1、Designation: D 1676 03An American National StandardStandard Test Methods forFilm-Insulated Magnet Wire1This standard is issued under the fixed designation D 1676; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last rev
2、ision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) 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 me
3、thods are intended 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 propertie
4、s of round, rectangular 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 4-12Burnout (AC Overloa
5、d Resistance) 13-21Chemical Resistance 22-28Coefficient of Friction 29-37Continuity, DC High Voltage 38-45Continuity, DC Low Voltage 46-53Completeness of Cure 54-60Cut-Through Temperature (Thermoplastic Flow) 61-68Dielectric Breakdown AC Voltage 69-75Dielectric Breakdown AC Voltage after Bending 76-
6、82Dielectric Breakdown AC Voltage at Elevated Temperatures 83-89Dielectric Breakdown AC Voltage after Conditioning in Refriger-ant Atmosphere 90-99Dimensional Measurement 100-106Dissipation Factor Measurement 107-114Electrical Resistance 115-121Elongation 122-129Extractables, Refrigerant 130-140Film
7、 Adherence and Flexibility 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
8、not purport to address all 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 i
9、n 9.5, 19.1, 19.3, 19.8, 52.1, 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:A 228/A 22
10、8M Specification for Steel Wire, Music SpringQuality2B 3 Specification for Soft or Annealed Copper Wire3B 43 Specification for Seamless Red Brass Pipe, StandardSizes4B 193 Test Method for Resistivity of Electrical ConductorMaterials3B 279 Test Method for Stiffness of Bare Soft Square andRectangular
11、Copper and Aluminum Wire for Magnet WireFabrication3B 324 Specification for Aluminum Rectangular and SquareWire for Electrical Purposes3B 609/B 609M Specification for Aluminum 1350 RoundWire, Annealed and Intermediate Tempers, for ElectricalPurposes3D 149 Test Method for Dielectric Breakdown Voltage
12、 andDielectric Strength of Solid Electrical Insulating Materialsat Commercial Power Frequencies5D 150 Test Methods for AC Loss Characteristics and Per-mittivity (Dielectric Constant) of Solid Electrical Insula-tion5D 374 Test Methods for Thickness of Solid Electrical Insu-lation5D 877 Test Method fo
13、r Dielectric Breakdown Voltage ofInsulating Liquids Using Disk Electrodes6D 1533 Test Methods for Water in Insulating Liquids byCoulometric Karl Fischer Titration6D 1711 Terminology Relating to Electrical Insulation51These test methods are under the jurisdiction of ASTM Committee D09 onElectrical an
14、d Electronic Insulating Materials and are the direct responsibility ofSubcommittee D09.10 on Magnet Wire Insulation.Current edition approved Apr. 10, 2003. Published June 2003. Originallyapproved in 1959. Last previous edition approved in 2002 as D 1676-02.2Annual Book of ASTM Standards, Vol 01.03.3
15、Annual Book of ASTM Standards, Vol 02.03.4Annual Book of ASTM Standards, Vol 02.01.5Annual Book of ASTM Standards, Vol 10.01.6Annual Book of ASTM Standards, Vol 10.03.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.D 2475 Specificati
16、on for Felt7D 2519 Test Method for Bond Strength of Electrical Insu-lating Varnishes by the Helical Coil Test8D 5423 Specification for Forced-Convection LaboratoryOvens for Evaluation of Electrical Insulation8E 4 Practices for Force Verification of Testing Machines9E 6 Terminology Relating to Method
17、s of Mechanical Test-ing9E 8 Test Methods of Tension Testing of Metallic Materials9E 220 Test Method for Calibration of Thermocouples byComparison Techniques10E 1356 Test Method for Assignment of the Glass TransitionTemperatures by Differential Scanning Calorimetry orDifferential Thermal Analysis11E
18、 1545 Test Method for Assignment of the Glass TransitionTemperature by Thermomechanical Analysis112.2 Other Documents:Federal Specification CCCM-911 for Bleached Muslin12IEC 60851 Methods of Test for Winding Wire123. Terminology3.1 Definitions:3.1.1 conductor, na wire or combination of wires notinsu
19、lated 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 apparatus such as coils for motors, transformers,generators, relays, magnets, etc.3.1.3 For definition of
20、other terms used in this test methodrefer to Terminology D 1711.3.2 Definitions of Terms Specific to This Standard:3.2.1 film coating, ncured enamel coating.3.2.2 film insulated wire, na conductor insulated with afilm coating.BOND STRENGTH OF ROUND FILM-INSULATEDSELF-BONDING MAGNET WIRE BY THE HELIC
21、ALCOIL 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 solventbonding methods are defined.5. Terminology5.1 Definitions of Terms Specific to This Standard:5.1.1 bon
22、d 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 reported as theforce required to break a test specimen in flexure.6. Summary of Test Method6.1 Flexura
23、l 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 canprovide information with regard to the bond strength of aparticular self-bonding outer coating in
24、 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 test shall conform to the requirements ofPractices E 4.8.2 Test FixtureThe test fixture shall confo
25、rm to the testfixture for bond strength tests required by Test Method D 2519.8.3 Mandrel HolderThe mandrel holder shall be a metalblock of sufficient size and thickness with a hole capable ofsupporting the winding mandrel in a vertical position duringthe bonding cycle of the helical coil.8.4 Winding
26、 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 mandrel and load ahelical coil during bonding of coil.8.6 Forced-Air OvenSee Specification D 5423.
