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1、 AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/86 Copyright 2006 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or tra
2、nsmitted, 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: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE
3、WEB ADDRESS: http:/www.sae.org ISSUED 2000-06 REAFFIRMED 2006-04 REVISED 2007-08 THIRD ANGLE PROJECTION CUSTODIAN: SAE AE-8/AE-8D REV. B FEDERAL SUPPLY CLASS 6145 AS22759/86 SHEET 1 OF 7 REV. B SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of
4、 technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years a
5、t which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. RATIONALE TOTAL REVISION AND UPDATE WORD-FOR-WORD MIL SPECIFICATIONS CONVERTED TO SAE STANDARDS. NOTICE THE REQUIREMENTS FOR ACQUIRING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS SPECI
6、FICATION SHEET AND THE ISSUE OF THE FOLLOWING SPECIFICATION LISTED IN THAT ISSUE OF THE DEPARTMENT OF DEFENSE INDEX OF SPECIFICATIONS AND STANDARDS (DODISS) SPECIFIED IN THE SOLICITATION: AS22759. THIS SPECIFICATION IS NOT INTENDED FOR USE IN NAVAL AIRCRAFT OR NAVAL AIR SYSTEMS APPLICATIONS. FIGURE
7、1 -,-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/86 REV. B AS22759/86 SHEET 2 OF 7 REV. B TABLE 1 - CONSTRUCTION DETAILS CONDUCTOR FINISHED WIRE DIAMETER (IN) DIAMETER (IN) WEIGHT (
8、LB/1000 FT) 2/ PART NO. 1/ WIRE SIZE STRANDING (NUMBER OF STRANDS X AWG GAUGE OF STRANDS) MIN MAX RESISTANCE AT 20 C (68 F) (OHMS/1000 FT MAX) MIN MAX MIN TARGET MAX M22759/86-26-* M22759/86-24-* M22759/86-22-* M22759/86-20-* M22759/86-18-* M22759/86-16-* M22759/86-14-* M22759/86-12-* M22759/86-10-*
9、 M22759/86-8-* M22759/86-6-* M22759/86-4-* M22759/86-2-* M22759/86-1-* M22759/86-01-* M22759/86-02-* M22759/86-03-* M22759/86-04-* 26 24 22 20 18 16 14 12 10 8 6 4 2 1 0 00 000 0000 19 X 38 19 X 36 19 X 34 19 X 32 19 X 30 19 X 29 19 X 27 37 X 28 37 X 26 133 X 29 133 X 27 133 X 25 665 X 30 817 X 30 1
10、045 X 30 1330 X 30 1665 X 30 2109 X 30 0.0175 0.0225 0.0285 0.0365 0.0455 0.0515 0.0645 0.0835 0.106 0.158 0.198 0.250 0.320 0.366 0.395 0.440 0.500 0.565 0.0194 0.0244 0.0304 0.0384 0.0484 0.0544 0.0684 0.0874 0.110 0.166 0.208 0.263 0.340 0.380 0.425 0.475 0.540 0.605 38.4 24.3 15.1 9.19 5.79 4.52
11、 2.88 1.90 1.19 0.658 0.418 0.264 0.170 0.139 0.108 0.085 0.068 0.054 0.033 0.038 0.043 0.051 0.061 0.068 0.081 0.100 0.122 0.180 0.219 0.276 0.344 0.388 0.420 0.475 0.530 0.590 0.037 0.042 0.047 0.055 0.065 0.073 0.086 0.105 0.127 0.188 0.229 0.288 0.364 0.408 0.450 0.505 0.560 0.630 1.29 1.87 2.70
