS MIL-STD-104 - Limits for Electrical Insulation Color MIL-STD-2223 - Insulated Electrical Wire, Te
14、st Methods for (Copies of these documents are available online at https:/assist.daps.dla.mil or from the Standardization Document Order Desk, Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.) 2.3 Non-Government publications. The following documents form a part of this document to the e
15、xtent specified herein. Unless otherwise specified, the documents are the issues of the documents of the documents cited in the solicitation or contract (see 6.2). ASTM INTERNATIONAL ASTM B263 - Standard Method for Determination of Cross-Sectional Area of Stranded Conductors ASTM B355 - Standard Spe
16、cification for Nickel-Coated Soft or Annealed Copper Wire ASTM B624 - Standard Specification for High Strength, High Conductivity, Copper-Alloy Wire for Electronic Application ASTM D910 - Standard Specification for Aviation Gasolines (Copies of these documents are available online at http:/www.astm.
17、org or from ASTM International, P.O. Box C700, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.) NCSL INTERNATIONAL NCSL Z540.3 - Calibration Laboratories and Measuring and Test Equipment, General Requirements (Copies of this document are available from http:/www.ncsli.org or from NCSL Inter
18、national, 2995 Wilderness Place, Suite 107, Boulder, CO 80381-5404.) NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA-WC 56 - 3.0 kHz Insulation Continuity Proof Testing for Wire and Cable (Copies of this document are available from http:/www.nema.org or from the National Electrical Manufac
19、turers Association, 1300 North 17th Street, Suite 1847, Rosslyn, VA 22209.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-25038J 4 SAE INTERNATIONAL SAE J1966 - Lubricating Oil, Aircraft Piston Engine (Nondispersant Mineral Oil) SAE AS1241
20、- Fire Resistant Phosphate Ester Hydraulic Fluid for Aircraft (Copies of these documents are available online at from http:/www.sae.org or from the SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001.) 2.4 Order of precedence. In the event of a conflict between the text of this docu
21、ment and the references cited herein, (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. REQUIREMENTS 3.1 Specification sheets. The indi
22、vidual item requirements shall be as specified herein and in accordance with the applicable specification sheets. In the event of any conflict between requirements of this specification and the specification sheet, the latter shall govern. 3.2 Qualification. Wires furnished under this specification
23、shall be products that are authorized by the qualifying activity for listing on the applicable qualified products list before contract award (see 6.6). 3.3 Materials. 3.3.1 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials shou
24、ld be used to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life-cycle costs. 3.3.2 Conductor material. Strands used in the manufacture of conductors shall be in accordance with ASTM B355,
25、 class 27, or ASTM B624 coated with 27% nickel by weight, as specified in the applicable specification sheet. 3.3.3 Insulating materials. 3.3.3.1 Primary insulation. The primary insulation shall consist of a concentric layer of glass fibers, ceramics, or layers of glass tape and tetrafluoroethylene
26、tape, or a combination of materials capable of withstanding 650F for 100 hours, and shall meet resistance, voltage, current, and other requirements specified herein or on the applicable specification sheet. Where fibrous primary insulation is used, the material shall be thoroughly impregnated with a
27、 silicone resin or other suitable compound so applied that it will not enter the strands of the conductor and affect good electrical contact. Asbestos shall not be used. 3.3.3.2 Outer layer. The outer layer of the wire shall consist of a closely woven braid of glass fiber impregnated with polytetraf
28、luoroethylene (PTFE), extruded PTFE, or tape-wrapped and cured PTFE. 3.4 Design and construction. 3.4.1 Conductors. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-25038J 5 3.4.1.1 Stranding. 3.4.1.1.1 Concentric-lay. Wire sizes 22 through 12
29、 shall be constructed with concentric-lay conductors and as specified in table II. Concentric-lay shall be interpreted to be a central core surrounded by one or more layers of helically wound strands. It is optional for the direction of lay for successive layers to be alternately reversed (true conc
30、entric-lay) or to be in the same direction (unidirectional lay). If the direction of lay for the successive layers is the same, the pitch or length of lay shall increase with each successive layer. The direction of lay of individual strands in the outer layer of the concentrically stranded conductor
31、s of finished wire sizes 22 through 12 shall be left hand. The length of lay in the outer layer shall be not less than 8 nor more than 16 times the maximum conductor diameter specified in table II. 3.4.1.1.2 Rope lay. Wire sizes 10 through 0000 shall be rope lay and as specified in table II and as f
32、ollows: a. Rope lay stranded conductors shall be laid up concentrically with a center core surrounded by one of more helically wound members. It is optional for the direction of lay for successive layers to be alternately reversed (true concentric-lay) or to be in the same direction (unidirectional
33、lay). The length of lay of the outer layer of rope lay stranded member forming the conductor shall be not less than 8 nor more than 14 times the outside diameter of the completed conductor. The direction of lay of the outside layer may be either left or right hand. b. Members of rope lay stranded co
34、nductors. The length of lay of the conductors composing the stranded members shall be not greater than 16 times the outside diameter of the member. Stranding of the individual members may be concentric or bunch. 3.4.1.2 Splices. Splices in individual strands or members shall be butt brazed. There sh
35、all be not more than one strand splice in any 10-foot length of a stranded concentric-lay conductor. There shall not be more than one splice in any 10-foot length of any member in a rope lay conductor, except that not more than one splice of an entire member shall be permitted in any 10 feet of a ro
36、pe 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. Provided by IHSNot for ResaleNo reproduction or networking permitted without licens
37、e from IHS-,-,-MIL-DTL-25038J 6 TABLE II. Wire construction details. Wire size Nominal CMA 1/of conductor (circular mils) Minimum CMA 1/of conductor (circular mils) K value Stranding number of strands x size (AWG) Allowable number of missing strands Nominal diameter of individual strands inch/(mm) M
38、aximum diameter of stranded conductor inch/(mm) 22 754 694 1.87 19 x 34 0 .0063/(.16) .033/(.84) 20 1,216 1,127 1.34 19 x 32 0 .0080/(.203) .041/(1.04) 18 1,900 1,770 1.34 19 x 30 0 .0100/(.254) .052/(1.32) 16 2,426 2,261 1.19 19 x 29 0 .0113/(.287) .061/(1.57) 14 3,831 3,570 1.38 19 x 27 0 .0142/(.
