1、 AEROSPACE STANDARD WIRE, THERMOCOUPLE, FP/POLYIMIDE/FP INSULATED, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN) THERMOCOUPLE EXTENSION, LIGHT WEIGHT, 260 C AS5419/6Copyright 2014 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval syst
2、em 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 USA) Fax: 724-776-0790 Email: CustomerService
3、sae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED 2003-02REAFFIRMED 2014-01THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8D FEDERAL SUPPLY CLASS AS5419/6 SHEET 1 OF 8 SAE Technical Standards Board Rules provide that: “This report ispublishedby SAE toadvance thestate of technicalandengineering sciences.
4、Theuse ofthis report is entirely voluntary, andits applicability and suitability forany particular use,including any patent infringement arising therefrom, isthe soleresponsibilityofthe user.”SAE reviews eachtechnicalreport at least every five years at which time itmay berevised, reaffirmed, stabili
5、zed, orcancelled. SAE invites yourwrittencomments andsuggestions. SAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS5419/6 RATIONALE AS5419/6 HAS BEEN REAFFIRMED TO COMPLY WITH THE SAE FIVE-YEAR REVIEW POLICY. Type “K” thermocoup
6、le conductors are typically used as extension leads for aerospace application. These wires are only to be used in a matched pair and procured under AS5419. Thermocouple extension wires are calibrated for use together in fabricating thermocouples. If each leg of the thermocouple extension wire is fro
7、m a different lot, recalibration of the thermocouple pair will be required.FIGURE 1 - Wire, Thermocouple, FP/Polyimide/FPComponent wire insulation system must conform to the similar wire type designatedin Table 1 of AS5419. Manufacturers must be qualified to AS22759/91 to produce this product.TABLE
8、1 - KP Construction DetailsTABLE 1A - KP Construction Details, inch-pound UnitsAEROSPACE STANDARD AS5419/6 SHEET 2 OF 8 WIRE, THERMOCOUPLE, FP/POLYIMIDE/FP INSULATED, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN) THERMOCOUPLE EXTENSION, LIGHT WEIGHT, 260 C TABLE 1B - KP Construction Details,
9、 SI UnitsNotesElectromotive Force (EMF) designator = Type KPS conductor from ANSI/MC96.1 with standard limits= Type KPH conductor from ANSI/MC96.1 with special limitsExample: Size 20 standard EMF limits - WC-20KPS-9; Size 20 special EMF limits - WC-20KPH-9These wires comply with the sealing range re
10、quirement for firewall connectors as specified in MIL-DTL-5015, MIL-DTL-38999, and MIL-C-83723 (superseded by MIL-C-26482 and MS3470 which are inactive for new design) except that 20 awg wire is not compatible with minimum sealing range of MIL-DTL-38999 16 awg contacts and 14 awg wire is not compati
11、ble with minimum sealing range of MIL-C-83723 (superseded by MIL-C-26482 and MS3470 which are inactive for new design) and MIL-DTL-38999 12 awg contacts.TABLE 2 - KN CONSTRUCTION DETAILSTABLE 2A - KN CONSTRUCTION DETAILS, INCH-POUND UNITSAEROSPACE STANDARD AS5419/6 SHEET 3 OF 8 WIRE, THERMOCOUPLE, F
12、P/POLYIMIDE/FP INSULATED, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN) THERMOCOUPLE EXTENSION, LIGHT WEIGHT, 260 C TABLE 2B - KN Construction Details, SI UnitsNotesElectromotive Force (EMF) designator = Type KPS conductor from ANSI/MC96.1 with standard limits= Type KPH conductor from ANSI/M
13、C96.1 with special limitsExample: Size 20 standard EMF limits - WC-20KNS-5; Size 20 special EMF limits - WC-20KNH-5These wires comply with the sealing range requirement for firewall connectors as specified in MIL-DTL-5015, MIL-DTL-38999, and MIL-C-83723 (superseded by MIL-C-26482 and MS3470 which ar