12、 4.25 6.40 8.20 12.4 18.9 29.3 54.7 84.1 136 210 274 324 410 518 646 1.42 2.04 2.90 4.48 6.65 8.50 12.9 19.7 30.8 56.6 86.5 140 218 283 338 429 531 667 1.55 2.20 3.10 4.70 6.90 8.80 13.4 20.4 31.6 58.5 88.9 144 226 292 352 448 544 688 1/ PART NUMBER: THE ASTERISKS IN THE PART NUMBER COLUMN OF TABLE
13、1 SHALL BE REPLACED BY COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. EXAMPLES: M22759/86-20-93 IS A 20 AWG WHITE WITH ORANGE STRIPE. 2/ THE ACCEPTABLE VALUE FOR THE CPK FOR THE FINISHED WIRE WEIGHT LISTED SHALL BE 1.3, USING A NORMAL (GAUSSIAN) DISTRIBUTION TO OBTAIN THOSE CPK VALUES. TABLE
14、 2 - WIRE INSULATION MATERIALS 1/ TAPE CODE THICKNESS (NOM) MATERIAL 1 0.0020 0.0005 (FP)/0.0010 (POLYIMIDE)/0.0005 (FP) 2 0.0010 FP (SKIVED) 3 0.0020 FP (SKIVED) 4 0.0020 FP (UNSINTERED) 5 0.0025 FP (UNSINTERED) 6 0.0030 FP (UNSINTERED) 1/ PHYSICAL PROPERTIES OF FP TAPES (SKIVED AND UNSINTERED) SHA
15、LL BE IN ACCORDANCE WITH AS22759 REQUIREMENTS. TABLE 3 - PHYSICAL PROPERTIES OF FP/POLYIMIDE/FP TAPES TENSILE STRENGTH 19,000 LB/IN SQ (AVERAGE MINIMUM) TENSILE MODULUS 350,000 LB/IN SQ (AVERAGE MINIMUM) ELONGATION 40 PERCENT (AVERAGE MINIMUM) DIELECTRIC STRENGTH 4000 VOLTS/MIL (AVERAGE MINIMUM) 0.0
16、005 FP LAYER (BOTTOM) DISTINGUISHABLE COLOR (NEXT TO CONDUCTOR) MAY BE USED AT MANUFACTURERS OPTION AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/86 REV. B AS22759/86 SHEET 3 OF 7 REV. B
17、 TABLE 4 - TAPE OVERLAP REQUIREMENTS 1/ WRAP 1 WRAP 2 WRAP 3 WRAP 4 PERCENT OVERLAP PERCENT OVERLAP PERCENT OVERLAP PERCENT OVERLAP WIRE SIZE TAPE CODE MIN MAX TAPE CODE MIN MAX TAPE CODE MIN MAX TAPE CODE MIN MAX NOMINAL WALL THICKNESS (MILS) 26 1 50.5 54.0 4 50.5 54.0 7.4 24 1 50.5 54.0 4 50.5 54.
18、0 7.4 22 1 50.5 54.0 4 50.5 54.0 7.4 20 1 50.5 54.0 4 50.5 54.0 7.4 18 1 50.5 54.0 4 50.5 54.0 7.4 16 1 50.5 54.0 5 50.5 54.0 8.3 14 1 50.5 54.0 5 50.5 54.0 8.3 12 1 50.5 54.0 6 50.5 54.0 9.1 10 1 50.5 54.0 6 50.5 54.0 9.1 8 2 20.5 35.0 1 50.5 55.0 6 67.0 71.0 13.2 6 2 20.5 35.0 1 50.5 55.0 6 67.0 7
19、1.0 13.2 4 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 2 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1/0 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 2/0 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 3/0 3 20.5 3
20、5.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 4/0 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1/ WRAP 1 IS INNERMOST TAPE WHICH IS IN CONTACT WITH THE CONDUCTOR. WRAPS 2, 3, AND 4 ARE PROGRESSIVELY FURTHER AWAY FROM THE CONDUCTOR CORE. RATINGS: TEMPERATURE RATING: 200 C (392 F) MAXIMUM CONTI
21、NUOUS CONDUCTOR TEMPERATURE. VOLTAGE RATING: 600 VOLTS (RMS) AT SEA LEVEL. ADDITIONAL REQUIREMENTS: WET ARC PROPAGATION RESISTANCE (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY): TEST IN ACCORDANCE WITH AS4373, METHOD 509. MEASURE THE DAMAGE OF THE BUNDLE ALONG THE AXIS. THE WIRE IS ACCEPTABLE IF TH
