1、Designation: D1676 03 (Reapproved 2011)Standard Test Methods forFilm-Insulated Magnet Wire1This standard is issued under the fixed designation D1676; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last revision. A numb
2、er in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope1.1 These test methods cover procedures for testing film-insulated magnet wire that is used in electrical apparatus.Thesetest methods are inten
3、ded primarily for the evaluation of theelectrical insulating materials used. The intent is that these testmethods be used, except where modified, by individual speci-fications for particular applications.1.2 These test methods present different procedures forevaluating given properties of round, rec
4、tangular or square,copper or aluminum film-insulated magnet wire.1.3 The values stated in inch-pound units are the standard.The SI units in parentheses are provided for information only.1.4 The test methods appear in the following sections:SectionsBond Strength 412Burnout (AC Overload Resistance) 13
5、21Chemical Resistance 2228Coefficient of Friction 2937Continuity, DC High Voltage 3845Continuity, DC Low Voltage 4653Completeness of Cure 5460Cut-Through Temperature (Thermoplastic Flow) 6168Dielectric Breakdown AC Voltage 6975Dielectric Breakdown AC Voltage after Bending 7682Dielectric Breakdown AC
6、 Voltage at Elevated Temperatures 8389Dielectric Breakdown AC Voltage after Conditioning in Refriger-ant Atmosphere 9099Dimensional Measurement 100 106Dissipation Factor Measurement 107 114Electrical Resistance 115 121Elongation 122 129Extractables, Refrigerant 130 140Film Adherence and Flexibility
7、141 148Formability:a) Elastic Ratio 152b) Low Stress Elongation 153c) Spring Back 154-155Heat Shock 156 162Oiliness 163 169Scrape Resistance, Unidirectional 170 177Solderability 178 185Resistance to Insulating Liquids and Hydrolytic Stability 186 1951.5 This standard does not purport to address all
8、of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use. Specific hazardstatements are given in 9.5, 19.1, 19.3, 19.8, 52
9、.1, 58, 59.1,74.1, 112.1, 135.4, and 182.3.NOTE 1This test method is related to IEC 60851. Since both methodscontain multiple test procedures, many procedures are technically equiva-lent while others differ significantly.2. Referenced Documents2.1 ASTM Standards:A228/A228M Specification for Steel Wi
10、re, Music SpringQualityB3 Specification for Soft or Annealed Copper WireB43 Specification for Seamless Red Brass Pipe, StandardSizesB193 Test Method for Resistivity of Electrical ConductorMaterialsB279 Test Method for Stiffness of Bare Soft Square andRectangular Copper andAluminum Wire for Magnet Wi
11、reFabricationB324 Specification for Aluminum Rectangular and SquareWire for Electrical PurposesB609/B609M Specification for Aluminum 1350 RoundWire, Annealed and Intermediate Tempers, for ElectricalPurposesD149 Test Method for Dielectric Breakdown Voltage andDielectric Strength of Solid Electrical I
12、nsulating Materialsat Commercial Power FrequenciesD150 Test Methods for AC Loss Characteristics and Permit-tivity (Dielectric Constant) of Solid Electrical InsulationD374 Test Methods for Thickness of Solid Electrical Insu-lation (Withdrawn 2013)2D877 Test Method for Dielectric Breakdown Voltage ofI
13、nsulating Liquids Using Disk ElectrodesD1533 Test Method for Water in Insulating Liquids byCoulometric Karl Fischer TitrationD1711 Terminology Relating to Electrical InsulationD2475 Specification for Felt1These test methods are under the jurisdiction of ASTM Committee D09 onElectrical and Electronic
14、 Insulating Materials and are the direct responsibility ofSubcommittee D09.12 on Electrical Tests.Current edition approved Aug. 1, 2011. Published August 2011. Originallyapproved in 1959. Last previous edition approved in 2003 as D1676-03. DOI:10.1520/D1676-03R11.2The last approved version of this h
15、istorical standard is referenced onwww.astm.org.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States1D2519 Test Method for Bond Strength of Electrical Insulat-ing Varnishes by the Helical Coil TestD5423 Specification for Forced-Convection
16、Laboratory Ov-ens for Evaluation of Electrical InsulationE4 Practices for Force Verification of Testing MachinesE6 Terminology Relating to Methods of Mechanical TestingE8 Test Methods for Tension Testing of Metallic MaterialsE220 Test Method for Calibration of Thermocouples ByComparison TechniquesE1
17、356 Test Method for Assignment of the Glass TransitionTemperatures by Differential Scanning CalorimetryE1545 Test Method for Assignment of the Glass TransitionTemperature by Thermomechanical Analysis2.2 Other Documents:Federal Specification CCCM-911 for Bleached Muslin3IEC 60851 Methods of Test for
