1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this publication ma
3、y be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside US
4、A) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS50861AAEROSPACESTANDARDAS50861 REV. A Issued 1998-03 Reaffirmed 2004-06 Revised 2011-01Supers
5、eding AS50861 Wire, Electric, Polyvinyl Chloride Insulated, Copper or Copper Alloy FSC 6145 RATIONALELimit Scope ballot required to incorporate AS50561-A3, update references, and remove government references. 1. SCOPE 1.1 Scope This specification covers polyvinyl chloride insulated single conductor
6、electric wires made with tincoated copper conductors or silver-coated copper alloy conductors as specified in the applicable detail specification. The polyvinyl chloride insulation of these wires may be used alone or in combination with other insulating or protective materials. 1.2 Classification Th
7、e wires shall be as described in the applicable detail specification. 1.2.1 Part numbers: Part numbers under this specification are coded as in the following example: M5086/1 - 22 - 9Applicable specifcation Wire size Insulation color sheet designator or designators 1.2.2 Temperature rating of finish
8、ed wire: The maximum conductor temperature of the finished wire for continuous use shall be as specified in the applicable detail specification (6.1.1). SAE AS50861A Page 2 of 272. APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. Unless oth
9、erwise specified the applicable issue of the other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, super
10、sedes applicable laws and regulations unless a specific exemption has been obtained.2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.AS5086/1* Wire, Electric,
11、 Polyvinyl Chloride Insulated, Nylon Jacket, Tin-Coated Copper Conductor, 600-Volt, 105 C AS5086/2* Wire, Electric, Polyvinyl Chloride Insulated, PVC - Glass - Nylon, Tin-Coated Copper Conductor, 600-Volt, 105 C AS5086/3* Wire, Electric, Polyvinyl Chloride Insulated, PVC - Glass - PVC - Nylon, Tin-C
12、oated Copper Conductor, 600-Volt, 105 C AS5086/48 Wire, Electric, Polyvinyl Chloride Insulated, Nylon Jacket, Tin-Coated Copper Conductor, 3000-Volt, 105 C AS5086/5* Wire, Electric, Polyvinyl Chloride Insulated, Polyvinylidene Fluoride Jacket, Tin-Coated Copper Conductor, 600-Volt, 110 C AS5086/6 Wi
13、re, Electric, Polyvinyl Chloride Insulated, Polyvinylidene Fluoride Jacket, Silver-Coated Copper Alloy Conductor, 600-Volt, 110 C AS5086/7* Wire, Electric, Polyvinyl Chloride Insulated, Nylon Jacket, Tin-Coated Copper Conductor, Medium Weight, 600-Volt, 105 C AS5086/8* Canceled, 14 November 1974 (Wi
14、re, Electric, Polyvinyl Chloride Insulated, Polyvinylidene Fluoride Jacket, Tin-Coated Copper Conductor, Light Weight, 600-Volt, 110 C) *SAE AS58091 Detail Specifications 2.2 U.S. Government Publications Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins
15、Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/.SD-6 Provisions Governing Qualification H4/H8 Catalog of Commercial and Government Entities (CAGE) (Battle Creek Customer Contact Center, Defense Logistics Information Service, 74 Washington Avenue N., Bat
16、tle Creek, MI 49017-3084) MIL-STD-104 Limits for Electrical Insulation Color MIL-STD-129 Military Marking for Shipment and Storage FED-STD-228 Cable and Wire, Insulated; Methods of Testing UU-T-450 Tissue, Facial SAE AS50861A Page 3 of 27MIL-C-572 Cords, Yarns and Monofilaments, Organic Synthetic Fi
17、ber MIL-STD-681 Identification Coding and Application of Hookup and Lead Wire TT-I-735 Isopropyl Alcohol MIL-Y-1140 Yarn, Cord, Sleeving, Cloth, and Tape, Glass MIL-PRF-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordnance MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL
18、-DTL-12000 Cable, Cord, and Wire, Electric, Packaging of MIL-PRF-23699 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base MIL-STD-29606 Wire, Electrical, Stranded, Uninsulated Copper, Copper Alloy, or Aluminum, or Thermocouple Extension, General Specification For MIL-DTL-83133 Turbine Fuel, Av
19、iation, Kerosene Types, NATO F-34 (JP-8) and NATO F-35 2.3 Other Publications 2.3.1 ASQ Publications Available from American Society for Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203, Tel: 800-248-1946 (United States or Canada) or +1-414-272-8575 (International), www.asq.org.ASQC Z1.4 Sa