22、E FOLLOWING CRITERIA ARE MET: 1. A MINIMUM OF 67 WIRES PASS THE DIELECTRIC TEST. 2. THREE WIRES OR LESS FAIL THE DIELECTRIC TEST IN ANY ONE BUNDLE. 3. ACTUAL DAMAGE TO THE WIRE IS NOT MORE THAN 3 INCHES IN ANY TEST BUNDLE. DRY ARC PROPAGATION RESISTANCE (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY)
23、: TEST IN ACCORDANCE WITH AS4373, METHOD 508. MEASURE THE DAMAGE OF THE BUNDLE ALONG THE AXIS. THE WIRE IS ACCEPTABLE IF THE FOLLOWING CRITERIA ARE MET: 1. A MINIMUM OF 67 WIRES PASS THE DIELECTRIC TEST. 2. THREE WIRES OR LESS FAIL THE DIELECTRIC TEST IN ANY ONE BUNDLE. 3. ACTUAL DAMAGE TO THE WIRE
24、IS NOT MORE THAN 3 INCHES IN ANY TEST BUNDLE. BLOCKING: 200 C 2 C (392 F 3.6 F). COLOR: WHITE IS THE PREFERRED COLOR AND SHALL BE IN ACCORDANCE WITH MIL-STD-104, CLASS 2. COLORS SHALL BE LASER MARKABLE AND MEET THE COLOR LIMITS BELOW. CONFORMITY OF COLOR SHALL NOT BE REQUIRED AFTER OVEN EXPOSURE. -,
25、-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/86 REV. B AS22759/86 SHEET 4 OF 7 REV. B MUNSELL COLOR LIMITS FOR UV LASER MARKABLE WIRE HUE VALUE CHROMA COLOR FROM TO FROM TO FROM TO
26、BLACK BLUE GREEN RED YELLOW BROWN ORANGE VIOLET 2.5N 5PB 2.5G 10RP 5Y 2.5YR 10R 2.5P 2.5N 7.5B 7.5G 5R 10Y 7.5R 2.5YR 7.5R 7 7 7 7 8 7 6 7 8.5 8 9 8 9 9 7 8 N/A 4 2 4 4 2 8 4 N/A 6 6 6 6 4 10 8 GRAY SAME AS BLACK SAME AS BLACK SAME AS BLACK COLOR STRIPING OR BANDING DURABILITY: 125 CYCLES (250 STROK
27、ES), 250 GRAMS WEIGHT. CONDUCTOR STRAND ADHESION: REQUIRED. CONTINUOUS LENGTHS: SCHEDULE B. DYNAMIC CUT-THROUGH (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY): TEST IN ACCORDANCE WITH AS4373, METHOD 703. BLADE SHALL BE THE STANDARD CUTTING BLADE EXCEPT THE CUTTING EDGE RADIUS SHALL BE 0.005 INCH 0.0
28、01 INCH. MINIMUM AVERAGE DYNAMIC CUT-THROUGH (LB) SHALL BE AS FOLLOWS: WIRE SIZE 23 C 5 C 150 C 5 C 200 C 5 C 26 10 LB 8 LB 6 LB 20 25 LB 20 LB 15 LB 16 25 LB 20 LB 15 LB FLAMMABILITY: TEST IN ACCORDANCE WITH AS4373, METHOD 801. REQUIREMENTS: DURATION OF AFTER-FLAME 3 SECONDS (MAX) FLAME TRAVEL 3 IN
29、CHES (MAX) NO FLAMING OF TISSUE FORCED HYDROLYSIS: (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY) 5000 HOURS AT 70 C. TEST 5 UNCONDITIONED AND 5 CONDITIONED SAMPLES OF AWG SIZE 20 ONLY IN ACCORDANCE WITH AS4373 METHOD 602. ALL SAMPLES MUST PASS THE DIELECTRIC TEST AS LISTED IN METHOD 602. HIGH FREQU
30、ENCY SPARK TEST: (WHEN USED IN LIEU OF IMPULSE DIELECTRIC TEST) TEST IN ACCORDANCE WITH AS4373, METHOD 505, 5.7 KILOVOLTS (RMS). TEST 100 PERCENT OF THE WIRE. HUMIDITY RESISTANCE: AFTER HUMIDITY EXPOSURE WIRE SHALL MEET THE REQUIREMENTS FOR INITIAL INSULATION RESISTANCE. IDENTIFICATION OF PRODUCT: N
