1、Designation: B 803 08Standard Specification forHigh-Strength Zinc5 % Aluminum-Mischmetal Alloy-CoatedSteel Core Wire for Use in Overhead Electrical Conductors1This standard is issued under the fixed designation B 803; the number immediately following the designation indicates the year oforiginal ado
2、ption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope*1.1 This specification covers round, high strength, zinc5 %aluminum-mischm
3、etal (Zn5AlMM) alloy-coated, steel corewire with one class of Zn5AlMM coating (MA3) for use inoverhead electrical conductors.1.2 This specification covers wire of diameter from 0.0500to 0.1900 in. inclusive or 1.27 to 4.82 mm inclusive.1.3 The values stated in either SI units or inch-pound unitsare
4、to be regarded separately as standard. The values stated ineach system may not be exact equivalents; therefore, eachsystem shall be used independently of the other. Combiningvalues from the two systems may result in non-conformancewith the standard.2. Referenced Documents2.1 The following documents
5、of the issue in effect on dateof material purchase form a part of this specification to theextent referenced herein.2.2 ASTM Standards:2A 90/A 90M Test Method for Weight Mass of Coating onIron and Steel Articles with Zinc or Zinc-Alloy CoatingsA 370 Test Methods and Definitions for Mechanical Testin
6、gof Steel ProductsA 751 Test Methods, Practices, and Terminology forChemical Analysis of Steel ProductsB 193 Test Method for Resistivity of Electrical ConductorMaterialsB 750 Specification for GALFAN (Zinc-5 % Aluminum-Mischmetal) Alloy in Ingot Form for Hot-Dip CoatingsE47 Test Methods for Chemical
7、 Analysis of Zinc Die-Casting AlloysE 1277 Test Method for Chemical Analysis of Zinc-5 %Aluminum-MischmetalAlloys by ICP Emission Spectrom-etryE29 Practice for Using Significant Digits in Test Data toDetermine Conformance with Specifications2.3 Other Standard:GF-1 Standard Practice for Determination
8、 of Cerium andLanthanum Compositions in GalfanAlloy (5 %Al-0.04 %La-0.04 % Ce-Bal SHG Zn)33. Terminology3.1 Abbreviations:Abbreviations:3.1.1 MMmischmetal3.1.2 Zn5AlMMzinc5 % aluminum mischmetal alloy3.2 Definitions:3.2.1 lotunless otherwise specified in the contract ororder, a lot shall consist of
9、all coils of wire of the samediameter and unit lengths submitted for inspection at the sametime.3.2.2 Product CodeDefines product coating type, coatingclass and strength grade. This specification covers only HighStrength ClassA Zn5AlMM coated products and identified asproduct code MA3.4. Ordering In
10、formation4.1 Orders for material under this specification shall includethe following information:4.1.1 Quantity of each size,4.1.2 Wire diameter in inches or millimeters (Section 13),4.1.3 Certification, if required (Section 18),4.1.4 Test report, if required (Section 18), and4.1.5 Package Size (Sec
11、tion 19).4.1.6 Product Code (Paragraph 3.2.2).4.1.7 Order Example: five multiple lengths of 12 000 ft.each, 0.1327 in. MA3 wire, packaged onto wooden non-returnable reels, with certified test report.1This specification is under the jurisdiction of ASTM Committee B01 onElectrical Conductors and is th
12、e direct responsibility of Subcommittee B01.05 onConductors of Ferrous Metals.Current edition approved Nov. 1, 2008. Published December 2008. Originallyapproved in 1989. Last previous edition approved in 2002 as B 803 02.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact
13、 ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.3Available from International Lead Zinc Research Organization, 2525 MeridianParkway, P.O. Box 12036, Research Triangle Park, NC 27709-20361*
