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1、SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of 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 therefr
2、om, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2004 SAE International All rights reserved. No part of this publication may
3、 be reproduced, stored in a retrieval system or transmitted, 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) Fa
4、x: 724-776-0790 Email: custsvcsae.org SAE WEB ADDRESS:http:/www.sae.org AEROSPACE STANDARD AS81044 Issued1998-07 Reaffirmed2004-06 Wire, Electrical, Crosslinked Polyalkene, Crosslinked Alkane- Imide Polymer, or Polyarlyene Insulated, Copper or Copper Alloy NOTICE This document has been taken directl
5、y from U.S. Military Specification MIL-W-81044B, Supplement 1A, Amendment 3 and contains only minor editorial and format changes required to bring it into conformance with the publishing requirements of SAE technical standards. The initial release of this document is intended to replace MIL-W-81044B
6、, Supplement 1A, Amendment 3. Any part numbers established by the original specification remain unchanged. The original Military Specification was adopted as an SAE standard under the provisions of the SAE Technical Standards Board (TSB) Rules and Regulations (TSB 001) pertaining to accelerated adop
7、tion of government specifications and standards. TSB rules provide for (a) the publication of portions of unrevised government specifications and standards without consensus voting at the SAE Committee level, and (b) the use of the existing government specification or standard format. Under Departme
8、nt of Defense policies and procedures, any qualification requirements and associated qualified products lists are mandatory for DOD contracts. Any requirement relating to qualified products lists (QPLs) has not been adopted by SAE and is not part of this technical report. SAE AS81044 - 2 - 1.SCOPE:
9、1.1Scope: This specification covers single conductor electric wires made as specified in the applicable specification sheet with tin-coated, silver-coated, or nickel-coated copper or copper alloy conductors insulated with crosslinked polyalkene, crosslinked alkane-imide polymer, or polyarylene. The
10、crosslinked polyalkene, crosslinked alkane-imide polymer, or polyarylene may be used alone or in combination with other insulation materials as specified in the specification sheet. 1.2Classification: The wires shall be as described in the applicable military specification sheet. 1.2.1Part numbers:
11、Part numbers under this specification are coded as in the following example: 1.2.2Temperature rating of finished wire: The maximum conductor temperature of the finished wire for continuous use shall be as specified in the applicable military specification sheet (6.1.1). 2.APPLICABLE DOCUMENTS: 2.1Go
12、vernment-furnished documents: The following documents of the issue in effect on date of invitation for bids or request for proposal, form a part of this specification to the extent specified herein: SPECIFICATIONS Federal TT-I-735Isopropyl Alcohol UU-T-450Tissue, Facial Military MIL-H-5606Hydraulic
13、Fluid, Petroleum Base; Aircraft, Missile, and Ordnance MIL-T-5624Turbine Fuel, Aviation, Grades JP-4 and JP-5 M81044/1-22-9 Applicable speci- fication sheet Wire sizeInsulation color designator or desig- nators SAE AS81044 - 3 - 2.1 (Continued): MIL-C-12000Cable, Cord, and Wire, Electric; Packaging
14、of MIL-L-23699Lubricating Oil, Aircraft Turbine Engine, Synthetic Base P-D-410Type I, Dishwashing Compound, Hand STANDARDS Federal FED-STD-228Cable and Wire, Insulated; Methods of Testing Military MIL-STD-104Limits for Electrical Insulation Color MIL-STD-105Sampling Procedures and Tables for Inspect
15、ion by Attributes MIL-STD-109Quality Assurance Terms and Definitions MIL-STD-129Marking for Shipment and Storage MIL-STD-202Test Methods for Electronic and Electrical Component Parts MIL-STD-681Identification Coding and Application of Hookup and Lead Wire SPECIFICATION SHEETS MIL-W-81044/6Wire, Elec
16、tric, Crosslinked Polyalkene Insulated, Tin-Coated Copper, Normal Weight, 600-Volt, 150C MIL-W-81044/7Wire, Electric, Crosslinked Polyalkene Insulated, Silver-Coated High Strength Copper Alloy, Normal Weight, 600-Volt, 150C MIL-W-81044/9Wire, Electric, Crosslinked Polyalkene Insulated, Tin-Coated Co
17、pper, Medium Weight, 600-Volt, 150C MIL-W-81044/10 Wire, Electric, Crosslinked Polyalkene Insulated, Silver-Coated High Strength Copper Alloy, Medium Weight, 600-Volt, 150C MIL-W-81044/12 Wire, Electric, Crosslinked Polyalkene Insulated, Tin-Coated Copper, Light Weight, 600-Volt, 150C MIL-W-81044/13
