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1、 AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260 C, 600 VOLTS AS22759/87 Copyright 2007 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 AS22759/87 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. 1/ STRA
7、NDED NICKEL COATED COPPER CONDUCTOR FIGURE 1 - GENERAL CONFIGURATION FP / POLYIMIDE / FP TAPE SIZES 26 THROUGH 10 FP TAPE SIZE 4 THROUGH 04 FP TAPE FP TAPE FP / POLYIMIDE / FP TAPE SIZES 8 THROUGH 6 FP TAPE FP / POLYIMIDE / FP TAPE FP TAPE 1/ 1/ 1/ FP FLUOROCARBON POLYMER, MODIFIED POLYTETRAFLUOROET
8、HYLENE (PTFE) AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260C, 600 VOLTS AS22759/87 REV. B AS22759/87 SHEET 2 OF 7 REV. B TABLE 1 - CONSTRUCTION DETAILS CONDUCTOR FINISHED WIRE DIAMETER (IN) DIAMETER (IN) WEI
9、GHT (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 MAXMIN TARGET MAX M22759/87-26-* M22759/87-24-* M22759/87-22-* M22759/87-20-* M22759/87-18-* M22759/87-16-* M22759/87-14-* M22759/87-12-* M22759/87-
10、10-* M22759/87-8-* M22759/87-6-* M22759/87-4-* M22759/87-2-* M22759/87-1-* M22759/87-01-* M22759/87-02-* M22759/87-03-* M22759/87-04-* 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
11、30 1045 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 0.0204 0.0244 0.0314 0.0394 0.0494 0.0554 0.0694 0.0894 0.112 0.169 0.212 0.268 0.340 0.380 0.425 0.475 0.540 0.605 42.2 25.9 16.0 9.77 6.10
12、4.76 3.00 1.98 1.24 0.694 0.436 0.275 0.177 0.144 0.113 0.089 0.071 0.056 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
13、2.70 4.25 6.35 8.10 12.3 19.0 30.0 54.7 84.1 136 210 274 324 410 518 646 1.42 2.04 2.90 4.45 6.60 8.40 12.8 19.7 30.8 56.6 86.5 140 218 283 338 429 531 667 1.55 2.20 3.10 4.65 6.85 8.70 13.3 20.2 31.6 58.5 88.9 144 226 292 352 448 544 688 1/ PART NUMBER: THE ASTERISKS IN THE PART NUMBER COLUMN OF TA
14、BLE 1 SHALL BE REPLACED BY COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. EXAMPLES: M22759/87-20-93 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. TA
15、BLE 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)
16、SHALL 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 4,000 VOLTS/MIL (AVERAGE MINIMUM)
17、 0.0005 FP LAYER (BOTTOM) DISTINGUISHABLE COLOR (NEXT TO CONDUCTOR) MAY BE USED AT MANUFACTURERS OPTION AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260C, 600 VOLTS AS22759/87 REV. B AS22759/87 SHEET 3 OF 7 REV
18、. B 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
19、54.0 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.
20、0 71.0 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.
21、5 35.0 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: 260 C (500 F) MAXIMUM CON
22、TINUOUS 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
23、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 IS NOT MORE THAN 3 INCHES IN ANY TEST BUNDLE. DRY ARC PROPAGATION RESISTANCE (TEST REQUIRED FOR INITIAL QUALIFICATION ONL
24、Y): 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 WIR
25、E IS NOT MORE THAN 3 INCHES IN ANY TEST BUNDLE. BLOCKING: 260 C 2 C (500 F 3.6 F) AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260C, 600 VOLTS AS22759/87 REV. B AS22759/87 SHEET 4 OF 7 REV. B COLOR: WHITE IS TH
26、E 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. MUNSELL COLOR LIMITS FOR UV LASER MARKABLE WIRE HUE VALUE CHROMA COLOR FROM TO FROM TO FROM TO BLACK
27、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 STROKES), 2
28、50 GRAMS WEIGHT CONDUCTOR STRAND ADHESION: NOT 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 0.001 IN