31、OT REQUIRED FOR SIZE 26. COLOR CODE DESIGNATOR NOT REQUIRED. IDENTIFICATION DURABILITY: 125 CYCLES (250 STROKES), 250 GRAMS WEIGHT. IMMERSION (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY): TEST IN ACCORDANCE WITH AS4373, METHOD 601 INCLUDING THE ADDITIONAL FLUIDS LISTED IN TABLE 5 OF THIS SPECIFICA
32、TION. USE MANDRELS AND WEIGHTS LISTED IN TABLE 6 FOR BEND TESTING. DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. FOR TURBINE FUEL IMMERSION TEST OF AS4373, EITHER JP4 OR MIL-DTL-83133 TYPE JP-8 (NATO TYPE F-34) MAY BE USED. -,-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMID
33、E INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/86 REV. B AS22759/86 SHEET 5 OF 7 REV. B TABLE 5 - FLUID TABLE TEST FLUID TEST TEMPERATURE (C (F) IMMERSION TIME (HOURS) A. SAE AMS 1424, ANTI-ICING AND DEICING DEFROSTING FLUID, UNDILUTED 48-50 (118-122) 20 B. SAE
34、 AMS 1424, ANTI-ICING AND DEICING DEFROSTING FLUID, DILUTED 60/40 (FLUID/WATER) RATIO 48-50 (118-122) 20 C. MIL-C-43616, CLEANING COMPOUND, AIRCRAFT SURFACE, TYPE I 48-50 (118-122) 20 D. ASTM D 1153, METHYL ISOBUTYL KETONE (FOR USE IN ORGANIC COATINGS) 20-25 (68-77) 168 E. AS1241, FIRE RESISTANT HYD
35、RAULIC FLUID FOR AIRCRAFT 48-50 (118-122) 20 F. MIL-PRF-7808, LUBRICATING OIL, AIRCRAFT TURBINE ENGINE, SYNTHETIC BASE 118-121 (244-250) 30 G. MIL-PRF-87937, CLEANING COMPOUND, AEROSPACE EQUIPMENT, TYPE II OR TYPE IV, UNDILUTED 63-68 (145-154) 20 H. MIL-PRF-87937, CLEANING COMPOUND, AEROSPACE EQUIPM
36、ENT, TYPE II OR TYPE IV, DILUTED 25/75 (FLUID/WATER) RATIO 63-68 (145-154) 20 I. TT-S-735, STANDARD TEST FLUIDS: HYDROCARBON, TYPE I 20-25 (68-77) 168 J. TT-S-735, STANDARD TEST FLUIDS: HYDROCARBON, TYPE II 20-25 (68-77) 168 K. TT-S-735, STANDARD TEST FLUIDS: HYDROCARBON, TYPE IV 20-25 (68-77) 168 L
37、. DIELECTRIC-COOLANT FLUID SYNTHETIC SILICATE ESTER BASE, MONSANTO COOLANOL 25 OR APPROVED EQUIVALENT 20-25 (68-77) 168 M. ASTM D 4814, GASOLINE, AUTOMOTIVE, COMBAT 20-25 (68-77) 168 IMPULSE DIELECTRIC TEST: 8.0 KILOVOLTS (PEAK). TEST 100 PERCENT OF THE WIRE. INSULATION RESISTANCE: SIZES 26 THROUGH
38、10, 5000 MEGOHMS FOR 1000 FEET (MIN) SIZES 8 THROUGH 04, 3000 MEGOHMS FOR 1000 FEET (MIN) INSULATION STATE OF SINTER: (QUALITY CONFORMANCE INSPECTION PERFORMED ON ONE SAMPLE PER LOT) EVALUATE FP LAYERS WITH A DIFFERENTIAL SCANNING CALORIMETER PER AS4373, METHOD 813. THIS TEST IS APPLICABLE TO 10 AWG
39、 AND SMALLER WIRES. THE DIFFERENCE IN ENERGY TO MELT BETWEEN THE FIRST AND SECOND HEATS SHALL BE LESS THAN OR EQUAL TO 3 JOULES/GRAM. LAMINATION SEALING: (GROUP II QUALITY CONFORMANCE TEST) WHEN TESTED IN ACCORDANCE WITH AS4373, METHOD 809 AT 260 C FOR 6 HOURS, THERE SHALL BE NO EVIDENCE OF TAPE SEP