18、 Wire, Electric, Crosslinked Polyalkene Insulated, Silver-Coated High Strength Copper Alloy, Light Weight, 600-Volt, 150C PUBLICATIONS Defense Logistics Services Center H4-1Federal Supply Code for Manufacturers Part 1, Name to Code H4-2Federal Supply Code for Manufacturers Part 2, Code to Name SAE A
19、S81044 - 4 - 2.1 (Continued): (Copies of specifications, standards, drawings, and publications required by suppliers in connection with specific procurement functions should be obtained from the procuring activity or as directed by the contracting officer.) 2.2Other publications: The following docum
20、ents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on date of invitation for bids or request for proposal shall apply: American Society for Testing and Materials B33-71Standard Specification for Tinned Soft or Annealed Copper Wire f
21、or Electrical Purposes B298-70aStandard Specification for Silver-Coated Soft or Annealed Copper Wire B355-69Standard Specification for Nickel-Coated Soft or Annealed Copper Wire (Copies of ASTM publications may be obtained from the American Society for Testing and Materials, 1916 Race Street, Philad
22、elphia, Pennsylvania 19103.) 3.REQUIREMENTS: 3.1Specification sheets: The requirements for the individual wires under this specification shall be as specified herein and in accordance with the applicable specification sheet. In the event of any conflict between the requirements of this specification
23、 and those of the specification sheet, the requirements of the specification sheet shall govern except as follows: a.All specification sheet references to tape abrasion or resistance to propellants shall be considered as cancelled. b.All specification sheet requirements for blocking shall be at the
24、rated temperature of the wire of that specification sheet (for example: the blocking test temperature of MIL-W-81044/12 shall be 150C in lieu of 225C). -,-,- SAE AS81044 - 5 - 3.2Classification of requirements: The applicable requirements are classified herein as follows: 3.3Qualification: The wire
25、furnished under this specification shall be a product which is qualified for listing on the applicable qualified products list at the time set for opening of bids (see 4.3 and 6.3). The provisions of 4.6 for retention of qualification are included in this requirement. 3.4Materials: 3.4.1Conductor ma
26、terial: All strands used in the manufacture of the conductors shall be tin-coated, silver-coated, or nickel-coated soft annealed copper conforming to ANSI/ASTM B33-71, B298-70a, or B355-69, as applicable, or shall be silver-coated or nickel-coated high strength copper alloy. Strands shall be free fr
27、om lumps, kinks, splits, scraped or corroded surfaces and skin impurities. In addition, the strands shall conform to the following requirements as applicable. 3.4.1.1Tin-coated copper strands: No additional requirements. The tin coating shall be as specified in ANSI/ASTM B33-71. 3.4.1.2Silver-coated
28、 copper strands: The strands shall have a coating thickness of not less than 40 micro-inches of silver when tested in accordance with ANSI/ASTM B298-70a. 3.4.1.3Nickel-coated copper strands: The strands shall have a coating thickness of not less than 50 micro-inches of nickel when tested in accordan
29、ce with ANSI/ASTM B355-69. Adhesion of the nickel coating shall be such that, after subjection to the procedures of 4.7.2.1, the strands shall still pass the continuity of coating test in ANSI/ASTM B355-69. 3.4.1.4High strength copper alloy: The strands shall be of the applicable AWG gage specified
30、in Table I and of such tensile properties that the conductor from the finished wire conforms to the requirements of 3.5.1.3.2 for elongation and tensile strength. The strands shall be silver-coated or nickel-coated in accordance with 3.4.1.2 or 3.4.1.3 as applicable. RequirementParagraph Qualificati
31、on3.3 Materials3.4 Construction3.5 Finished Wire3.6 -,-,- SAE AS81044 - 6 - SAE AS81044 - 7 - 3.4.2Insulating material: All primary insulation shall be crosslinked polyalkene, crosslinked alkane- imide polymer, or polyarylene, as specified in the applicable specification sheet. Insulation coatings o
32、r jackets, if present, shall also be of the material specified in the specification sheet. All insulating materials, including primary insulation and coating or jacket, shall be certified virgin material (3.4.2.1) containing no additives except those required as pigmentation for colors, lubricants u
33、sed in extrusion and stabilizers. The physical properties of the materials shall be such that, when tested in accordance with 4.7.5.7 after extrusion on the finished wire, the insulation will meet the elongation and tensile strength requirements set forth in the specification sheet. 3.4.2.1Virgin ma
34、terial: For purposes of this specification, virgin material shall be 100 percent new material which has been through only the processes essential to its manufacture and its application to the wire and has been through these essential processes one time only. Any material which has previously been pr
