DLA DSCC-DWG-04035 REV B-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED LIGHT WEIGHT SILVER COATED HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY 200.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical modifications to agree with SAE-AS22759/81. Editorial changes throughout. Update format. Added approved supplier. 13 March 2009 Abdo Abdouni B Added approved supplier. 8 September 2010 Abdo Abdouni Prepared in accordance with ASME Y14.100 Selected

2、item drawing REV PAGE REV STATUS OF PAGES REV B A A A A A A A B PAGE 1 2 3 4 5 6 7 8 9 PMIC PREPARED BY DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OHIO 43218-3990 William Carpenter Original date of drawing 12 July 2004 CHECKED BY TITLE Lee Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYTETRAFLUOROETHYLENE

3、/POLYIMIDE INSULATED, LIGHT WEIGHT, SILVER COATED, HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY, 200C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04035 A 037Z3 REV B PAGE 1 OF 9 AMSC N/A 6145-E097-001 .CURRENT DESIGN ACTIVITY CAGE CODE 037Z3 HAS CHANGED NAMES TO: DLA LAND AN

4、D MARITIME COLUMBUS, OHIO 43218-3990 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 04035 REV A PAGE 2 1 SCOPE 1.1 Scope. This drawing covers the performance char

5、acteristics for a composite wire using a seamless polytetrafluoroethylene/ hydrolysis resistant polyimide tape wrap insulation system, with a light weight stranded conductor. 1.2 Part or Identifying Number (PIN). The complete PIN should be as follows: 04035 - 20 - 9 1.2.1 Alloy conductor. The size 2

6、6 conductor should be ultra - high strength copper alloy. The breaking strength should be 21.5 lbs. (min.) and the conductor elongation 6.0% (min.). All other gauge sizes should be high strength copper alloy in accordance with SAE-AS22759. FP Fluorocarbn Polymer, modified Poltetrafluprpethylene (PTF

7、E) FIGURE 1. General configuration. Wire size (see table I) DSCC drawing number Insulation color designator (see table I) CONDUCTOR, STRANDED, SMALL DIAMETER, SILVER COATED, HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY FP / POLYIMIDE / FP TAPE FP TAPE Provided by IHSNot for ResaleNo reproductio

8、n or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04035 REV A PAGE 3 TABLE I. Details of construction. PIN Wire size (AWG) Conductor Finished wire Stranding (number of strands X gauge (AWG) of strands) Diamet

9、er (inches) Resistance At 20C ohms/1000ft. (max) Diameter (inches) Weight lb/1000ft. (max) Min Max Min Max 04035-26-* 26 19 X 38 .0175 .0204 56.4 .030 .034 1.43 04035-24-* 24 19 X 36 .0225 .0244 28.4 .034 .038 1.93 04035-22-* 22 19 X 34 .0285 .0314 17.5 .040 .043 2.85 04035-20-* 20 19 X 32 .0365 .03

10、94 10.7 .048 .051 4.38 * The asterisks in the part number column in table I should be replaced by color code designators (see 1.2.2). Example: 04035-26-93 is white with an orange stripe. 1.2.2 Color. The wire insulation color should be indicated by the color designator (see 1.2) and as specified in

11、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, color limits should be in accordance with MIL-STD-104, class I, or in accordance with table V of this draw

12、ing. 2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.2 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the so

13、licitation or contract. DEPARTMENT OF DEFENSE STANDARDS MIL-STD-104 - Limits for Electrical Insulation Color MIL-STD-202 - Test Method Standard Electronic and Electrical Component Parts MIL-STD-2223 - Test Methods for Insulated Electric Wire (Copies of these documents are available online at https:/

14、assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these

15、 documents are those cited in the solicitation or contract. ASTM INTERNATIONAL ASTM B298 - Standard Specification for Silver Coated Soft or Annealed Copper Wire for Electronic Purposes ASTM B624 - Standard Specification for High Strength, High Conductivity Copper Alloy Wire for Electronic Applicatio

16、n ASTM D3032 - Standard Test Methods for Hookup Wire Insulation ASTM D4591 - Standard Test Method for Determining 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

17、Barr Harbor Drive, PO Box C700, West Conshohocken, Pennsylvania, USA 19428-2959.) 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 04035 REV A PAGE 4 NCSL INTERNATI

18、ONAL NCSL 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 In

19、sulated Electric Wire SAE-AS22759 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/81 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Light Weight, Silver Coated, High Strength or Ultra High Strength Copper Alloy, 200C, 600 Volts (Copies of these docum

20、ents are available from http:/www.sae.org/ or SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001). 3. REQUIREMENTS 3.1 DSCC requirements. Items described in this drawing shall meet the requirements of SAE-AS22759 and SAE-AS22759/81 except as specified herein. Any requirements inclu

21、ded in this drawing shall be in addition to, or supersede those requirements included in SAE-AS22759 and SAE-AS22759/81. In case of conflict between the requirements in this drawing, SAE-AS22759 and SAE-AS22759/81, the requirements of this drawing shall take precedence. 3.2 Design configuration. The

22、 design, construction, and physical dimensions shall be as specified in this drawing. 3.2.1 Design documentation. Design documentation 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.

