DLA DSCC-DWG-04036 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED LIGHT WEIGHT NICKEL COATED HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY 260.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Modifications to agree with AS22759/82. Editorial changes throughout. Update format. 7/25/07 Abdo Abdouni B Added approved supplier. Editorial changes throughout 30 March 2009 Abdo Abdouni C Added approved supplier. 8 September 2010 Abdo Abdouni Prepared in

2、accordance with ASME Y14.100 Selected item drawing REV PAGE REV STATUS OF PAGES REV C B B B B B B B C 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, ELECTRIC

3、AL, COMPOSITE, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, LIGHT WEIGHT, NICKEL COATED, HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY, 260C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04036 A 037Z3 REV C PAGE 1 OF 9 AMSC N/A 6145-E097-002 .CURRENT DESIGN ACTIVITY CAGE CODE 0

4、37Z3 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 COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04036 REV B PAGE 2 FP Fluorocarbon Polym

5、er, modified Polytetrafluoroethylene (PTFE) FIGURE 1. General configuration. 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, with a light weight stranded

6、conductor. 1.2 Part or Identifying Number (PIN). The complete PIN should be as follows: 04036 - 20 - 9 1.2.1 Alloy conductor: The size 26 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

7、 sizes should be high strength copper alloy in accordance with SAE-AS22759. Wire size (see table I) DSCC drawing number Insulation color designator (see table I) CONDUCTOR, STRANDED, SMALL DIAMETER, NICKEL COATED, HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY FP / POLYIMIDE / FP TAPE FP TAPE Pro

8、vided 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 04036 REV B PAGE 3 TABLE I. Details of construction. PIN Wire size (AWG) Conductor Finished wire Stranding (number of

9、strands X AWG gauge of strands) Diameter (inches) Resistance at 20C ohms/1000ft. (max) Diameter (inches) Weight lb/1000ft. (max) Min Max Min Max 04036-26-* 26 19 X 38 .0175 .0204 58.4 .030 .034 1.43 04036-24-* 24 19 X 36 .0225 .0254 30.1 .034 .038 1.93 04036-22-* 22 19 X 34 .0285 .0314 18.6 .040 .04

10、3 2.85 04036-20-* 20 19 X 32 .0365 .0404 11.4 .048 .051 4.38 * The asterisks in the part number column of table I should be replaced by color code designators (see 1.2.2). Example: 04036-26-93 is white with an orange stripe. 1.2.2 Color. The wire insulation color should be indicated by the color des

11、ignator (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, color limits should be in accordance with MIL-STD-104, class I, or i

12、n table V of this drawing. 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 the extent specified herein. Unless otherwise specified, the issues of these documents a

13、re 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 documents are available online at https:/assist.daps.dla.mil/quicksearch/ or from the Standard

14、ization 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 otherwise specified, the issues of these documents are those cited in the solicitation or

15、 contract. ASTM INTERNATIONAL ASTM B355 - Standard Specification for Nickel Coated Soft or Annealed Copper Wire ASTM B624 - Standard Specification for High Strength, High Conductivity Copper Alloy Wire for Electronic Application ASTM D3032 - Standard Test Methods for Hookup Wire Insulation ASTM D459

16、1 - 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 Barr Harbor Drive, PO Box C700, West Conshohocken, Pennsylvania, USA 1942

17、8-2959.) 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 04036 REV B PAGE 4 NCSL INTERNATIONAL NCSL-Z540.3 - General Requirements for Calibration of Measuring and

18、Test Equipment (Copies of these documents are available from http:/www.ncsli.org or to National Conference of Standards Laboratories (NCSL), 2995 Wilderness Place, Suite 107, Boulder, CO 80301-5404.) SAE INTERNATIONAL SAE-AS4373 - Test Methods for Insulated Electric Wire SAE-AS22759 - Wire, Electric