20、mpling Procedures and Tables for Inspection by Attributes 2.3.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ANSI/ASTM B 3 Standard Specification for Soft or Annealed Copper Wire ANSI/ASTM
21、 B 33 Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes ANSI/ASTM B 298- Standard Specification for Silver-Coated Soft or Annealed Copper Wire ANSI/ASTM D 1371 Recommended Practice for Cleaning Plastic Specimens for Insulation Resistance, Surface Resistance, and
22、Volume Resistivity Testing ANSI/ASTM D 3032 Standard Test Methods for Hookup Wire Insulation ASTM D 4066-94B Nylon, Injection and Extrusion Materials (PA) SAE AS50861A Page 4 of 273. REQUIREMENTS 3.1 Detail Specifications The requirements for the individual wires under this specification shall be as
23、 specified herein and in accordance with the applicable detail specification. In the event of discrepancy between this specification and the requirements of the applicable detail specification, the requirements of the detail specification shall govern, except that all detail specificationprovisions
24、concerning resistance to tape abrasion shall be considered as cancelled as of the issue date of Amendment 1 to this specification. 3.2 Classification of Requirements The applicable requirements are classified herein as follows: Requirement ParagraphQualification 3.3 Materials 3.4 Construction 3.5 Fi
25、nished Wire 3.6 3.3 Qualification The wire furnished under this specification shall be a product which is qualified for listing on the applicable qualified products list at the time set for opening of bids (see 4.3 and 6.4). The provisions of 4.6 for retention of qualification are included in this r
26、equirement. 3.4 Materials 3.4.1 Conductor material: All strands used in the manufacture of the conductors shall be tin coated soft annealed copper or silver coated high strength copper alloy, as specified in the applicable detail specification. Strands shall be free from lumps, kinks, splits, scrape
27、d or corroded surfaces, and skin impurities. In addition, the strands shall conform to the following requirements as applicable. 3.4.1.1 Tin-coated soft annealed copper strands: The strands shall be as specified in ANSI/ASTM B 33. 3.4.1.2 Silver-coated high strength copper alloy strands: The strands
28、 shall be of the applicable AWG gage specified in Table 2 and of such tensile properties that the conductor from the finished wire conforms to the requirements of 3.5.1.3.2 for elongation and tensile strength. The strands shall have a coating thickness of not less than 40 micro-inches of silver and
29、shall meet the continuity of coating requirement of ANSI/ASTM B 298 when tested in accordance with that standard. 3.4.2 Insulating Material 3.4.2.1 Primary and secondary insulation: The primary insulation and, when specified, secondary insulation for all wires under this specification shall be an ex
30、truded polyvinyl chloride composition. The properties of the extruded polyvinyl chloride in the finished wire shall be as specified in Table 1.SAE AS50861A Page 5 of 27TABLE 1 - PROPERTIES OF EXTRUDED POLYVINYL CHLORIDE INSULATIONAND POLYVINYLIDENE FLUORIDE JACKET COMPOUNDS PROPERTYPOLYVINYLCHLORIDE
31、POLYVINYLIDENEFLUORIDETensile strength Initial (psi) (min avg) 1800 5000ElongationInitial (%) (min avg) After aging: Qualification procedure (% of initial) (min avg) Acceptance procedure (% if initial) (min avg) 1007090250-Corrosive effect To pass test(see 4.7.5.3) -3.4.2.2 Glass braid: When a glass
32、 braid is specified in the applicable detail specification, it shall be a tightly formed, uniformly surfaced braid composed of electrical-grade continuous filament glass yarn of MIL-Y-1140. For wire sizes 10 and larger, the yarn shall gage 13 000 to 16 000 yards per pound, before treatment. For wire
33、 sizes 12 and smaller, the yarn shall gage 13 000 to 24 000 yards per pound, before treatment. The braid shall be treated with suitable saturants to facilitate stripping and to cause the braid to adhere to the next outer layer of material. 3.4.2.3 Jacket 3.4.2.3.1 Polyamide (nylon): When an extruded
34、 polyamide jacket is specified, it shall be made of clear ASTM D 4066 Type PA0611, PA0612, PA0621 or equivalent material as approved by the Qualifying activity (see 6.4). Certified test data shall be furnished by the wire supplier to establish conformity of the polyamide extruding material to the re
