1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 06 24 Revised Para 3.0 inserted; Para 3.1, 3.13, 4 deleted, corrected numbering 1994 08 10 NC00E1024447036 Released L. Mastrofrancesco Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 1 of 5 CABLE, LOW T
2、ENSION, MODIFIED POLYESTER INSULATED, WSA-M1L133-A1 COPPER AND TINNED COPPER CONDUCTOR 1. SCOPE The materials defined by this specification are stranded insulated low tension wires for use throughout the vehicle. The wire insulation system shall be suitable for continuous operation between temperatu
3、res of - 55 to 150 C. 2. APPLICATION The products described by this specification are intended for use in automotive electrical systems and harnesses, especially in areas where mechanical toughness, temperature, fluids, and flex life are of concern. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PROD
4、UCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 CONDUCTOR 3.2.1 Conductor Material (ASTM B 3 or B 33, prior to bunching) 3.2.2 Conductor Elongation (ASTM B 3 or B 33, values per Table I, prior to
5、 insulating) 3.2.3 Conductor Diameter (ASTM D 3032, Sec. 15 optical method, values per Table I) 3.2.4 The conductor area may be determined by measuring individual strand diameters and calculating the sum of the individual strand areas. 3.2.5 Conductor Resistance (Table I) 3.3 FINISHED WIRE 3.3.1 The
6、 insulating material shall be an extrusion of modified polyester material. The surface shall be smooth and without cracks, knots, blisters or other faults. 3.3.2 Dimensions (ASTM D 3032, Sec. 15 and 16, values per Table I) ENGINEERING MATERIAL SPECIFICATIONWSA-M1L133-A1 Printed copies are uncontroll
7、ed Copyright 2003, Ford Global Technologies, Inc. Page 2 of 5 3.3.3 Tensile and Elongation (ASTM D 3032, Sec. 17 using 25 mm jaw separation and bench marks, and a jaw separation speed of 50 mm per minute. 3.3.3.1 Tensile, min 27 mPa 3.3.3.2 Elongation, min 250% 3.3.4 The color of the finished wires
8、are per the Munsell Color Coding System and shall conform to Table III. The following method shall be used to evaluate the color of the cables. Comparison must be made by a person with normal or corrected vision, under cool white fluorescent lighting. The surface being inspected and the tolerance se
9、t must be in the same plane. Cable samples must be placed flat, overlapping the color standard. Color tolerance Reference Sets are available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096. 3.4 FAULT TESTING OF THE COMPLETE DELIVERY (In process testing) (ASTM D 3032, Sec. 13) 3.5 DIELECTRIC (
10、SAE J1128, PARA 4.3) No dielectric breakdown is allowed. 3.6 COLD BEND (SAE J1128, Sec. 4.4 for Type SXL except at - 55 C. No cracking or breakdown of the finished cable insulation is allowed. 3.7 PINCH RESISTANCE (SAE J1128, para 4.9, values per Table I) 3.8 HEAT AGING The tensile specimen shall be
11、 prepared per ASTM D 3032, Section 17, and then conditioned in an air circulating oven for 168 h at 165 +/- 2 C. Upon removal from the oven, the samples shall be conditioned at 20 +/- 5 C for a minimum of 4 h, and then tested for retention of tensile strength and elongation per paragraph 3.3.3. 3.8.
