DLA DSCC-DWG-04043 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED NORMAL WEIGHT SILVER COATED HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY 20.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Modifications to agree with SAE AS22759/89. Editorial changes throughout. 6/22/07 Lee Suroweic B Technical modifications to agree with SAE-AS22759/90. Editorial changes throughout. Update format. Added approved supplier. March 1, 2009 Abdo Abdouni C Added ap

2、proved 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 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 drawin

3、g 12 July 2004 CHECKED BY TITLE Lee Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY, 200C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04043 A 037Z3 REV C PAGE 1 OF 9

4、 AMSC N/A 6145-E097-007 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 COLUMBUS, OH 43218-3990 SIZE CAGE CO

5、DE DWG NO. A 037Z3 04043 REV B PAGE 2 FP Fluorocarbon Polymer, modified Polytetrafluoroethylene (PTFE) FIGURE 1. General configuration. 1 SCOPE 1.1 Scope. This drawing covers the performance characteristics for a composite wire using a PTFE/ hydrolysis resistant polyimide tape wrap insulation system

6、, with a light weight stranded conductor. 1.2 Part or Identifying Number (PIN). The complete PIN should be as follows: 04043 - 20 - 9 1.2.2 Copper alloy conductor. The copper-alloy conductor for size 26 conductor should be ultra - high strength copper alloy. The breaking strength should be 21.5 lbs.

7、 (min.) and the conductor elongation 6.0% (min.). All other gauge 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, SILVER COATED, HIGH STRENGTH OR ULTR

8、A HIGH STRENGTH COPPER ALLOY FP / POLYIMIDE / FP TAPE FP 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 04043 REV B PAGE 3 TABLE I. Details of construction.

9、PIN Wire size (AWG) Conductor Finished wire Stranding (number of strands X gauge (AWG) of strands) Diameter (inches) Resistance at 20C ohms/1000ft. (max) Diameter (inches) Weight lb/1000ft. (max) Min Max Min Max 04043-26-* 26 19 X 38 .0175 .0204 56.4 .033 .037 1.55 04043-24-* 24 19 X 36 .0225 .0244

10、28.4 .038 .042 2.15 04043-22-* 22 19 X 34 .0285 .0314 17.5 .043 .047 3.00 04043-20-* 20 19 X 32 .0365 .0395 10.7 .051 .055 4.55 * The asterisks in the PIN column should be replaced by color code designators (see 1.2.3). Example: 04TBD-26-93 is white with an orange stripe. 1.2.3 Color. The wire insul

11、ation color should be indicated by the color designator (see 1.2) and as specified in the contract or 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 acc

12、ordance with MIL-STD-104, class I, or in table V of this drawing. 2. APPLICABLE DOCUMENTS 2.1 General. The documents 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

13、 for additional information or as examples. While every effort has been made to ensure the completeness of this list, 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 Governme

14、nt documents. 2.2.1 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 are those cited in the solicitation or contract. FEDERAL STANDARD

15、S MIL-STD-104 - Limits for Electrical Insulation Color MIL-STD-681 - Identification Coding and Application of Hookup and Lead Wire 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 Standardiz

16、ation Document Order 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 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 c

17、ontract. 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 04043 REV B PAGE 4 ASTM INTERNATIONAL ASTM B298 - Standard Specification for Silver Coated Soft or Anneale

18、d Copper Wire for Electronic Purposes 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 D4591 - Standard Test Method for Determining Temperatures and Heats of Transit

19、ions 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 NCSL - Z540.3 - General Requirements for Calib

20、ration 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 Electric Wire SAE-AS22759 - Wire, Electri

21、cal, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/89 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal Weight, Silver Coated, High Strength or Ultra High Strength Copper Alloy, 200C, 600 Volts (Copies of these documents are available from http:/www.sae.org/ or SA

22、E 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-AS22759/89 except as specified herein. Any requirements included in this drawing shall be in addition to, or

23、supersede those requirements included in SAE-AS22759 and SAE-AS22759/89. In case of conflict between the requirements in this drawing, SAE-AS22759 and SAE-AS22759/89, the requirements of this drawing shall take precedence. 3.2 Design configuration. The design, construction, and physical dimensions s