14、e inactive for new design) except that 20 awg wire is not compatible with minimum sealing range of MIL-DTL-38999 16 awg contacts and 14 awg wire is not compatible with minimum sealing range of MIL-C-83723 (superseded by MIL-C-26482 and MS3470 which are inactive for new design) and MIL-DTL-38999 12 a
15、wg contacts.TABLE 3 - Wire Insulation Materials1TABLE 4 - Physical Properties of FP/Polyimide/FP TapeAEROSPACE STANDARD AS5419/6 SHEET 4 OF 8 WIRE, THERMOCOUPLE, FP/POLYIMIDE/FP INSULATED, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN) THERMOCOUPLE EXTENSION, LIGHT WEIGHT, 260 C TABLE 5 - Tap
16、e Overlap Requirements1WIRE RATINGS AND ADDITIONAL REQUIREMENTSTEMPERATURE RATING: 260 C (500 F) max continuous conductor temperatureVOLTAGE RATING: Not applicableWET ARC PROPAGATION RESISTANCE (Test required for initial qualification only): Test in accordance with AS4373, Method 509. Measure the da
17、mage of the bundle along the axis. The wire is acceptable if the following criteria are met:1. A minimum of 64 wires pass the dielectric test2. Three wires or less fail the dielectric test in any one bundle3. Actual damage to the wire is not more than 3 in (76.2 mm) in any test bundleDRY ARC PROPAGA
18、TION RESISTANCE (Test required for initial qualification only): Test in accordance with AS4373, Method 301. Measure the damage of the bundle along the axis. The wire is acceptable if the following criteria are met:1. A minimum of 64 wires pass the dielectric test2. Three wires or less fail the diele
19、ctric test in any one bundle3. Actual damage to the wire is not more than 3 in (76.2 mm) in any test bundleBLOCKING: 260 C 2 C (500 F 3.6 F)COLOR: In accordance with MIL-STD-104, Class 1: white and green only. Conformity of color to the limits of MIL-STD-104 shall not be required after oven exposure
20、.CONDUCTOR STRAND ADHESION: Not requiredDYNAMIC CUT-THROUGH (Test required for initial qualification only): Test size 20 only in accordance with ASTM D 3032, Section 22. Blade shall be the standard cutting blade except the cutting edge radius shall be 0.005 in 0.001 in (0.127 mm 0.025 mm). Minimum d
21、ynamic cut-through of 14 lb (6.4 kg) at 23 C 2 C (73 F 3.6 F) and 5 lb (2.3 kg) at 200 C 2 C (392 F 3.6 F).FLAMMABILITY: Test in accordance with AS4373, Method 801HIGH FREQUENCY SPARK TEST (When used in lieu of Impulse Dielectric Test): Test in accordance with AS4373, Method 505; 5.7 kilovolts (rms)
22、. Test 100% of the wire.HUMIDITY RESISTANCE: After humidity exposure, wire shall meet the requirement for initial insulation resistanceAEROSPACE STANDARD AS5419/6 SHEET 5 OF 8 WIRE, THERMOCOUPLE, FP/POLYIMIDE/FP INSULATED, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN) THERMOCOUPLE EXTENSION,
23、 LIGHT WEIGHT, 260 C WIRE RATINGS AND ADDITIONAL REQUIREMENTS (Continued)IDENTIFICATION: The finished wire shall be identified by a printed marking applied to the outer surface of the wire. The printed marking shall be legible, black in color, and withstand a durability test of 125 cycles (250 strok
24、es) (min), 250 grams weight. The size of the printed characters shall be consistent with the magnitude of the surface upon which it is printed. The distance between the end of one mark and the beginning of the next shall be a maximum of 12 in. The printed marking shall be applied with the vertical a
25、xes of the print characters lengthwise on wire whose nominal diameter is 0.050 in (1.27 mm) or smaller. The vertical axes of the printed characters may be crosswise or lengthwise on wire whose nominal diameter is 0.051 in (1.30 mm) or larger.IMMERSION (Test required for initial qualification only):
26、Test in accordance with AS4373, Method 601, including additional fluids of Table 6 of this supplement. Use mandrels and weights listed in Table 7 of this supplement for bend testing. Dielectric test, 2,500 volts (rms) 60 Hz. For the turbine fuel immersion test of AS4373, either JP-4 or MIL-T-83122 T