12、1 Retention of Tensile Strength, min 80% 3.8.2 Retention of Elongation, min 50% 3.9 RESISTANCE TO FLAME PROPAGATION (SAE J1128, para 4.5) ENGINEERING MATERIAL SPECIFICATIONWSA-M1L133-A1 Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 5 3.10 FLUID RESISTANCE 3
13、10.1 Retention of Tensile Strength and Elongation The tensile specimen shall be prepared per ASTM D 3032, Section 17, for each fluid and test condition listed in Table II. After immersion, the tensile specimen shall be blotted with an absorbent tissue and dried at room temperature for 1 hour. Speci
14、mens shall be tested for retention of tensile strength and elongation, per paragraph 3.3.3, and shall meet the minimum requirements listed in Table II. 3.10.2 Swelling A 300 mm sample of finished cable shall be prepared for each fluid listed in Table II. Each sample shall be immersed to within 40 mm
15、 of the ends of the cable for the time and temperatures listed in Table II. Upon removal from the test fluids, the cable sample shall be blotted with an absorbent tissue and the change in outer diameter measured per ASTM D 3032. Change in diameter shall be defined as follows and shall not exceed the
16、 amount specified in Table II. % Change = 100 x (D1 - D0)/D0 Where: D1 = post-immersion outer diameter D0 = pre-immersion outer diameter 3.11 FOGGING (Interior Glass Surface) (FLTM BO 116-03) Fog Number, min 60 Formation of a clear film, droplets or crystals is cause for rejection. ENGINEERING MATER
17、IAL SPECIFICATIONWSA-M1L133-A1 Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 5 TABLE I CONSTRUCTION DETAILS STRANDED WIRE FINISHED CABLE PERFORMANCE DETAIL SIZE (AWG) STRANDING (Numbering x AWG) MAXIMUM DIAMETER (mm) MAXIMUM RESISTANCE (milliohms/m) DIAMETE
18、R (mm) NOMINAL WEIGHT (kg/km) PINCH RESISTANCE (kg) 22 7x30 0.762 52.5 1.17+/-.05 4 * 22 7x30 0.762 51.9 1.57+/-.08 5 3.1 22 7x30 0.762 52.5 1.57+/-.08 5 3.1 22 19x34 0.762 53.2 1.57+/-.08 5 3.1 22 19x34 0.762 52.5 1.57+/-.08 5 3.1 22 154x44 0.838 61.7 1.19+/-.05 4 3.1 20 7x28 0.965 32.8 1.37+/-.05
19、6 * 20 7x28 0.965 31.5 1.78+/-.08 7 4.5 20 7x28 0.965 32.8 1.78+/-.08 7 4.5 20 19x32 0.965 31.3 1.40+/-.05 6 * 20 19x32 0.965 32.4 1.78+/-.08 8 4.5 20 19x32 0.965 31.3 1.78+/-.08 8 4.5 18 7x26 1.19 21.6 1.60+/-.05 9 * 18 7x26 1.19 21.1 2.01+/-.08 10 5.0 18 7x26 1.19 21.6 1.98+/-.08 10 5.0 18 19x30 1
20、19 20.4 1.65+/-.05 10 * 18 19x30 1.19 20.5 2.01+/-.08 11 5.0 18 19x30 1.19 20.4 2.01+/-.08 11 5.0 16 19x29 1.35 15.9 1.83+/-0.8 12 * 16 19x29 1.35 15.8 2.16+/-.08 14 5.9 16 19x29 1.35 15.9 2.21+/-.08 14 5.9 * Not Applicable ENGINEERING MATERIAL SPECIFICATIONWSA-M1L133-A1 Printed copies are uncontro
21、lled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 5 TABLE II FLUIDS TABLE Test Fluid Temperature (C) Time (hrs.) Tensile Min Retn. (%) Elongation Min Retn. (%) Max Dia Change (%) ASTM D 471, Oil # 1 150 24 80 80 5 IRM902* 150 24 80 80 IRM903* 150 24 75 80 5 Gasoline, ASTM D 471, Fuel C 2
22、5 24 80 80 5 Diesel Fuel, ASTM D 975, Fuel 2D 70 24 75 80 5 Power Steering Fluid 50 24 80 80 5 Transmission Fluid, Dexron II 150 24 80 80 5 Brake Fluid, (DOT Type 3) 50 24 80 80 5 Methyl Alcohol 65* 24 80 80 5 Ethyl Alcohol 78* 24 80 80 10 * Replacement oil for ASTM D 471, Oil #2 * Replacement oil for ASTM D 471, Oil #3 * Reflux Temperature at Atmospheric Pressure TABLE III FINSISHED CABLE COLORS Code Solid Color Target Munsell Designation (Hue/Value/Chroma) 0 Black 5BG/3/1 2 Red 5/R/4/8 5D Dark Green 5BG/4/4 6L Light Blue 7.0B/5.7/5.2 8 Gray 5GY/5/1 9 White 2.5GY/8/2