24、hall 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. Provided by IHSNot for ResaleNo reproduction or networking permitted without l

25、icense from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04043 REV B PAGE 5 3.3 Material. 3.3.1 Conductor. Conductors shall be made of high strength or ultra high strength copper-alloy wire in accordance with ASTM B624, and 1.2.1 and table I of this

26、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 shall not be less than 50 microinches (1.27 m) when tested in accordance with ASTM B298. 3.3.2 Insulation. Insulation shall be polytetraf

27、luoroethylene and polytetrafluoroethylene/polyimide tape as 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 2 .0020 .0020 .0005 FP/.0010 polyimide/.0005 FP FP (Unsintered) 1/ Phy

28、sical 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) Dielectric strength 4,000 volts/mil (

29、average min) .0005 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 Tape code Percent overlap Min

30、 Max Min Max 26 1 50.5 54.0 2 50.5 54.0 7.4 24 1 50.5 54.0 2 50.5 54.0 7.4 22 1 50.5 54.0 2 50.5 54.0 7.4 20 1 50.5 54.0 2 50.5 54.0 7.4 1/ Wrap 1 is innermost tape which is in contact with the conductor. 3.5 Performance testing. Wire supplied to this drawing shall be qualified in accordance with SA

31、E-AS22759/89 and shall meet any 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 apply: a. A minimum of 70 wires shall pass the impulse dielect

32、ric test in accordance with 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. Provided by IHSNot for ResaleNo reproduction or n

33、etworking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04043 REV B PAGE 6 3.5.2 Solderability (conformance inspection test). The conductor shall meet the solderability requirements for stranded conductors in accordance

34、with MIL-STD-202, method 208. The following details shall apply: a. Unless otherwise specified, five specimens shall 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 requi

35、red 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 considered “failed” when it can no

36、 longer pass the dielectric test method of SAE-AS4373, method 602. d. Average the time to failure for all of the specimens evaluated. 3.5.4 Insulation state of sinter (conformance inspection test). FP layers shall be evaluated with a differential scanning calorimeter in accordance with ASTM D4591. T

37、he FP layers shall meet the following requirements: a. First heat: Less than 25 Joules/gram (J/g). b. Second heat: Maximum 3 J/g change when compared to first heat. c. Bonding between FP layers shall be homogenous. 3.5.5 Lamination sealing (conformance inspection test). When tested in accordance wit

38、h SAE-AS4373, method 809 at 200C, there shall be no evidence of tape separation or lifting. 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 insulat

39、ion 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 strip force shall be as follows: Wire size (AWG) Minimum force Max

40、imum force 26 20 0.25 lbs 6.0 lbs 3.5.7 UV laser marking (test required for initial qualification only). White FP materials shall be formulated in such a manner to achieve a 55% minimum contrast level when marked by an ultraviolet (UV) laser source operating at a fluence of 0.9 0.1 J/cm2. The contra

41、st level shall be evaluated in accordance with method 711 of SAE-AS4373. Non-white insulation colors shall meet the Munsell color limit requirements shown in table V. 3.5.8 Color (conformance inspection test). Colors shall be in accordance with MIL-STD-104, class 1, except for UV laser markable wire

42、 as shown in table V. White is the preferred background insulation color. Color conformity to the limits in accordance with MIL-STD-104 shall not be required after oven exposure. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER,

43、COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04043 REV B PAGE 7 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

44、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 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 o

45、f color marking requirements specified in SAE-AS22759. The following shall apply to the durability 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. 200C maximum continuous conductor temperature. 3.6.2 Voltage rating.

46、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 stamp marking or other methods which significantly penetrate the insulation. The PIN shall be specified in 1.2

47、herein. 3.8 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically ad

48、vantageous life cycle costs. 3.9 Workmanship. The electrical cord supplied to this specification shall be of high quality workmanship. It shall be homogenous throughout its length, free of irregularities and free of defects that affect it s life, serviceability, or appearance The cord shall be unifo

49、rm in shape and free of kinks, splints, cuts, cracks, abrasions, peeled surfaces, or other imperfections. 4. VERIFICATION 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows: a. Qualification inspection (see 4.2). b. Conformance inspection (see 4.3). 4.1.1 Equipment calibration. All test equipment and inspection facilities shall be maintaine