19、al, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/82 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Light Weight, Nickel Coated, High Strength or Ultra High Strength Copper Alloy, 260C, 600 Volts (Copies of these documents are available from http:/www.sae.org/ or SAE

20、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-AS22759/82 except as specified herein. Any requirements included in this drawing should be in addition to, or s

21、upersede those requirements included in SAE-AS22759 and SAE-AS22759/82. In case of conflict between the requirements in this drawing, SAE-AS22759 and SAE-AS22759/82, the requirements of this drawing shall take precedence. 3.2 Design configuration. The design, construction, and physical dimensions sh

22、ould 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. Conductors shall be made of high strength or ul

23、tra 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 nickel coated. The nickel coating shall not be less than 50 microinches (1.27 m) w

24、hen tested in accordance with ASTM B355. 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. 1/ Tape code Thickness nominal (inches) Mater

25、ial 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-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS,

26、OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04036 REV B 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) Dielectric strength 4,000 volts/mil (average min) .0004

27、5 FP Layer Distinguishable color (next to conductor) 3.4 Wire construction and physical dimensions. See figure 1 and in tables I and IV. TABLE IV. Tape overlap requirements. 1/ Wrap 1 Wrap 2 Nominal wall thickness (mils) Wire size Tape code Percent overlap Tape code Percent overlap Min Max Min Max 2

28、6 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. 3.5 Performance testing. Wire supplied to thi

29、s drawing shall be qualified in accordance with SAE-AS22759/82 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, method 3006, the following requirements shall a

30、pply: 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 any bundle when measured along the axis. 3.5.

31、2 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 shall apply: a. Number of specimens: 5. b. Wire size to be tested: 20 AWG. c. A specimen is con

32、sidered “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. 3.5.3 Insulation state of sinter (conformance inspection test). FP layers shall be evaluated with a differential scanning calorimeter in

33、 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 homogenous. No evidence of tape edges or seams shall be present on

34、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. 3.5.4 Lamination sealing (conformance inspection test). When tested in accordance with SAE-AS4373, method 809 at 260C, there shall be no evidence of tape separation

35、 or lifting. There shall be no visible tape ridges that can contribute to tearing of the tape. 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 04036 REV B PAGE 6 3

36、.5.5 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 shall be left on the conductor when viewed with the naked eye. The following details shal

37、l 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 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 init

38、ial 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 layer. The following details shall apply: a. Wire size: 22 AWG. b. Temperature: 23C. c. Weight: 300 grams (10.6 oz). d. Edged abr

39、ading 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 replaced with an aluminum/Mylar film of similar thickness with the conductive (aluminum) side out. The conductive surface is used

40、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 surface facing down (perpendicular with the test specimen). (2) Remove approximately 1 inch (25.4 mm) of insulation from the end of

41、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, ensuring the rod is level and perpendicular to the specimen surface. (5) Zero the counter on the abrasion tester. (6) Turn the t

42、ester 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 detects continuity between the abrading rod and the conductor. (8) Record the number of cycles to failure. (9) Repeat the procedure a mi

43、nimum of 10 times (100 times preferred) to generate a statistically significant sample. (10) Average the results. 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 per

44、cent 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 V. Contrast level is defined as: CL = 3.5.9 Color (conformance

45、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 not be required after oven exposure. (Reflectance of the backgroun

46、d insulation - Reflectance of the laser mark) (Reflectance of the background insulation) 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 04036 REV B PAGE 7 TABLE V

47、. 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 2.5YR 6 7 8 10 Violet 2.5P 7.5R 7 8 4 8 Gray S

48、ame 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 du

49、rability of color marking test. a. Weight: 250 grams (8.82 oz). b. Strokes: 250 strokes (125 cycles). 3.6 Ratings. 3.6.1 Temperature rating. 260C maximum continuous conductor temperature. 3.6.2 Voltage rating. 600 Vrms at sea level. 3.7 Marking. The finished wire shall be identified by a printed marking applied to the outer surface or the wire. The identification mark shall not be applied by hot