DLA DSCC-DWG-04044 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED NORMAL WEIGHT NICKEL COATED HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY 26.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Modifications to agree with SAE AS22759/90. Editorial changes throughout. 06/30/07 Lee Suroweic B Added approved supplier. Editorial changes throughout. 1 March 2009 Abdo Abdouni C Added approved supplier. 8 September 2010 Abdo Abdouni Prepared in accordance

2、 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, ELECTRICAL, COMPOS

3、ITE, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, HIGH STRENGTH OR ULTRA HIGH STRENGTH COPPER ALLOY, 260C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04044 A 037Z3 REV C PAGE 1 OF 9 AMSC N/A 6145-E097-008 CURRENT DESIGN ACTIVITY CAGE CODE 037Z3 HAS C

4、HANGED 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 04044 REV B PAGE 2 FP Fluorocarbon Polymer, modifi

5、ed 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 conductor.

6、 1.2 Part or Identifying Number (PIN). The complete PIN should be as specified on the requirements drawing and constructed using the following format: 04044 - 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. (mi

7、n.) 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, NICKEL COATED, HIGH STRENGTH OR ULTRA HI

8、GH 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 04044 REV B PAGE 3 TABLE I. Details of construction AWG c

9、onductors. PIN Wire size (AWG) Conductor Finished wire Stranding (number of strands X gauge (AWG) of strands) Diameter (in.) Resistance at 20C ohms/1000ft (max) Diameter (in.) Weight lb/1000ft. (max) Min Max Min Max 04044-26-* 26 19 X 38 .0175 .0204 58.4 .033 .037 1.55 04044-24-* 24 19 X 36 .0225 .0

10、254 30.1 .038 .042 2.15 04044-22-* 22 19 X 34 .0285 .0314 18.6 .043 .047 3.00 04044-20-* 20 19 X 32 .0365 .0404 11.4 .051 .055 4.55 * The asterisks in the PIN column of table I should be replaced by color code designators (see 1.2.2). Example: 04044-26-93 is white with an orange stripe. 1.2.2 Color.

11、 The wire insulation color should be indicated by the color designator (see 1.2) and as specified in the contract. 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

12、in accordance with MIL-STD-104, class I, or in accordance with 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

13、. 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-681 - Identification Coding and Application of Hookup and Lead Wire MIL-STD-2223 - Test Methods fo

14、r Insulated Electric Wire (Copies of these documents 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

15、document to the extent specified herein. Unless otherwise 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 B624 - Standard Specification for High Strengt

16、h, 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 Transitions of Fluoropolymers by Differential Scanning Calorimetry (Copies of these documents ar

17、e available from http:/www.astm.org/ or ASTM International, 100 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

18、SIZE CAGE CODE DWG NO. A 037Z3 04044 REV B PAGE 4 NCSL INTERNATIONAL NCSL Z540.3 - General Requirements for Calibration of Measuring and Test Equipment (Copies of these documents are available from http:/www.ncsli.org or to National Conference of Standards Laboratories (NCSL), 2995 Wilderness Place,

19、 Suite 107, Boulder, CO 80301-5404.) SAE INTERNATIONAL SAE-AS4373 - Test Methods for Insulated Electric Wire SAE-AS22759 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/90 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal Weight, Nickel Coated, H

20、igh Strength or Ultra High Strength Copper Alloy, 260C, 600 Volts (Copies of these documents 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 requireme

21、nts of SAE-AS22759 and SAE AS22759/90 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-AS22759/90. In case of conflict between the requirements in this drawing, SAE-AS22759, and SAE-AS22759/

22、90, 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 documentation shall be retained by the manufacturer and shall be available upon request fo

23、r review by the contracting activity, DSCC, or contractor. 3.3 Material. 3.3.1 Conductor. Conductors shall be made of high strength or ultra high strength copper-alloy in accordance with ASTM B624, paragraph 1.2.1, and table I of this drawing. All strands shall be free from lumps, kinks, splits, sca

24、rred 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 tape in accor

25、dance with 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/ Physical properties of PTFE unsintered tape shall be in accordanc

26、e with SAE AS22759. 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 04044 REV B PAGE 5 TABLE III. Physical properties of FP/Polyimide/FP tapes. Tensile strength 19

27、,000 lb/in2(average min) Tensile modulus 350,000 lb/in2(average min) Elongation 40 percent (average min) Dielectric strength 4,000 volts/mil (average min) .0005 FP Layer Distinguishable color (next to conductor) 3.4 Wire construction and physical dimensions. See figure 1 and table IV. TABLE IV. Tape

28、 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 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

29、which is in contact with the conductor. 3.5 Performance testing. Wire supplied to this drawing shall be qualified in accordance with SAE-AS22759/90 and shall meet any requirements of this drawing. 3.5.1 Wet arc propagation resistance (test required for initial qualification only). When tested in acc

30、ordance with MIL-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.

31、0 inch (25.4 mm) in length in any bundle when measured along the axis. 3.5.2 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. Numb

32、er 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. 3.5.3 Insulation state of sinter (conformance inspection test

33、). FP layers shall 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 s

34、hall be homogenous. 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. 3.5.4 Lamination sealing (conformance inspection test). When tested in accordance with SA

35、E-AS4373 method 809 at 260C, 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. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS C

36、OLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04044 REV B PAGE 6 3.5.5 Strippability (conformance inspection test). There shall be no evidence of separation or elongation of FP layers when stripped with standard hand held tools using proper stripping blades. No evidence of insulation shall b

37、e left on the conductor when viewed with the naked eye. The following details shall apply: a. Test size: 26 AWG to 20 AWGs 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

38、26 20 0.25 lbs 6.0 lbs 3.5.6 Durability (PTFE outer layer) (Test required for initial qualification only). When tested as specified, 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 siz

39、e: 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 replaced with an aluminum/Mylar film of similar thickn

40、ess 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 surface facing down (perpendicular with the test specime

41、n). (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, ensuring the rod is level and perpendicular to the s

42、pecimen 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 detects continuity between the abrading rod and the conducto

43、r. (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. 3.5.7 UV laser marking (test required for initial qualification only). When marked with an ultraviolet (UV) la

44、ser source at 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 sh

45、own in table V. Contrast level is defined as: CL = 3.5.8 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 VII. White is the preferred background insulation color. Color conformity to the limits of MIL-ST

46、D-104 shall not be required after oven exposure. (Reflectance of the background 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 COL

47、UMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04044 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 8 9 4 6 Brow

48、n 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 3.5.9 Color striping or banding durability (conformance inspection test). Colored stripes or bands shall meet the durability of color marki

49、ng 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. 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