29、CH. MINIMUM AVERAGE DYNAMIC CUT-THROUGH (LB) SHALL BE AS FOLLOWS: WIRE SIZE 23 C 5 C 150 C 5 C 200 C 5 C 260 C 5 C 26 10 LB 8 LB 6 LB 4 LB 20 25 LB 20 LB 15 LB 10 LB 16 25 LB 20 LB 15 LB 10 LB FLAMMABILITY: TEST IN ACCORDANCE WITH AS4373, METHOD 801. REQUIREMENTS: DURATION OF AFTER-FLAME 3 SECONDS (
30、MAXIMUM) FLAME TRAVEL 3.0 INCHES (MAXIMUM) 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 SAE AS4373 METHOD 602. ALL SAMPLES MUST PASS THE DIELECTRIC TEST
31、 AS LISTED IN METHOD 602. HIGH FREQUENCY 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 RESI
32、STANCE. IDENTIFICATION OF PRODUCT: NOT 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
33、 LISTED IN TABLE 5 OF THIS SPECIFICATION. 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, ELECTRICA
34、L, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260C, 600 VOLTS AS22759/87 REV. B AS22759/87 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,
35、UNDILUTED 48-50 (118-122) 20 B. SAE 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
36、) 168 E. SAE AS1241, FIRE RESISTANT HYDRAULIC 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-879
37、37, CLEANING COMPOUND, AEROSPACE EQUIPMENT, 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: H
38、YDROCARBON, TYPE IV 20-25 (68-77) 168 L. 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 IN
39、SULATION RESISTANCE: SIZES 26 THROUGH 10, 5000 MEGOHMS FOR 1000 FEET (MINIMUM) SIZES 8 THROUGH 04, 3000 MEGOHMS FOR 1000 FEET (MINIMUM) INSULATION STATE OF SINTER: (QUALITY CONFORMANCE INSPECTION PERFORMED ON ONE SAMPLE PER LOT) EVALUATE FP LAYERS WITH A DIFFERENTIAL SCANNING CALORIMETER PER AS4373,
40、 METHOD 813. THIS TEST IS APPLICABLE TO 10 AWG 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
41、 HOURS, THERE SHALL BE NO EVIDENCE OF TAPE SEPARATION OR LIFTING. THREE SAMPLES PER LOT SHALL BE TESTED. LIFE CYCLE: 500 HOURS AT 290 C 2 C (554 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,
42、 STILL CONFORM TO THE REQUIRED TEST MANDRELS DIAMETERS 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).
43、 DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. SHRINKAGE: TEST AT 290 C 2 C (554 F 3.6 F). MAXIMUM CHANGE IN MEASUREMENT 26 - 10 AWG 0.091 INCH. 8 - 04 AWG 0.125 INCH. SMOKE: 260 C 5 C (500 F 9 F); NO VISIBLE SMOKE. SOLDERABILITY: NOT REQUIRED. THIS SLASH SHEET IS PRIMARILY INTENDED FOR CRIMP TERMINATIO
44、NS. FOR SOLDERABILITY APPLICATIONS USE THE SILVER COATED COPPER VERSION OF THIS SPECIFICATION. STRIPPABILITY: (GROUP II QUALITY CONFORMANCE TEST) AFTER STRIPPING WITH TOOLS AS DEFINED IN AS22759 AND AS5457, NO FRAGMENTS OF ANY LAYER SHALL EXTEND MORE THAN 0.031 INCHES BEYOND THE END OF THE POLYIMIDE
45、 TAPE LAYER. THIS TEST IS APPLICABLE TO WIRE SIZES 10 AWG AND SMALLER. AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260C, 600 VOLTS AS22759/87 REV. B AS22759/87 SHEET 6 OF 7 REV. B INSULATION STRIP FORCE: (GROU
46、P 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 FORCES (LB) SHALL BE AS FOLLOWS. NO EVIDENCE OF INSULATION SHALL BE LEFT ON THE CONDUCTOR WHEN VIEWED WITH THE NAKED EYE. WIRE SIZE MI
47、N 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. THERMAL INDEX: 260 C (500 F) MINIMUM FOR 10,000 HOURS (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY).
48、TEST SIZE 20 ONLY IN ACCORDANCE WITH ASTM D 3032, SECTION 14. THERMAL SHOCK RESISTANCE: OVEN TEMPERATURE, 260 C 5 C (500 F 9 F), MAXIMUM CHANGE IN MEASUREMENT, 26 - 10 AWG 0.091 INCH. 8 - 04 AWG 0.125 INCH. 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 J/CM 2 0.1 J/CM2. THE CONTRAST LEVEL SHALL BE EVALUATED IN ACCORDANCE WITH METHOD 711 OF AS4373. THE CONTRAST LEVEL IS DEFINED AS (Refle