40、ARATION OR LIFTING. THREE SAMPLES PER LOT SHALL BE TESTED. LIFE CYCLE: 500 HOURS AT 230 C 2 C (446 F 3.6 F). DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. USE MANDRELS COATED WITH POLYTETRAFLUOROETHYLENE SUCH THAT THE DIAMETER OF THE MANDRELS, AFTER COATING, STILL CONFORM TO THE REQUIRED TEST MANDRELS D
41、IAMETERS OF TABLE 6. 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 AND WEIGHTS SPECIFIED IN TABLE 6. CHAMBER TEMPERATURE, -65 C 2 C (-85 F 3.6 F). DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. SHR
42、INKAGE: TEST AT 230 C 2 C (446 F 3.6 F). MAXIMUM CHANGE IN MEASUREMENT 26 - 10 AWG 0.091 INCH. 8 - 04 AWG 0.125 INCH. SMOKE: 200 C 5 C (392 F 9 F); NO VISIBLE SMOKE. SOLDERABILITY: REQUIRED. STRIPPABILITY: (GROUP II QUALITY CONFORMANCE TEST) AFTER STRIPPING WITH TOOLS AS DEFINED IN AS22759 AND AS545
43、7, NO FRAGMENTS OF ANY LAYER SHALL EXTEND MORE THAN 0.031 INCHES BEYOND THE END OF THE POLYIMIDE TAPE LAYER. THIS TEST IS APPLICABLE TO WIRE SIZES 10 AWG AND SMALLER. AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR
44、, 200 C, 600 VOLTS AS22759/86 REV. B AS22759/86 SHEET 6 OF 7 REV. B INSULATION STRIP FORCE: (GROUP II QUALITY CONFORMANCE TEST). TEST SIZE 26 - 14 WIRE ONLY IN ACCORDANCE WITH ASTM D 3032 SECTION 27. THE LENGTH OF THE INSULATION SLUGS SHALL BE 0.25 INCHES. STRIP FORCE SHALL BE AS LISTED BELOW. NO EV
45、IDENCE OF INSULATION SHALL BE LEFT ON THE CONDUCTOR WHEN VIEWED WITH THE NAKED EYE. WIRE SIZE MIN FORCE MAX FORCE 26-20 0.25 LB 6.0 LB 18-14 0.50 LB 7.0 LB TAPE OVERLAP: IN ACCORDANCE WITH MIL-STD-2223, METHOD 6005. TENSILE MODULUS: TEST COMPOSITE FILM IN ACCORDANCE WITH ASTM D 882, METHOD A. THERMA
46、L INDEX: 200 C (392 F) MINIMUM FOR 10,000 HOURS (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY). TEST SIZE 20 ONLY IN ACCORDANCE WITH ASTM D 3032, SECTION 14. THERMAL SHOCK RESISTANCE: OVEN TEMPERATURE, 200 C 2 C (392 F 3.6 F), MAXIMUM CHANGE IN MEASUREMENT, 26 - 10 AWG 0.091 INCH. 8 - 04 AWG 0.125 I
47、NCH. NO CRACKING. UV LASER MARKING: (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY) WHITE FP MATERIALS SHALL BE FORMULATED IN SUCH A MANNER TO ACHIEVE A 55% MINIMUM CONTRAST LEVEL WHEN MARKED BY AN ULTRAVIOLET (UV) LASER SOURCE OPERATING AT A FLUENCE OF 0.9 0.1 J/CM. THE CONTRAST LEVEL SHALL BE EVALU
48、ATED IN ACCORDANCE WITH METHOD 711 OF AS4373 APPLIES TO 10 AWG AND SMALLER WIRES. THE CONTRAST LEVEL IS DEFINED AS: (REFLECTANCE OF THE BACKGROUND INSULATION - REFLECTANCE OF THE LASER MARK) CL = x 100 REFLECTANCE OF THE BACKGROUND INSULATION WRAP (MANDREL WRAP): NO CRACKING, NO DIELECTRIC BREAKDOWN. USE MANDRELS SPECIFIED IN TABLE 6. DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. TABLE 6 - TEST MANDREL AND TEST LOAD REQUIREMENTS TEST MANDREL DIAMETER 1/ (INCHES) TEST LOAD 1/ (LB) WIRE SIZE (AWG) COLD BEND LIFE CYCLE/ BEND TEST