18、Winding Wire33. Terminology3.1 Definitions:3.1.1 conductor, na wire or combination of wires notinsulated from each other, suitable for carrying electric current.3.1.2 magnet wire, na metal electrical conductor, coveredwith electrical insulation, for use in the assembly of electricalinductive apparat
19、us such as coils for motors, transformers,generators, relays, magnets, etc.3.1.3 For definition of other terms used in this test methodrefer to Terminology D1711.3.2 Definitions of Terms Specific to This Standard:3.2.1 film coating, ncured enamel coating.3.2.2 film insulated wire, na conductor insul
20、ated with afilm coating.BOND STRENGTH OF ROUND FILM-INSULATEDSELF-BONDING MAGNET WIRE BY THE HELICALCOIL TEST4. Scope4.1 This test method covers the determination of the bondstrength of a self-bonding outer coating on round film-insulatedmagnet wires (AWG 14 through 44). Both thermal and solventbond
21、ing methods are defined.5. Terminology5.1 Definitions of Terms Specific to This Standard:5.1.1 bond strength, na measure of the force required toseparate surfaces which have been bonded together.5.1.1.1 DiscussionFor magnet wire which has been selfbonded or varnish treated, the bond strength is repo
22、rted as theforce required to break a test specimen in flexure.6. Summary of Test Method6.1 Flexural strength tests are made on bonded helical coilsto determine the force required to break the coil under specifiedconditions.7. Significance and Use7.1 Bond strength values obtained by flexural tests ca
23、nprovide information with regard to the bond strength of aparticular self-bonding outer coating in combination with aparticular round film-insulated magnet wire when measuredunder conditions described in this test method.8. Apparatus8.1 Testing MachineTensile testing machines used forbond strength t
24、est shall conform to the requirements ofPractices E4.8.2 Test FixtureThe test fixture shall conform to the testfixture for bond strength tests required by Test Method D2519.8.3 Mandrel HolderThe mandrel holder shall be a metalblock of sufficient size and thickness with a hole capable ofsupporting th
25、e winding mandrel in a vertical position duringthe bonding cycle of the helical coil.8.4 Winding TensionsThe winding tensions are listed inTable 1.8.5 Bonding WeightsBonding weights (listed in Table 1)should be made with a hole through the center to allow theweight to slip freely over the winding ma
26、ndrel and load ahelical coil during bonding of coil.8.6 Forced-Air OvenSee Specification D5423.3Available from Standardization Documents Order Desk, Bldg. 4 Section D, 700Robbins Ave., Philadelphia, PA 19111-5094, Attn: NPODS.TABLE 1 Helical Coil Bond ParametersWire Size,AWGMandrel DiameterARecommen
27、dedWinding TensionBond WeightsAin. mm g N g N44 0.011 0.28 2.5 0.025 0.80 0.00843 0.011 0.28 2.5 0.025 0.80 0.00842 0.016 0.41 5.0 0.50 1.60 0.01641 0.016 0.41 5.0 0.50 1.60 0.01640 0.022 0.56 10.0 0.098 3.15 0.03139 0.022 0.56 10.0 0.098 3.15 0.03138 0.022 0.56 10.0 0.098 3.15 0.03137 0.032 0.81 20
28、.0 0.196 6.30 0.06236 0.032 0.81 20.0 0.196 6.30 0.06235 0.032 0.81 20.0 0.196 6.30 0.06234 0.044 1.12 40.0 0.392 12.5 0.12333 0.044 1.12 40.0 0.392 12.5 0.12332 0.044 1.12 40.0 0.392 12.5 0.12331 0.063 1.60 80.0 0.785 25.0 0.24530 0.063 1.60 80.0 0.785 25.0 0.24529 0.063 1.60 80.0 0.785 25.0 0.2452
29、8 0.088 2.24 160.0 1.569 50.0 0.49027 0.088 2.24 160.0 1.569 50.0 0.49026 0.088 2.24 160.0 1.569 50.0 0.49025 0.124 3.15 315.0 3.089 100.0 0.98124 0.124 3.15 315.0 3.089 100.0 0.98123 0.124 3.15 315.0 3.089 100.0 0.98122 0.177 4.50 630.0 6.178 200.0 1.96121 0.177 4.50 630.0 6.178 200.0 1.96120 0.177
30、 4.50 630.0 6.178 200.0 1.96119 0.248 6.30 1250.0 12.258 400.0 3.92318 0.248 6.30 1250.0 12.258 400.0 3.92317 0.248 6.30 1250.0 12.258 400.0 3.92316 0.354 8.99 2500.0 24.517 800.0 7.84515 0.354 8.99 2500.0 24.517 800.0 7.84514 0.354 8.99 2500.0 24.517 800.0 7.845A 2 % on all mandrels and bond weight
31、s.D1676 03 (2011)29. Test Specimen Preparation9.1 Select the appropriate mandrel from Table 1, spray itwith a suitable release agent (fluorocarbon or silicone spray isadequate), and allow it to dry. Carefully wind onto the preparedmandrel a length of wire, long enough to wind a helical coil atleast
32、3 in. (76 mm) long. The winding tension shall be asprescribed in Table 1. Ensure that the coil is wound withoutspace between turns.9.2 Prepare six or more coils from each wire sample.9.3 Thermal BondingMount the mandrel supporting thecoil vertically in the mandrel holder and loaded with thebonding w
33、eight specified in Table 1. Place the mandrel holderand coil into a forced-air oven at a specified temperature for aspecified time, after which the assembly is removed from theoven and cooled to room temperature. Remove the coil fromthe mandrel and inspect the coil for breaks or physical damageprior
34、 to testing.9.4 Solvent BondingAfter winding, immerse the coil andmandrel into the specified solvent for 5 s. Immediatelythereafter, secure the mandrel supporting the coil in themandrel holder and load the coil with the bonding weightspecified in Table 1. Dry the coils for1hatroom temperature.Carefu