14、A Summary of Changes section appears at the end of this standard.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.5. Materials and Manufacture5.1 The base metal shall be steel produced by the open-hearth, electric furnace, or basic oxy
15、gen process.5.2 The wire shall be cold drawn and coated withZn5AlMM alloy to produce the desired properties.6. Chemical Composition6.1 The steel shall conform to the requirements prescribedin Table 1.6.2 Chemical analysis of the steel shall be conducted inaccordance with Test Methods, Practices, and
16、 TerminologyA 751.6.3 The ingot form of zinc-5 % aluminum-mischmetal alloyshall conform to Specification B 750.6.3.1 For a two-step coating operation where the firstcoating is zinc (hot-dip galvanized or electrogalvanized), thefinal bath may have an aluminum content of up to 7.2 %, toprevent depleti
17、on of the aluminum content of the bath.6.3.2 Method of AnalysisThe determination of chemicalcomposition shall be made in accordance with suitable chemi-cal (Test Methods E47for Tin), ICP Argon Plasma Spectro-metric (Practice E 1277), or other methods. In case of dispute,the results secured by Practi
18、ce E 1277 shall be the basis ofacceptance.6.3.3 A Method of Coating Material AnalysisRefer toSpecification B 750. In case of dispute, the results secured byPractice E 1277 shall be the basis of acceptance.7. Tensile Test7.1 The Zn5AlMM-coated steel core wire shall conformto the tensile and elongatio
19、n requirements prescribed in Table2 or Table 3.7.2 Tensile tests shall be conducted in accordance with TestMethods and Definitions A 370, using the initial settings fordetermining stress at 1 % extension given in Table 4 or Table5 of this specification.7.3 Test SpecimensThe test specimens shall be f
20、ree ofbends or kinks other than the curvature resulting from the usualcoiling operations. Any hand straightening necessary to permitinsertion of the specimen in the jaws of the testing machineshall be performed by drawing between wood blocks or bysome other equally satisfactory means.8. Wrap Test8.1
21、 The material, as represented by the test specimens, shallnot fracture when the Zn5AlMM alloy-coated wire iswrapped at a rate not exceeding 15 turns/min in a close helixof at least eight turns around a cylindrical mandrel with adiameter equal to three times the specified diameter of the wireunder te
22、st, 65%.9. Coating Test9.1 The Zn5AlMM alloy-coated wire shall conform to thecoating requirements prescribed in Table 6 or Table 7.9.2 The coating test shall be conducted in accordance withTest Method A 90/A 90M.10. Adherence of Coating Test10.1 The Zn5AlMM alloy-coated wire shall be capable ofbeing
23、 wrapped in a close helix at a rate not exceeding 15TABLE 1 Chemical RequirementsElement Composition, %Carbon 0.50 to 0.88Manganese 0.50 to 1.30Phosphorus, max 0.035Sulfur, max 0.045Silicon 0.10 to 0.35TABLE 2 Tensile RequirementsSpecified DiameterStress at 1 %Extension, minUltimate TensileStrength,
24、 minElongation in 10in., min %in. ksi ksi0.0500 to 0.0899, incl 210 235 3.00.0900 to 0.1199, incl 205 230 3.00.1200 to 0.1399, incl 200 225 3.50.1400 to 0.1900, incl 195 220 3.5TABLE 3 Tensile Requirements (Metric)Specified DiameterStress at 1 %Extension, minUltimate TensileStrength, minElongation i
25、n 250mm, min %mm MPa MPa1.27 to 2.28, incl 1450 1620 3.02.29 to 3.04, incl 1410 1590 3.03.05 to 3.55, incl 1380 1550 3.53.56 to 4.82, incl 1340 1520 3.5TABLE 4 Initial Settings for Determining Stress at 1 % ExtensionSpecified Diameter Initial Stress Initial Setting of Extensometer,in./in.in. ksi0.05
26、00 to 0.0899, incl 15 0.0005 (0.05 % Extension)0.0900 to 0.1199, incl 30 0.0010 (0.10 % Extension)0.1200 to 0.1900, incl 46 0.0015 (0.15 % Extension)TABLE 5 Initial Settings for Determining Stress at 1 % Extension(Metric)Specified Diameter Initial Stress Initial Setting of Extensometer,mm/mmmm MPa1.
