SAE-AS-22759-91B-2007.pdf

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1、 AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, LIGHT WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/91 Copyright 2007 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or tran

2、smitted, 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 W

3、EB 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 AS22759/91 SHEET 1 OF 6 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 at

5、 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 STANDARS. NOTICE THE REQUIREMENTS FOR ACQUIRING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS SPECIFI

6、CATION 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 1

7、- GENERAL CONFIGURATION CONDUCTOR, STRANDED, SILVER COATED COPPER FP TAPE FP / POLYIMIDE / FP TAPE FP FLUOROCARBON POLYMER, MODIFIED POLYTETRAFLUOROETHYLENE (PTFE) -,-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, LIGHT WEIGHT, SILVER COATED, COPPER CONDUCT

8、OR, 200 C, 600 VOLTS AS22759/91 REV. B AS22759/91 SHEET 2 OF 6 REV. B TABLE 1 - CONSTRUCTION DETAILS CONDUCTOR FINISHED WIRE DIAMETER (IN) DIAMETER (IN) WEIGHT (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 M

9、AX)MIN MAX MIN TARGET MAX M22759/91-26-* M22759/91-24-* M22759/91-22-* M22759/91-20-* M22759/91-18-* M22759/91-16-* M22759/91-14-* M22759/91-12-* M22759/91-10-* 26 24 22 20 18 16 14 12 10 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 0.0175 0.0225 0.0285 0.0365 0.0455 0.051

10、5 0.0645 0.0835 0.106 0.0194 0.0244 0.0304 0.0384 0.0484 0.0544 0.0684 0.0874 0.110 38.4 24.3 15.1 9.19 5.79 4.52 2.88 1.90 1.19 0.030 0.034 0.040 0.048 0.056 0.063 0.076 0.096 0.119 0.034 0.038 0.043 0.051 0.060 0.067 0.080 0.100 0.123 1.16 1.70 2.55 4.02 6.16 7.75 12.0 18.4 28.5 1.31 1.85 2.75 4.2

11、6 6.43 8.09 12.5 19.2 30.0 1.45 2.00 2.96 4.50 6.70 8.40 12.9 19.9 30.8 1/ PART NUMBER: THE ASTERISKS IN THE PART NUMBER COLUMN OF TABLE 1 SHALL BE REPLACED BY COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. EXAMPLES: M22759/91-20-93 IS A 20 AWG WHITE WITH ORANGE STRIPE. 2/THE ACCEPTABLE VALU

12、E FOR THE CPK FOR THE FINISHED WIRE WEIGHT LISTED SHALL BE 1.3, USING A NORMAL (GAUSSIAN) DISTRIBUTION TO OBTAIN THOSE CPK VALUES. TABLE 2 - WIRE INSULATION MATERIALS 1/ TAPE CODE THICKNESS (NOM) MATERIAL 1 0.0012 0.00045 (FP)/0.00065 (POLYIMIDE)/0.0001 (FP) 2 0.0020 FP (UNSINTERED) 3 0.0025 FP (UNS

13、INTERED) 1/ PHYSICAL PROPERTIES OF FP UNSINTERED TAPES SHALL BE IN ACCORDANCE WITH MIL-W-22759 REQUIREMENTS. TABLE 3 - PHYSICAL PROPERTIES OF FP/POLYIMIDE/FP TAPES TENSILE STRENGTH 20,000 LB/IN SQ (AVERAGE MINIMUM) TENSILE MODULUS 400,000 LB/IN SQ (AVERAGE MINIMUM) ELONGATION 40 PERCENT (AVERAGE MIN

14、IMUM) DIELECTRIC STRENGTH 4,000 VOLTS/MIL (AVERAGE MINIMUM) 0.00045 FP LAYER DISTINGUISHABLE COLOR (NEXT TO CONDUCTOR) TABLE 4 - TAPE OVERLAP REQUIREMENTS 1/ WRAP 1 WRAP 2 PERCENT OVERLAP PERCENT OVERLAP WIRE SIZE TAPE CODE MIN MAX TAPE CODE MIN MAX NOMINAL WALL THICKNESS (MILS) 26 1 50.5 54.0 2 50.

15、5 54.0 5.8 24 1 50.5 54.0 2 50.5 54.0 5.8 22 1 50.5 54.0 2 50.5 54.0 5.8 20 1 50.5 54.0 2 50.5 54.0 5.8 18 1 50.5 54.0 2 50.5 54.0 5.8 16 1 50.5 54.0 2 50.5 54.0 5.8 14 1 50.5 54.0 2 50.5 54.0 5.8 12 1 50.5 54.0 3 50.5 54.0 6.7 10 1 50.5 54.0 3 50.5 54.0 6.7 1/ WRAP 1 IS INNERMOST TAPE WHICH IS IN C

16、ONTACT WITH THE CONDUCTOR WITH THE 0.00045 INCH FP SIDE OF THE TAPE AGAINST THE CONDUCTOR. AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, LIGHT WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/91 REV. B AS22759/91 SHEET 3 OF 6 REV. B RATINGS:

17、TEMPERATURE RATING: 200 C (392 F) MAXIMUM CONTINUOUS 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 BUND

18、LE ALONG THE AXIS. THE WIRE IS ACCEPTABLE IF THE FOLLOWING CRITERIA ARE MET: 1. A MINIMUM OF 64 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

19、 (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY): 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 64 WIRES PASS THE DIELECTRIC TEST. 2. THREE WIRES OR LESS FAIL THE DIELECTRIC TEST I