35、quired type and grade. When a braided polyamide jacket is specified, the material shall conform to Type P of MIL-C-572 and shall be impregnated with polyamide finisher. 3.4.2.3.2 Polyvinylidene fluoride: Jackets of this material shall be extruded clear polyvinylidene fluoride having the tensile and
36、elongation properties shown in Table 1. 3.5 Construction Construction of the wire shall be as specified herein and in the applicable detail specification. 3.5.1 Conductor 3.5.1.1 Stranding 3.5.1.1.1 Concentric lay stranding: The conductors of wire sizes 30 through 10 shall be concentric-lay conducto
37、rs constructed as specified in Table 2. Concentric lay shall be interpreted to be a central strand surrounded by one or more layers of helically wound strands. It is optional for the direction of lay of the successive layers to be alternately reversed (true concentric lay) or to be in the same direc
38、tion (unidirectional lay). The strands shall be assembled in a geometric arrangement of concentric layers, so as to produce a smooth and uniform conductor, circular in cross-section and free of any crossovers, high strands, or other irregularities. The direction of lay of the individual strands in t
39、he outer layer of the concentrically stranded conductors of finished wire shall be left hand. The length of lay of the outer layer shall not be less than 8 nor more than 16 times the maximum conductor diameter as specified in the applicable detail specification SAE AS50861A Page 6 of 273.5.1.1.2 Rop
40、e lay stranding: The conductors of wire sizes 8 through 0000 shall be rope-lay as specified in Table 2 and in (a) and (b) below. a. Rope-lay stranded conductors shall be laid up concentrically with a central member surrounded by one or more layers of helically wound members. It is optional for the d
41、irection of lay of successive layers to be alternately reversed (true concentric lay), or to be in the same direction (unidirectional lay). The length of lay of the outer layer of rope-lay stranded members forming the conductor shall not be less than 10 or more than 14 times the outside diameter of
42、the completed conductor. The direction of lay of the outside layer shall be either left or right hand. b. Members of rope-lay stranded conductors: The length of lay of the wires composing the stranded members shall be not greater than 16 times the outside diameter of the member. Stranding of the ind
43、ividual members may be either concentric or bunch. 3.5.1.2 Splices: Splices in individual strands or members shall be butt brazed. There shall not be more than one strand-splice in any two lay lengths of a stranded concentric-lay conductor or in any two lay lengths of any member in a rope lay conduc
44、tor, except that not more than one splice of an entire member shall be permitted in any two lay lengths of a rope lay conductor. Splices in members of a rope lay construction shall be so finished that the conductor diameter is not increased at the point of brazing. In no case shall the whole conduct
45、or be spliced at one point. TABLE 2 - DETAILS OF CONDUCTORS Size Desig- nation Nominal Conductor Area (Cir.Mils) 1/ Stranding (No. of Strands +AWG Gage of Strands) Allowable No. of Missing Strands (Max) Nominal Dia of Individual Strands (inch) 1/ Diameter of Stranded Conductor Maximum Resitance of F
46、inished Wire 2/ Breaking Strength, Alloy Conductor (lbs) (min) Min. (inch) Max (Inch) General Purpose Small Diameter Tin Coated Copper Silver Coated Alloy Tin Coated Copper Silver CoatedAlloy Tin CoatedCopper Silver Coated Alloy 30 112 7 x 38 0 0.0040 0.011 0.013 0.012 0.013 0.012 111.1 117.4 5.17 2
47、8 175 7 x 36 0 0.0050 0.014 0.016 0.015 0.016 0.015 68.6 74.4 8.16 26 304 19 x 38 0 0.0040 0.018 0.021 0.020 0.020 0.020 41.3 44.8 14.2 24 475 19 x 36 0 0.0050 0.023 0.026 0.025 0.024 0.024 26.2 28.4 22.4 22 754 19 x 34 0 0.0063 0.029 0.033 0.032 0.031 0.031 16.2 17.5 35.8 20 1,216 19 x 32 0 0.0080
48、0.037 0.041 0.040 0.039 0.039 9.88 10.7 58.1 18 1,900 19 x 30 0 0.0100 0.046 0.051 - 0.049 - 6.23 16 2,426 19 x 29 0 0.0113 0.052 0.058 - 0.055 - 4.81 14 3,831 19 x 27 0 0.0142 0.065 0.073 - 0.069 - 3.06 12 5,874 37 x 28 0 0.0126 0.084 0.090 - 0.089 - 2.02 10 9,354 37 x 26 0 0.0159 0.106 0.114 - 0.1
49、12 - 1.26 8 16,983 133 x 29 0 0.0113 0.158 0.173 - 0.169 - 0.701 6 26,818 133 x 27 0 0.0142 0.198 0.217 - 0.212 - 0.445 4 42,615 133 x 25 0 0.0179 0.250 0.274 - 0.268 - 0.280 2 66,500 665 x 30 2 0.0100 0.320 0.340 - - - 0.183 1 81,700 817 x 30 2 0.0100 0.360 0.380 - - - 0.149 0 104,500 1,045 x 30 3 0.0100 0.405 0.425 - - - 0.116 00 133,000 1,330 x 30 3 0.0100 0.4