27、27 to 2.28, incl 110 0.0005 (0.05 % Extension)2.29 to 3.04, incl 210 0.0010 (0.10 % Extension)3.05 to 4.82, incl 320 0.0015 (0.15 % Extension)TABLE 6 Zn5AlMM Alloy CoatingSpecified Diameter ofCoated WireArea DensityofZn5AlMMAlloy Coatingmin ofUncoatedWireSurface, oz/ft2in. Class A0.0500 to 0.0599, i
28、ncl 0.600.0600 to 0.0749, incl 0.650.0750 to 0.0899, incl 0.700.0900 to 0.1039, incl 0.750.1040 to 0.1199, incl 0.800.1200 to 0.1399, incl 0.850.1400 to 0.1799, incl 0.900.1800 to 0.1900, incl 1.00B803082turns/min around a cylindrical mandrel having a diameter asprescribed in Table 8 or Table 9, wit
29、hout cracking or flaking thecoating to such an extent that any Zn5AlMM alloy can beremoved by rubbing with the bare fingers.NOTE 1Loosening or detachment during the adhesion test of super-ficial, small particles of Zn5AlMM alloy formed by mechanicalpolishing of the surface of the coated wire shall n
30、ot be considered causefor rejection.11. Joints11.1 No joints shall be made in the finished wire.11.2 Joints may be made at any stage of processing prior tofinal cold drawing by the electric butt-weld or flash orflash-welding process.11.3 Welding equipment and procedure shall be such that itcan be de
31、monstrated that the ultimate tensile strength of afinished wire specimen containing the welded section shall benot less than 96 % of the specified minimum stress at 1 %extension.11.4 A welded section shall not be required to meet thestress at 1 % extension, elongation, and wrap tests.12. Density and
32、 Resistivity12.1 For the purpose of calculating mass per unit length,cross sections, and so forth, the density of Zn5AlMMalloy-coated steel wire at 20C shall be taken as 0.281lb/in.3(7780 kg/m3).12.2 A maximum resistivity of Zn5AlMM alloy-coatedsteel wire is not guaranteed but a typical value of 0.1
33、9157Vmm2/m may be used for purpose of calculation. For conver-sion to other units of conductivity or resistivity, refer to TestMethod B 193.13. Dimensions and Permissible Variations13.1 The specified diameter of the Zn5AlMM alloy-coated wire shall be expressed in decimal fractions of an inchto four
34、decimal places, or in millimeters to two decimal places.13.2 To determine the applicable tolerance range from Table10 or Table 11, round the specified diameter to the nearest0.001 in. (0.01 mm) in accordance with the rounding method ofPractice E29.13.3 Measure the largest and smallest diameter taken
35、 at thesame cross section rounded to the nearest 0.001 in. (0.01 mm)in accordance with the rounding method of Practice E29.Calculate the average of the two measurements. The calculatedvalue shall not differ from the specified diameter by more thanthe applicable tolerance range shown in Table 10 or T
36、able 11.14. Workmanship, Finish, and Appearance14.1 The Zn5AlMM alloy coating shall be reasonablysmooth, continuous, of reasonably uniform thickness and freeof imperfections not consistent with good commercial practice.15. Number of Tests and Retests15.1 One test specimen shall be taken from each 50
37、00 lb(2500 kg) or fraction thereof in the inspection lot.15.2 Each specimen shall be tested for compliance withSections 7, 8, 10, and 13. At least half of the specimens shallbe tested for compliance with Section 9.15.3 Should one or more of the test specimens fail any ofthe tests specified, the nonc
38、onforming coil or coils may beremoved and the balance of the lot subjected to retests. Forretest purposes, two additional coils for each 5000 lbs (2500kg) in the lot shall be sampled and tested for the property inwhich the original sample failed to comply.TABLE 7 Zn5AlMM Alloy Coating (Metric)Specif