39、361) .074/(1.88) 12 6,088 5,672 1.67 19 x 25 0 .0179/(.455) .093/(2.36) 10 9,880 9,208 4.22 49 x 27 0 .0142/(.361) .128/(3.25) 8 16,983 15,827 2.29 133 x 29 0 .0113/(.287) .176/(4.47) 6 26,818 24,994 2.31 133 x 27 0 .0142/(.361) .218/(5.54) 4 42,615 39,715 2.55 133 x 25 0 .0179/(.455) .272/(6.91) 2
40、66,500 61,344 3.21 665 x 30 2 .0100/(.254) .345/(8.76) 1 81,700 75,365 2.89 817 x 30 2 .0100/(.254) .384/(9.75) 0 104,500 96,397 3.24 1,045 x 30 3 .0100/(.254) .432/(11.0) 00 133,000 122,687 3.15 1,330 x 30 3 .0100/(.254) .490/(12.4) 000 167,200 166,500 3.09 1,665 x 30 4 .0100/(.254) .548/(13.9) 000
41、0 210,900 194,547 3.32 2,109 x 30 5 .0100/(.254) .615/(15.6) 1/ Circular mil area (CMA) 3.4.2 Insulation. 3.4.2.1 Removability of insulation. The insulation layer, or layers, shall be formed concentrically around the conductor. The insulation shall fit the conductor snugly but strip freely without a
42、dherence or damage to the conductor when removed by conventional wire stripping devices. 3.4.2.2 Concentricity. The primary insulation shall be formed concentrically around the conductor. When measured in accordance with 4.6.2 , the concentricity shall be not less than 70 percent. 3.4.2.3 Color. The
43、 color of the outer layer and any stripes shall be in accordance with MIL-STD-104, class 2. 3.5 Finished wire diameter. The diameter of the finished wire shall be as specified in the applicable specification sheet. 3.6 Finished wire weight. The weight of the finished wire shall be as specified in th
44、e applicable specification sheet. 3.7 Performance. 3.7.1 Conductor tensile strength and elongation. Strands of the finished wire shall have a tensile strength of not less than 35,000 psi and an elongation of not less than 10 percent for regular strength conductors. For high strength copper alloy con
45、ductors, the tensile strength shall be not less than 55,000 psi and the elongation shall be not less than 6 percent. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-25038J 7 3.7.2 High temperature endurance. The resistance of the conductor sh
46、all not increase more than 15 percent during conditioning at 650 F. 3.7.3 Bend. A wire shall show no visible cracks when bent around a mandrel with the diameter specified in the applicable specification sheet. 3.7.4 Wet dielectric. A wire shall show no evidence of electrical breakdown (arcing or fla
47、shing) between the conductor and salt water after being immersed for 5 hours at room temperature and having a potential of 1,500 V rms at 60Hz applied after the immersion period. 3.7.5 Conductor resistance. The conductor resistance of the finished wire shall be as specified in the applicable specifi
48、cation sheet. 3.7.6 Fluid immersion. The wire shall meet the bend and wet dielectric requirements of 3.7.3 and 3.7.4 after being immersed for 8 hours at the temperatures and in the types of fluids specified in 4.6.7. 3.7.7 Cold bend. The wire shall show no evidence of cracking of the outer surface o
49、f the insulation and shall meet the wet dielectric requirements of 3.7.4 after being exposed to a cold temperature of -65F for 4 hours and bent as specified in the applicable specification sheet. 3.7.8 Flame resistance. The insulation shall be flame resistant. No insulation shall flake or fall off during exposure to flame up to 2,000F. At no time shall the insulation resistance be less than 50