35、lly remove the coils from the mandrels and further dryin a forced air oven for 15 6 2 min at 100 6 3C (unlessotherwise specified). Cool the coil to room temperature, inspectfor breaks or physical damage, and test.9.5 Resistance BondingMount the mandrel supporting thecoil vertically in a mandrel hold
36、er and loaded with the bondingweight specified in Table 1. Energize the coil with enoughcurrent and time to allow bonding. Remove the coil from themandrel and inspect for breaks or physical damage, and test.Specific bonding conditions shall be agreed upon between themanufacturer and the user. (Warni
37、ngLethal voltages are apotential hazard during the performance of this test. It isessential that the test apparatus, and all associated equipmentelectrically connected to it, be properly designed and installedfor safe operation. Solidly ground all electrically conductiveparts which it is possible fo
38、r a person to contact during thetest. Provide means for use at the completion of any test toground any parts which were at high voltage during the test orhave the potential for acquiring an induced charge during thetest or retaining a charge even after disconnection of thevoltage source. Thoroughly
39、instruct all operators as to thecorrect procedures for performing tests safely. When makinghigh voltage tests, particularly in compressed gas or in oil, itis possible for the energy released at breakdown to be suffcientto result in fire, explosion, or rupture of the test chamber.Design test equipmen
40、t, test chambers, and test specimens so asto minimize the possibility of such occurrences and to eliminatethe possibility of personal injury. If the potential for fire exists,have fire suppression equipment available.)10. Procedure10.1 Use a rate of loading such that the duration of the testshall be
41、 greater than the full-scale response time of the loadrecording instrument.10.2 Prepare sufficient specimens to obtain six data pointsfor each wire sample. One or more of the specimens may bedestroyed in adjusting the rate of loading.10.3 Break specimens according to the test proceduresdescribed in
42、Test Method D2519.10.4 Tests at other than room temperature can be performed,if desired, using an insulated heat-resistant enclosure, designedto fit around the test fixture and in the stress strain analyzer.Place the specimens in the fixture in the oven for 15 min butnot more than 30 min after the o
43、ven has recovered to the settemperature 6 2C. Break the specimens according to the testprocedures described in Test Method D2519. The specified testtemperature and minimum bond strength shall be agreementupon between the manufacturer and the user.11. Report11.1 Report the following:11.1.1 Identifica
44、tion of size, build and type of insulationused,11.1.2 Heat or solvent bonding (including temperature ortype of solvent, or both),11.1.3 Test temperature, and11.1.4 Atable listing the individual values in pounds, gramsor newtons of bond strength and their averages.12. Precision and Bias412.1 In compa
45、ring two averages of six observations, thedifferences should not exceed the critical difference in Table 2,in 95 out of 100 cases when all of the observations are taken bythe same well-trained operator using the same piece of testequipment and specimens randomly drawn from the samesample of material
46、.12.2 PrecisionTwo averages of observed values should beconsidered significantly different at the 95 % probability levelif the difference equals or exceeds the critical differences listedin Table 2.12.3 BiasThis test method has no bias because the valueof bond strength is determined solely in terms
47、of this testmethod.BURNOUT (AC OVERLOAD RESISTANCE)13. Scope13.1 This test method and equipment described herein isused to determine the ac overload resistance of 18AWG heavy4Supporting data are available from ASTM International Headquarters. RequestRR:D09-1007.TABLE 2 Critical Differences, Percent
48、of Average Pounds toBreakANumber ofObservations ineach AverageSingle-OperatorPrecisionWithin-LaboratoryPrecisionBetween-LaboratoryPrecision610 1 12AThe critical differences were calculated usingt=1.960, which is based on infinitedegrees of freedomD1676 03 (2011)3build film-insulated round copper mag
49、net wire by measuringthe time to obtain a dielectric failure when subjected to astep-wise increase in AC overload current.14. Terminology14.1 Definitions of Terms Specific to This Standard:14.1.1 burnout (of magnet wire), nthe time required fordielectric failure to occur between wires of a twisted pair as aresult of heating due to controlled ac overload current.14.1.2 one twist (dielectric twist specimen), none 360revolution of the head of the dielectric twist maker.15. Summary of Test Method15.1 A controlled current (I) is p