39、ied Diameter ofCoated WireArea DensityofZn5AlMMCoating, min,of UncoatedWireSurface,g/m2mm Class A1.27 to 1.52, incl 1831.53 to 1.90, incl 1981.91 to 2.28, incl 2142.29 to 2.64, incl 2292.65 to 3.04, incl 2443.05 to 3.55, incl 2593.56 to 4.57, incl 2744.58 to 4.82, incl 305TABLE 8 Mandrel Size for Ad
40、herence TestSpecified Wire DiameterRatio ofMandrelDiameter toWire Diameterin.0.0500 to 0.0899, incl 30.0900 to 0.1399, incl 40.1400 to 0.1900, incl 5TABLE 9 Mandrel Size for Adherence Test (Metric)Specified Wire DiameterRatio ofMandrelDiameter toWire Diametermm1.27 to 2.28, incl 32.29 to 3.04, incl
41、43.05 to 4.82, incl 5TABLE 10 Permissible Variations in Diameter of Zn5AlMMAlloy-Coated Steel WireNOTE 1 It is recognized that the surface of coatings, particularly thoseproduced by the hot-dip method of coating, are not perfectly smooth anddevoid of irregularities. If the tolerances shown in the ta
42、ble are rigidlyapplied to such irregularities that are inherent to the product, unjustifiedrejections of wire that would actually be satisfactory for use could occur.It is intended that these tolerances be used in gaging the wires where thereis a minimum of such diameter irregularities due to hot di
43、p coating.Specified Diameter Permissible Variationin.in.Plus Minus0.0500 to 0.0749, incl 0.0015 0.0010.0750 to 0.1199, incl 0.002 0.0020.1200 to 0.1399, incl 0.003 0.0020.1400 to 0.1900, incl 0.004 0.003B80308315.4 Should any of the retest specimens fail to meet theproperties specified, the lot repr
44、esented by the test specimensshall be rejected.15.5 Instead of rejecting the entire lot as provided in 15.4,the producer may test specimens from every coil in the lot forthe property in which failure occurred, and reject only thenonconforming coils.16. Inspection16.1 Unless otherwise specified in th
45、e contract or purchaseorder, the manufacturer shall be responsible for the perfor-mance of all inspection and test requirement specified.16.2 All inspections and tests shall be made at the place ofmanufacture unless otherwise especially agreed to by themanufacturer and the purchaser at the time of t
46、he purchase.16.3 The manufacturer shall afford the inspector represent-ing the purchaser all reasonable manufacturers facilities tosatisfy him that the material is being furnished in accordancewith this specification.17. Rejection and Rehearing17.1 Material that fails to conform to the requirements
47、ofthis specification shall be rejected. Rejection should be re-ported to the producer or supplier promptly and in writing. Incase of dissatisfaction with the results of the test, the produceror supplier may make claim for a rehearing.18. Certification18.1 When specified in the purchase order or cont
48、ract, aproducers or suppliers certification shall be furnished to thepurchaser showing that the material was manufactured,sampled, tested, and inspected in accordance with this speci-fication and has been found to meet the requirements. Whenspecified in the purchase order or contract, a report of th
49、e testresults shall be furnished.19. Packaging and Package Marking19.1 The unit lengths shall be as specified in the contract ororder. Length tolerances shall be 62 % unless otherwisespecified by the purchaser (See Explanatory Note 1).19.2 Package dimensions, kind of package (coils, reels, orreelless coils), and quantity of wire in each package shall beagreed upon by the manufacturer and the purchaser.19.3 A durable tag shall be securely attached to eachpackage showing the nominal diameter of wire, length, ap-proximate weight