20、N ANY ONE BUNDLE. 3. ACTUAL DAMAGE TO THE WIRE 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

21、 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 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

22、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), 250 GRAMS WEIGHT CONDUCTOR STRAND ADHESION: REQUIRED CONTINUOUS LENGTHS: SCHEDULE B DYNAMIC CUT-THROUGH (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY: TEST

23、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 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 20 LB 15 LB

24、15 LB FLAMMABILITY: TEST IN ACCORDANCE WITH AS4373, METHOD 801: REQUIREMENTS: DURATION OF AFTER-FLAME 3 SECONDS (MAXIMUM) FLAME TRAVEL 3.0 INCHES (MAXIMUM) NO FLAMING OF TISSUE -,-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, LIGHT WEIGHT, SILVER COATED, C

25、OPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/91 REV. B AS22759/91 SHEET 4 OF 6 REV. B 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

26、THE DIELECTRIC TEST 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 INITI

27、AL INSULATION RESISTANCE. 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

28、 ADDITIONAL FLUIDS 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. TABLE 5 - FLUID TABLE TEST

29、 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 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 SURF

30、ACE, 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. 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-PR

31、F-87937, CLEANING COMPOUND, AEROSPACE EQUIPMENT, TYPE II OR TYPE IV, UNDILUTED 63-68 (145-154) 20 H. MIL-PRF-87937, 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) 16

32、8 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. DIELECTRIC-COOLANT FLUID SYNTHETIC SILICATE ESTER BASE, MONSANTO COOLANOL 25 OR APPROVED EQUIVALENT 20-25 (68-77) 168 M. ASTM D 4814, GASOLINE, AUT

33、OMOTIVE, COMBAT 20-25 (68-77) 168 IMPULSE DIELECTRIC TEST: 8.0 KILOVOLTS (PEAK). TEST 100 PERCENT OF THE WIRE INSULATION RESISTANCE: 5000 MEGOHMS FOR 1000 FEET (MINIMUM) INSULATION STATE OF SINTER: (QUALITY CONFORMANCE INSPECTION PERFORMED ON ONE SAMPLE PER LOT) EVALUATE FP LAYERS WITH A DIFFERENTIA

34、L SCANNING CALORIMETER PER AS4373, METHOD 813. 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

35、 BE NO EVIDENCE OF TAPE SEPARATION 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 T

36、HE 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). DIELECTRIC TEST, 2

37、500 VOLTS (RMS), 60 HZ. -,-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, LIGHT WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/91 REV. B AS22759/91 SHEET 5 OF 6 REV. B SHRINKAGE: 0.091 INCH (MAXIMUM) AT 230 C 2 C (554 F 3.6 F). SMOKE: 200

38、 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 AS5457, NO FRAGMENTS OF ANY LAYER SHALL EXTEND MORE THAN 0.031 INCHES BEYOND THE END OF THE POLYIMIDE TAPE LAYER. INSULATION STRIP FO

39、RCE: (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. THE STRIP FORCE SHALL BE AS FOLLOWS. THERE SHALL BE NO EVIDENCE OF INSULATION LEFT ON THE CONDUCTOR WHEN VIEWED WITH THE NAKED EYE

40、. 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. THERMAL INDEX: 200 C (392 F) MINIMUM FOR 10,000 HOURS (TEST REQUIRED FOR INITIAL QUALIFIC

41、ATION 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, 0.091 INCHES. NO CRACKING. UV LASER MARKING: (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY) WHITE FP MATERIALS SHALL BE FORMU

42、LATED 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 (Reflectance of the background

43、 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 DIAM

44、ETER 1/ (INCHES) TEST LOAD 1/ (LB) WIRE SIZE (AWG) COLD BEND LIFE CYCLE/ BEND TEST WRAP COLD BEND LIFE CYCLE/ BEND TEST 26 24 22 20 18 16 14 12 10 1.00 1.00 1.00 1.00 1.50 1.50 2.00 2.00 3.00 0.375 0.500 0.500 0.500 0.750 1.00 1.00 1.50 2.00 0.125 0.125 0.125 0.125 0.250 0.250 0.375 0.375 0.375 3.00

45、 3.00 4.00 4.00 5.00 5.00 5.00 5.00 6.00 0.50 0.75 1.00 1.50 2.00 2.00 3.00 3.00 3.00 1/ TOLERANCE SHALL BE 3 PERCENT OF THE GIVEN VALUES. AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, LIGHT WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 C, 600 VOLTS AS22759/91

46、 REV. B AS22759/91 SHEET 6 OF 6 REV. B QUALIFICATION OF WIRE: FOR QUALIFICATION, A SOURCE IS REQUIRED TO SUBMIT DATA ON QUALITY CONFORMANCE TESTS AND ANY FINISHED WIRE TESTS AS REQUIRED BY THE QUALIFICATION AUTHORIZATION LETTER. ALL OTHER TESTING WILL BE PERFORMED BY THE QUALIFYING ACTIVITY AT THE S

47、OURCES EXPENSE. DUE TO THE EXTENDED TIME PERIOD OVER WHICH THE THERMAL INDEX TEST IS PERFORMED, A SOURCE MAY BECOME QUALIFIED UNDER THIS SPECIFICATION SHEET WHILE THIS TEST IS STILL IN PROGRESS. NOTES: THE CHANGE BAR ( l ) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REVISIONS, NOT EDITORIAL CHANGES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES A COMPLETE REVISION OF THE DOCUMENT.