27、7Annual Book of ASTM Standards, Vol 07.01.8Annual Book of ASTM Standards, Vol 10.02.9Annual Book of ASTM Standards, Vol 03.01.10Annual Book of ASTM Standards, Vol 14.03.11Annual Book of ASTM Standards, Vol 14.02.12Available from Standardization Documents Order Desk, Bldg. 4 Section D,700 Robbins Ave
28、., Philadelphia, PA 19111-5094, Attn: NPODS.TABLE 1 Helical Coil Bond ParametersWire Size,AWGMandrel DiameterARecommendedWinding 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
29、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 20.0 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 0.39
30、2 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 0.24528 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 0.9812
31、3 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 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.
32、84515 0.354 8.99 2500.0 24.517 800.0 7.84514 0.354 8.99 2500.0 24.517 800.0 7.845A6 2 % on all mandrels and bond weights.D16760329. Test Specimen Preparation9.1 Select the appropriate mandrel from Table 1, spray itwith a suitable release agent (fluorocarbon or silicone spray isadequate), and allow i
33、t to dry. Carefully wind onto the preparedmandrel a length of wire, long enough to wind a helical coil atleast 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 Th
34、ermal BondingMount the mandrel supporting thecoil vertically in the mandrel holder and loaded with thebonding weight 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 cool
35、ed to room temperature. Remove the coil fromthe mandrel and inspect the coil for breaks or physical damageprior to testing.9.4 Solvent BondingAfter winding, immerse the coil andmandrel into the specified solvent for 5 s. Immediately there-after, secure the mandrel supporting the coil in the mandrelh
36、older and load the coil with the bonding weight specified inTable 1. Dry the coils for1hatroom temperature. Carefullyremove the coils from the mandrels and further dry in a forcedair oven for 15 6 2 min at 100 6 3C (unless otherwisespecified). Cool the coil to room temperature, inspect forbreaks or
37、physical damage, and test.9.5 Resistance BondingMount the mandrel supporting thecoil vertically in a mandrel holder 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 physic
38、al damage, and test.Specific bonding conditions shall be agreed upon between themanufacturer and the user. (WarningLethal 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
39、designed and installedfor safe operation. Solidly ground all electrically conductiveparts which it is possible for 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
40、an induced charge during thetest or retaining a charge even after disconnection of thevoltage source. Thoroughly 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 relea
41、sed at breakdown to be suffcientto result in fire, explosion, or rupture of the test chamber.Design test equipment, 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 su
42、ppression equipment available.)10. Procedure10.1 Use a rate of loading such that the duration of the testshall be 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 ma
43、y bedestroyed in adjusting the rate of loading.10.3 Break specimens according to the test proceduresdescribed in Test Method D 2519.10.4 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 st
44、ress strain analyzer.Place the specimens in the fixture in the oven for 15 min butnot more than 30 min after the oven has recovered to the settemperature 6 2C. Break the specimens according to the testprocedures described in Test Method D 2519. The specified testtemperature and minimum bond strength
45、 shall be agreementupon between the manufacturer and the user.11. Report11.1 Report the following:11.1.1 Identification 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 A table listing the i
46、ndividual values in pounds, gramsor newtons of bond strength and their averages.12. Precision and Bias1312.1 In comparing 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 wel
47、l-trained operator using the same piece of testequipment and specimens randomly drawn from the samesample of material.12.2 PrecisionTwo averages of observed values should beconsidered significantly different at the 95 % probability levelif the difference equals or exceeds the critical differences li
48、stedin Table 2.12.3 BiasThis test method has no bias because the valueof bond strength is determined solely in terms 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 18 AWG heavybuild fi
49、lm-insulated round copper magnet wire by measuring13Supporting data are available from ASTM International Headquarters. RequestRR: D09-1007.TABLE 2 Critical Differences, Percent of Average Pounds toBreakANumber ofObservations ineach AverageSingle-OperatorPrecisionWithin-LaboratoryPrecisionBetween-LaboratoryPrecision610 1 12AThe critical differences were calculated using t = 1.960, which is based oninfinite degrees of freedomD1676033the time to obtain a dielectric failure when subjected to astep-wise increase in AC overload current.14. Terminology14.1 Definitions of
