DLA DSCC-DWG-04041 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED NORMAL WEIGHT NICKEL COATED COPPER CONDUCTOR 260 DEGREE C 600 VOLT.pdf

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1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical modifications to agree with SAE-AS22759/8. Editorial changes throughout. Update format. 8/15/2007 Abdo Abdouni B Editorial changes throughout. Update format. Added approved supplier. In revision A, the correct title of the specification should read

2、 as SAE-AS22759/87. 12 March 2009 Abdo Abdouni C Added approved supplier. 8 September 2010 Abdo Abdouni Prepared in accordance with ASME Y14.100 Selected item drawing REV PAGE REV STATUS OF PAGES REV C B B B B B B B B C C PAGE 1 2 3 4 5 6 7 8 9 10 11 PMIC PREPARED BY DEFENSE SUPPLY CENTER, COLUMBUS

3、COLUMBUS, OHIO 43218-3990 William Carpenter Original date of drawing 12 July 2004 CHECKED BY TITLE Lee Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. N

4、O. 04041 A 037Z3 REV C PAGE 1 OF 11 AMSC N/A 6145-E096-002 .CURRENT DESIGN ACTIVITY CAGE CODE 037Z3 HAS CHANGED NAMES TO: DLA LAND AND MARITIME COLUMBUS, OHIO 43218-3990 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS

5、COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04041 REV B PAGE 2 FP Fluorocarbon Polymer, modified Polytetrafluoroethylene (PTFE) FIGURE 1. General configuration. FP / POLYIMIDE / FP TAPE SIZES 26 THROUGH 10 CONDUCTOR, STRANDED, SMALL DIAMETER, NICKEL COATED COPPER FP TAPE CONDUCTOR, STRAND

6、ED, SMALL DIAMETER, NICKEL COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE SIZES 8 THROUGH 6 CONDUCTOR, STRANDED, SMALL DIAMETER, NICKEL COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE SIZES 4 THROUGH 4/0 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,

7、-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04041 REV B PAGE 3 1 SCOPE 1.1 Scope. This drawing covers the performance characteristics for a composite wire using a seamless polytetrafluoroethylene/ hydrolysis resistant polyimide tape wrap insulation system,

8、 with a normal weight stranded conductor. 1.2 Part or Identifying Number (PIN). The complete PIN should be as follows: 04041 - 20 - 9 TABLE I. Details of construction (AWG conductors). PIN. Wire size Conductor Finished wire Stranding (number of strands X gauge (AWG) of strands) Diameter (in.) Resist

9、ance at 20C ohms/1000ft (max) Diameter (in.) Weight lb/1000ft. (max) Min Max Min Max 04041-26-* 26 19 X 38 .0175 .0204 42.24 .033 .037 1.55 04041-24-* 24 19 X 36 .0225 .0244 25.9 .038 .042 2.20 04041-22-* 22 19 X 34 .0285 .0314 16.0 .043 .047 3.00 04041-20-* 20 19 X 32 .0365 .0394 9.77 .051 .055 4.5

10、5 04041-18-* 18 19 X 30 .0455 .0494 6.10 .061 .065 6.70 04041-16-* 16 19 X 29 .0515 .0554 4.76 .068 .073 8.60 04041-14-* 14 19 X 27 .0645 .0694 3.00 .081 .086 12.95 04041-12-* 12 37 X 28 .0835 .0894 1.98 .100 .105 20.1 04041-10-* 10 37 X 26 .106 .112 1.24 .122 .127 31.4 04041-8-* 8 133 X 29 .158 .16

11、9 .694 .180 .188 57.6 04041-6-* 6 133 X 27 .198 .212 .436 .219 .229 88.3 04041-4-* 4 133 X 25 .250 .268 .275 .276 .288 143 04041-2-* 2 665 X 30 .320 .340 .177 .344 .364 223 04041-1-* 1 817 X 30 .366 .380 .144 .388 .408 289 04041-01-* 0 1045 X 30 .395 .425 .113 .420 .450 345 04041-02-* 00 1330 X 30 .