35、ocessed in any other manner is considered nonvirgin material. This requirement shall apply to the manufacture of all ingredients and components used. 3.5Construction: Construction of the wire shall be as specified herein and in the applicable military specification sheet. 3.5.1Conductor: 3.5.1.1Stra
36、nding: 3.5.1.1.1Concentric lay stranding: The conductors of wire sizes 30 through 10 shall be concentric-lay conductors constructed as specified in Table I. Concentric lay shall be interpreted to be a central strand surrounded by one or more layers of helically wound strands. It is optional for the
37、direction of lay of the successive layers to be alternately reversed (true concentric lay) or to be in the same direction (unidirectional lay). The strands shall be assembled in a geometric arrangement of concentric layers, so as to produce a smooth and uniform conductor, circular in cross-section a
38、nd free of any crossovers, high strands, or other irregularities. The direction of lay of the individual strands in the outer layer of the concentrically stranded conductors of finished wire shall be left hand. The length of lay of the outer layer shall not be less than 8 nor more than 16 times the
39、maximum conductor diameter as specified in the applicable military specification sheet. 3.5.1.1.2Rope lay stranding: The conductors of wire sizes 8 through 0000 shall be rope-lay as specified in Table I and in (a) and (b) below. (a) Rope-lay stranded conductors shall be laid up concentrically with a
40、 central member surrounded by one or more layers of helically wound members. It is optional for the direction of lay of successive layers to be alternately reversed (true concentric lay), or to be in the same direction (unidirectional lay). The length of lay of the outer layer of rope-lay stranded m
41、embers forming the conductor shall not be less than 10 or more than 14 times the outside diameter of the completed conductor. The direction of lay of the outside layer shall be either left or right hand. -,-,- SAE AS81044 - 8 - 3.5.1.1.2 (Continued): (b) Members of rope-lay stranded conductors: The
42、length of lay of the wires composing the stranded members shall be not greater than 16 times the outside diameter of the member. Stranding of the individual members may be either concentric or bunch. 3.5.1.2Splices: Splices in individual strands or members shall be butt brazed. There shall not be mo
43、re than one strand-splice in any two lay lengths of a stranded concentric-lay conductor or in any two lay lengths of any member in a rope lay conductor, except that not more than one splice of an entire member shall be permitted in any two lay lengths of a rope lay conductor. Splices in members of a
44、 rope lay construction shall be so finished that the conductor diameter is not increased at the point of brazing. In no case shall the whole conductor be spliced at one point. 3.5.1.3Elongation and tensile strength of conductor: 3.5.1.3.1Soft or annealed copper: The individual strands removed from f
45、inished wires with soft or annealed copper conductors, wire sizes 20 and larger, or the whole soft or annealed copper conductor removed from finished wire, sizes 22 and smaller, shall have the following minimum elongation when tested in accordance with 4.7.5.6.1: Sizes 24 and smaller - 6 percent (mi
46、nimum) Sizes 22 and larger - 10 percent (minimum) There shall be no tensile strength requirements for soft or annealed copper conductors. 3.5.1.3.2High strength copper alloy: The whole conductor removed from finished wires with high strength copper alloy conductors shall exhibit elongation of 6 perc
47、ent, minimum, and a tensile breaking strength conforming with Table I, when tested in accordance with 4.7.5.6.2. 3.5.1.4Conductor diameter: The diameter of the conductor shall be as specified in Table I. Applicability of the “general purpose” or of the “small diameter” Table I requirements for maxim
48、um conductor diameter shall be as indicated in the military specification sheet. 3.5.2Insulation: The insulation shall be constructed as specified in the applicable specification sheet. All insulation shall be readily removable by conventional wire stripping devices without damage to the conductor.
49、3.5.3Flaws test of primary insulation: One hundred percent of the wire shall be inspected for dielectric flaws after application of the primary insulation and prior to the application of any other material to the wire. This inspection shall be made by either the chain electrode spark test of 4.7.4 or the impulse dielectric test of 4.7.5.1, at the option of the supplier, using the test voltages specified for primary insu