27、ype JP-8 (NATO Type F-34) may be used.IMPULSE DIELECTRIC TEST: 8.0 kilovolts (peak), 100% testINSULATION STATE OF SINTER: (Test required for initial qualification only) Evaluate FP layers with a Differential Scanning Calorimeter per ASTM D 4591. Applicable for 10 AWG and smaller.Energy to Melt (Joul
28、es/gram)First Heat Less than 25 J/gINSULATION RESISTANCE (min): 5,000 megohms for 1,000 ft (1,524 megohms for 1.0 km)LIFE CYCYLE: 500 hours at 290 C 2 C (554 F 3.6 F) Dielectric test, 2,500 volts (rms), 60 Hz. Use mandrels coated with polytetrafluoroethylene such that the diameter of the mandrels af
29、ter coating still conform to the required test mandrel diameters in Table 7 of this supplement. After oven exposure, layers shall not separate and/or tapes shall not lift along the insulation or at the ends.LOW TEMPERATURE (Cold Bend): Use mandrels specified in Table 7 of this supplement. Chamber te
30、mperature, -65 C 2 C (-85 F 3.6 F) Dielectric test, 2,500 volts (rms), 60 Hz.SHRINKAGE: 0.091 in (2.31 mm) (max) at 290 C 2 C (554 F 3.6 F)SMOKE: 260 C 5 C (500 F 9 F); no visible smokeSOLDERABILITY: Not requiredSTRIPABILITY (Group II Quality Conformance Test): Test in accordance with ASTM D 3032, S
31、ection 27. The length of the insulation slugs shall be 0.25 in (6.35 mm). The maximum strip force shall be 4 lb (1.8 kg) for sizes 20-22 and 6 lb (2.7 kg) for sizes 18-14. No evidence of insulation left on the conductor when viewed with the naked eye.THERMAL INDEX: 260 C (500 F) minimum for 10,000 h
32、ours (test required for initial qualification only). Test size 20 only in accordance with ASTM D 3032, Section 14.THERMAL SHOCK RESISTANCE: Oven temperature, 260 C 2 C (500 F 3.6 F); maximum change in measurement 0.091 in (2.31 mm).WRAP (Mandrel Wrap): No cracking, no dielectric breakdown. Use mandr
33、els specified in Table 7 of this supplement. Dielectric test, 2, 500 volts (rms), 60 Hz.AEROSPACE STANDARD AS5419/6 SHEET 6 OF 8 WIRE, THERMOCOUPLE, FP/POLYIMIDE/FP INSULATED, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN) THERMOCOUPLE EXTENSION, LIGHT WEIGHT, 260 C TABLE 6 - Immersion Test F
34、luidsAEROSPACE STANDARD AS5419/6 SHEET 7 OF 8 WIRE, THERMOCOUPLE, FP/POLYIMIDE/FP INSULATED, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN) THERMOCOUPLE EXTENSION, LIGHT WEIGHT, 260 C TABLE 7 - Test Mandrel and Test Load RequirementsTABLE 7A - Test Mandrel and Test Load Requirements, inch-pou
35、nd UnitsTABLE 7B - Test Mandrel and Test Load Requirements, SI UnitsAEROSPACE STANDARD AS5419/6 SHEET 8 OF 8 WIRE, THERMOCOUPLE, FP/POLYIMIDE/FP INSULATED, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN) THERMOCOUPLE EXTENSION, LIGHT WEIGHT, 260 C ADDITIONAL CONDUCTOR REQUIREMENTSSTRAND MATERI
36、AL: Type KPH and KPS strands shall be made from an alloy of 90% nickel - 10% chromium and Type KNH and KNS strands shall be made from an alloy of 95% nickel - 2% aluminum - 2% manganese - 1% silicon and minor traces of other materials and shall conform to ANSI-MC96.1.SPLICES: Splices in individual s
37、trands or groups of individual strands shall be butt brazed with silver solder. Splices shall be so constructed and disposed throughout the conductor that the diameter, configuration, conductor resistance, flexibility, and mechanical strength of the completed conductor are not adversely affected.SOL
38、DERABILITY: Not applicableELONGATION: Not applicableTENSILE STRENGTH: Not applicableELECTROMOTIVE FORCE: EMF shall conform to ANSI/MC96.1 whereas Type KPS and KNS are used for standard EMF limits, Type KPH and KNH for special limitsCOATING: Not applicableNOTEThe wires form a thermocouple and are intended for use as the extension portion of the thermocouple system.