23、 Conductors shall be made of high strength or ultra high strength copper alloy wire in accordance with ASTM B624 and in table I of this drawing. All strands shall be free from lumps, kinks, splits, scarred or corroded surfaces and skin impurities. Strands shall be silver coated. The silver coating s

24、hall not be less than 40 microinches (1.02 m) when tested in accordance with ASTM B298. 3.3.2 Insulation. Insulation shall be polytetrafluoroethylene and polytetrafluoroethylene/polyimide tape in tables II and III. The polyimide tape shall be hydrolysis resistant. TABLE II. Wire insulation materials

25、. 1/ Tape code Thickness Nominal (inches) Material 1 2 .0012 .0020 .00045 FP/.00065 polyimide/.0001 FP FP (Unsintered) 1/ Physical properties of PTFE unsintered tape shall be in accordance with SAE-AS22759. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS

26、-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04035 REV A PAGE 5 TABLE III. Physical properties of FP/Polyimide/FP tapes. Tensile strength 20,000 lb/in2(average min) Tensile modulus 400,000 lb/in2(average min) Elongation 40 percent (average min) Dielectr

27、ic strength 4,000 volts/mil (average min) .00045 FP Layer Distinguishable color (next to conductor) 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 Nominal wall thickness (mils) Wire size Tape code Percent overlap

28、 Tape code Percent overlap Min Max Min Max 26 1 50.5 54.0 2 50.5 54.0 5.8 24 1 50.5 54.0 2 50.5 54.0 5.8 22 1 50.5 54.0 2 50.5 54.0 5.8 20 1 50.5 54.0 2 50.5 54.0 5.8 1/ Wrap 1 is innermost tape which is in contact with the conductor, with the .00045 inch FP side of the tape against the conductor. 3

29、.5 Performance testing. Wire supplied to this drawing shall be qualified in accordance with SAE-AS22759/81 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-STD-2223, met

30、hod 3006, the following requirements shall apply: a. A minimum of 68 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) in length in a

31、ny bundle when measured along the axis. 3.5.2 Solderability (conformance inspection test). The conductor shall meet the solderability requirements for stranded conductors in accordance with MIL-STD-202, method 208. The following details shall apply: a. Unless otherwise specified, five specimens shal

32、l be prepared and tested for solderability using method 208 of MIL-STD-202. b. The specimens shall be tested without steam aging using a type R flux. 3.5.3 Forced hydrolysis (test required for initial qualification only). When tested in accordance with SAE-AS4373, method 602, the minimum average per

33、formance shall be 5000 hours at 70C. The following details 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 spe

34、cimens evaluated. 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 04035 REV A PAGE 6 3.5.4 Insulation state of sinter (conformance inspection test). FP layers shal

35、l be evaluated with a differential scanning calorimeter in accordance with 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 homogenou

36、s. No evidence of tape edges or seams shall be present on the outer 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 SAE-AS4373 method 8

37、09 at 200C, there shall be no evidence of tape separation or lifting. 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 h

38、and held tools using proper stripping blades. No evidence of insulation shall be left on the conductor when viewed with the naked eye. The following details shall apply: a. Test size: 26 AWG to 20 AWG in accordance with ASTM D3032 section 27. b. Length of insulation slugs shall be .25 inches. c. The

39、 strip force shall be as follows: Wire size (AWG) Minimum force Maximum force 26 20 0.25 lbs 6.0 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 su

40、rface cut through of the outer 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,

41、except the polyimide shall be 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

42、abrading rod with the edged surface 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 th

43、e abrading rod on the specimen, 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 co

44、ntinue until the tester detects 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 Res

45、aleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04035 REV A PAGE 7 3.5.8 UV laser marking (test required for initial qualification only). When marked with an ultraviolet (UV) laser source a

46、t 1.5 J/cm2, white FP tape shall have a contrast level of 65 percent minimum average and colored FP tape shall have a 62 percent minimum average. This requirement applies to the outer most FP insulation layer. Non-white insulation colors shall meet the Munsell color limit requirements shown in table

47、 V. Contrast level is defined as: CL = 3.5.9 Color (conformance inspection test). Colors shall be in accordance with MIL-STD-104, class 1, except for UV laser markable wire as shown in table V. White is the preferred background insulation color. Color conformity to the limits of MIL-STD-104 shall no

48、t be required after oven exposure. TABLE V. Munsell color limits for UV laser markable wire. Color Hue Value Chroma From To Min Max From To Black 2.5RN 2.5RN 7 8.5 N/A N/A Blue 5PB 7.5B 7 8 4 6 Green 2.5G 7.5G 7 9 2 6 Red 10RP 5R 7 8 4 6 Yellow 5Y 10Y 8 9 4 6 Brown 2.5YR 7.5R 7 9 2 4 Orange 10R 2.5Y

49、R 6 7 8 10 Violet 2.5P 7.5R 7 8 4 8 Gray Same as black Same as black Same as black Same as black Same as black Same as black 3.5.10 Color striping or banding durability (conformance inspection test). Colored stripes or bands shall meet the durability of color marking requirements specified in SAE-AS22759. The following shall apply to the durability of color marking test. a. Weight: 250 grams (8.82