12、440 .476 .089 .475 .505 432 04041-03-* 000 1665 X 30 .500 .540 .071 .530 .560 542 04041-04-* 0000 2109 X 30 .565 .605 .056 .590 .630 681 * The asterisks in the PIN column of table I should be replaced by color code designators (see 1.2.1). Example: 04041-26-93 is white with an orange stripe. 1.2.1 C

13、olor. The wire insulation color should be indicated by the color designator (see 1.2) and as specified in the contract or purchase order. The insulation color should be in accordance with MIL-STD-681, system 1, differentiation color coding chassis wiring (3 numbers maximum). For laser marked wires,

14、color limits should be in accordance with MIL-STD-104, class I, or in accordance with table V of this drawing. Wire size (see table I or II) DSCC drawing number Insulation color designator (see table I or II) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from I

15、HS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04041 REV B PAGE 4 2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to th

16、e extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. DEPARTMENT OF DEFENSE STANDARDS MIL-STD-104 - Limits for Electrical Insulation Color MIL-STD-2223 - Test Methods for Insulated Electric Wire (Copies of these document

17、s are available online at https:/assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.2 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless oth

18、erwise specified, the issues of these documents are those cited in the solicitation or contract. ASTM INTERNATIONAL ASTM B355 - Standard Specification for Nickel Coated Soft or Annealed Copper Wire ASTM D3032 - Standard Test Methods for Hookup Wire Insulation ASTM D4591 - Standard Test Method for De

19、termining Temperatures and Heats of Transitions of Fluoropolymers by Differential Scanning Calorimetry (Copies of these documents are available from http:/www.astm.org/ or ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, Pennsylvania, USA 19428-2959.) NCSL INTERNATIONAL NCS

20、L Z540.3 - General Requirements for Calibration of Measuring and Test Equipment (Copies of these documents are available online at http:/www.ncsli.org or from NCSL International 2995 Wilderness Place, Suite 107 Boulder, Colorado 80301-5404.) SAE INTERNATIONAL SAE-AS4373 - Test Methods for Insulated

21、Electric Wire SAE-AS22759 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/87 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal Weight, Silver Coated, Copper Conductor, 200C, 600 Volts (Copies of these documents are available from http:/www.sae.or

22、g/ or SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04041 REV B PAGE 5 3. REQUIREMENTS 3.1

23、 DSCC requirements. Items described in this drawing shall meet the requirements specified in SAE-AS22759 and SAE-AS22759/87 except as specified herein. Any requirements included in this drawing shall be in addition to, or supersede those requirements included in SAE-AS22759 and SAE-AS22759/87. In ca

24、se of conflict between the requirements in this drawing, SAE-AS22759 and SAE-AS22759/87, the requirements of this drawing shall take precedence. 3.2 Design configuration. The design, construction, and physical dimensions shall be as specified in this drawing. 3.2.1 Design documentation. Design docum

25、entation shall be retained by the manufacturer and shall be available upon request for review by the contracting activity, DSCC, or contractor. 3.3 Material. 3.3.1 Conductor. Material shall be made of soft annealed copper wire in accordance with ASTM B355. All strands shall be free from lumps, kinks

26、, splits, scarred or corroded surfaces and skin impurities. Strands shall be nickel coated. The nickel coating shall not be less than 50 microinches (1.27 m) when tested in accordance with ASTM B355. 3.3.2 Insulation. Insulation shall be polytetrafluoroethylene and polytetrafluoroethylene/polyimide

27、tape specified in tables II and III. The polyimide tape shall be hydrolysis resistant. TABLE II. Wire insulation materials. 1/ Tape code Thickness nominal (inches) Material 1 .0020 .0005 FP/.0010 polyimide/.0005 FP 2 .0010 FP (Skived) 3 .0020 FP (Skived) 4 .0020 FP (Unsintered) 5 .0025 FP (Unsintere

28、d) 6 .0030 FP (Unsintered) 1/ Physical properties of PTFE unsintered tape shall be in accordance with SAE-AS22759. TABLE III. Physical properties of FP/Polyimide/FP tapes. Tensile strength 19,000 lb/in2(average min) Tensile modulus 350,000 lb/in2(average min) Elongation 40 percent (average min) Diel

29、ectric strength 4,000 volts/mil (average min) .0005 FP Layer Distinguishable color (next to conductor) may be used at manufacturers option Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CA

30、GE CODE DWG NO. A 037Z3 04041 REV B PAGE 6 3.4 Wire construction and physical dimensions. See figure 1 and tables I and IV. TABLE IV. Tape overlap requirements. 1/ Wrap 1 Wrap 2 Wrap 3 Wrap 4 Nominal wall thickness (mils) 2/ Wire size Tape code Percent overlap Tape code Percent overlap Tape code Per

31、cent overlap Tape code Percent overlap Min Max Min Max Min Max Min Max 22 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 20 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 18 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 16 1 50.5 54.0 5 50.5 54.0 - - - - - - 8.3 14 1 50.5 54.0 5 50.5 54.0 - - - - - - 8.3 12 1 50.5 54.0

32、 6 50.5 54.0 - - - - - - 9.1 10 1 50.5 54.0 6 50.5 54.0 - - - - - - 9.1 8 2 20.5 35 1 50.5 55.0 6 67.0 71.0 - - - 13.2 6 2 20.5 35 1 50.5 55.0 6 67.0 71.0 - - - 13.2 4 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 2 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1 3 20.5 35 1 50.5 55.0 6 50

33、.5 54.0 6 50.5 54.0 16.2 1/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 2/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 3/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 4/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1/ Wrap 1 is innermost tape which is in contact with th

34、e conductor. 3.5 Performance testing. Wire supplied to this drawing shall be qualified in accordance with SAE-AS22759/87 and shall meet any additional requirements of this drawing. 3.5.1 Wet arc propagation resistance (test required for initial qualification only). When tested in accordance with MIL

35、-STD-2223, method 3006, the following requirements shall be met: a. A minimum of 70 wires shall pass the impulse dielectric test of SAE-AS22759. b. Not more than two wires shall fail the impulse dielectric test in any one bundle. c. Actual damage to the wire shall be not more than 1.0 inch (25.4 mm)

36、 in length in any bundle when measured along the axis. 3.5.2 Solderability. Not applicable. 3.5.3 Forced hydrolysis (test required for initial qualification only). When tested in accordance with SAE-AS4373, method 602, the minimum average performance shall be 5000 hours at 70C. The following details

37、 shall apply: a. Number of specimens: 5. b. Wire size to be tested: 20 AWG. c. A specimen is considered “failed” when it can no longer pass the dielectric test method of SAE-AS4373 method 602. d. Average the time to failure for all of the specimens evaluated. Provided by IHSNot for ResaleNo reproduc

38、tion or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04041 REV B PAGE 7 3.5.4 Insulation state of sinter (conformance inspection test). FP layers shall be evaluated with a differential scanning calorimeter sp

39、ecified in ASTM D4591. The FP layers shall meet the following requirements: a. First heat: Less than 25 Joules/gram (J/g). b. Second heat: Maximum 2 J/g change when compared to first heat. c. Bonding between FP layers shall be homogenous. No evidence of tape edges or seams shall be present on the ou

40、ter FP layer when visually examined with the unaided eye. The outer surface will be smooth and free of tape edges at the overlap. 3.5.5 Lamination sealing (conformance inspection test). When tested in accordance with AS4373 method 809 at 260C, there shall be no evidence of tape separation or lifting

41、. There shall be no visible tape ridges that can contribute to tearing of the tape. 3.5.6 Strippability (conformance inspection test). There shall be no evidence of separation or elongation of FP layers when stripped with standard hand held tools designed for such use. No evidence of insulation shal

42、l be left on the conductor when viewed with the naked eye. The following details shall apply: a. Test size: 26 AWG - 14 AWG wire only in accordance with ASTM D3032 section 27. b. Length of insulation slugs shall be .25 inches (6.35 mm). c. The strip force shall be as follows: Wire size (AWG) Minimum

43、 force Maximum force 26 - 20 0.25 lbs 6.0 lbs 18 - 14 0.50 lbs 7.0 lbs 3.5.7 Durability (PTFE outer layer) (Test required for initial qualification only). When tested as specified below, the wire shall withstand an average of 100 cycles without failure due to tear or surface cut through of the outer

44、 layer. The following details shall apply: a. Wire size: 22 AWG. b. Temperature: 23C. c. Weight: 300 grams (10.6 oz). d. Edged abrading rod diameter: .026 inch (0.66 mm) nominal. e. Test specimens shall be manufactured to emulate the wire construction specified herein, except the polyimide shall be

45、replaced with an aluminum/Mylar film of similar thickness with the conductive (aluminum) side out. The conductive surface is used in a circuit path to determine when the abrading rod has penetrated the PTFE layer. f. Test method: (1) Install a .026 inch (0.66 mm) edged abrading rod with the edged su

46、rface facing down (perpendicular with the test specimen). (2) Remove approximately 1 inch (25.4 mm) of insulation from the end of the specimen and connect the circuit detection clip to the exposed conductor. (3) Apply the appropriate weights to the fixture. (4) Place the abrading rod on the specimen

47、, ensuring the rod is level and perpendicular to the specimen surface. (5) Zero the counter on the abrasion tester. (6) Turn the tester on. The rod will begin to oscillate over the surface of the specimen with an approximate 1 inch (25.4 mm) stroke. (7) The test will continue until the tester detect

48、s continuity between the abrading rod and the conductor. (8) Record the number of cycles to failure. (9) Repeat the procedure a minimum of 10 times (100 times preferred) to generate a statistically significant sample. (10) Average the results. Provided by IHSNot for ResaleNo reproduction or networki

49、ng permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04041 REV B PAGE 8 3.5.8 UV laser marking (test required for initial qualification only). When marked with an ultraviolet (UV) laser source at 1.5 J/cm2, white FP tape shall have a contrast level of 65 percent minimum average and colored FP tape