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SAE AS 22759A-2006

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AEROSPACESTANDARD
AS22759
REV.A
Issued2001-07Revised2006-12
SupersedingAS22759

(RWire,Electrical,Fluoropolymer-Insulated,CopperorCopperAlloy

RATIONALE
Updatereferences,includeamendment,clarifyqualification/qualityassurancerequirements,addMIL-C-29606conductorrequirements,addMIL-STD-2223testmethods,andincludenewrequirementsforhybridwires.1.SCOPE
AS22759specificationcoversfluoropolymer-insulatedsingleconductorelectricalwiresmadewithtin-coated,silver-coated,ornickel-coatedconductorsofcopperorcopperalloyasspecifiedintheapplicabledetailspecification.Thefluoropolymerinsulationmaybepolytetrafluoroethylene(PTFE,fluorinatedethylenepropylene(FEP,polyvinylidenefluoride(PVF2,ethylene-tetrafluoroethylenecopolymer(ETFE,orotherfluoropolymerresin.Thefluoropolymermaybeusedaloneorincombinationwithotherinsulationmaterials.1.1PartNumbers
Unlessotherwisespecifiedpartnumbersarecodedasinthefollowingexample(see3.5.5and3.5.6:M22759/1-22-9
M22759/1:Applicabledetailspecificationdesignator(see3.1-22:WireSize:(see3.1
-9:Insulationcolor(see3.5.51.2
TemperatureRatingsofFinishedWires
Themaximumconductortemperaturesofthefinishedwiresforcontinuoususearespecifiedinthedetailspecifications.2.APPLICABLEDOCUMENTS
Thefollowingpublicationsformapartofthisdocumenttotheextentspecifiedherein.ThelatestissueofSAEpublicationsshallapply.Theapplicableissueofotherpublicationsshallbetheissueineffectonthedateofthepurchaseorder.Intheeventofconflictbetweenthetextofthisdocumentandreferencescitedherein,thetextofthisdocumenttakesprecedence.Nothinginthisdocument,however,supersedesapplicablelawsandregulationsunlessaspecificexemptionhasbeenobtained.

__________________________________________________________________________________________________________________________________________SAETechnicalStandardsBoardRulesprovidethat:“ThisreportispublishedbySAEtoadvancethestateoftechnicalandengineeringsciences.Theuseofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarisingtherefrom,isthesoleresponsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhichtimeitmaybereaffirmed,revised,orcancelled.SAEinvitesyourwrittencommentsandsuggestions.Copyright©2006SAEInternational
Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystemortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofSAE.
TOPLACEADOCUMENTORDER:Tel:877-606-7323(insideUSAandCanadaTel:724-776-4970(outsideUSA
Fax:724-776-0790Email:CustomerService@sae.orgSAEWEBADDRESS:http://www.sae.org

SAE
2.1SAEPublications
AS22759RevisionA-2-
AvailablefromSAEInternational,400CommonwealthDrive,Warrendale,PA15096-0001,Tel:877-606-7323(insideUSAandCanadaor724-776-4970(outsideUSA,www.sae.org.AMS1424AS1241AS4373AS4461AS54572.1.1
Deicing/Anti-IcingFluid,Aircraft,SAETypeIFireResistantHydraulicFluidforAircraftTestMethodsforInsulatedElectricWire
AssemblyandSolderingCriteriaforHighQuality/HighReliabilitySolderedWireandCableTerminationinAerospaceVehicles
AerospaceStandardforHand-HeldWireStripperTools
AS22759DetailSpecifications
Wire,Electrical,Fluoropolymer-Insulated,PTFEandPTFE-CoatedGlass,Silver-CoatedCopperConductor,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,PTFE,andPTFE-Coated-Glass,Nickel-CoatedCopperConductor,600-Volt
AS22759/1AS22759/2
AS22759/3Wire,Electrical,Fluoropolymer-Insulated,TFE-Glass-TFE,MediumWeight,Nickel-CoatedCopper
Conductor,600-VoltAS22759/4AS22759/5AS22759/6AS22759/7AS22759/8AS22759/9AS22759/10AS22759/11
Wire,Electrical,Fluoropolymer-Insulated,TFE-Glass-FEP,MediumWeight,Silver-CoatedCopperConductor,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,AbrasionResistantExtrudedPTFE,Silver-CoatedCopperConductor,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,AbrasionResistantExtrudedPTFE,Nickel-CoatedCopperConductor,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,AbrasionResistantExtrudedPTFE,MediumWeight,Silver-CoatedCopperConductor,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,AbrasionResistantExtrudedPTFE,MediumWeight,Nickel-CoatedCopperConductor,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,Silver-CoatedCopperConductor,1,000-VoltWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,Nickel-CoatedCopperConductor,1,000-VoltWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,Silver-CoatedCopperConductor,600-Volt
AS22759/12Wire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,Nickel-CoatedCopperConductor,600-VoltAS22759/13Wire,Electrical,Fluoropolymer-Insulated,FEP-PVF2,MediumWeight,Tin-CoatedCopperConductor,
600-VoltAS22759/14Wire,Electrical,Fluoropolymer-Insulated,FEP-PVF2,LightWeight,Tin-CoatedCopperConductor,600-Volt

SAE
AS22759RevisionA-3-
AS22759/15Wire,Electrical,Fluoropolymer-Insulated,FEP-PVF2,LightWeight,Silver-CoatedHighStrengthCopper
AlloyConductor,600-VoltAS22759/16Wire,Electrical,Fluoropolymer-Insulated,ExtrudedETFE,MediumWeight,Tin-CoatedCopperConductor,600-Volt,150°CAS22759/17Wire,Electrical,Fluoropolymer-Insulated,ExtrudedETFE,MediumWeight,Silver-CoatedHighStrength
CopperAlloyConductor,600-Volt,150°CAS22759/18Wire,Electrical,Fluoropolymer-Insulated,ExtrudedETFE,LightWeight,Tin-CoatedCopperConductor,
AS22759/19AS22759/20AS22759/21AS22759/22AS22759/23AS22759/28AS22759/29AS22759/30AS22759/31AS22759/32AS22759/33AS22759/34AS22759/35AS22759/41AS22759/42
600-Volt,150°CWire,Electrical,Fluoropolymer-Insulated,ExtrudedETFE,LightWeight,Silver-CoatedHighStrength
CopperAlloyConductor,600-Volt,150°CWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,Silver-CoatedHighStrengthCopperAlloy
Conductor,1,000-VoltWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,Nickel-CoatedHighStrengthCopperAlloy
Conductor,1,000-VoltWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,Silver-CoatedHighStrengthCopperAlloy
Conductor,600-VoltWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,Nickel-CoatedHighStrengthCopperAlloy
Conductor,600-VoltWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,PolyimideCoated,Silver-CoatedCopper
Conductor,600-VoltWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,PolyimideCoated,Nickel-CoatedCopper
Conductor,600-VoltWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,PolyimideCoated,Silver-CoatedHighStrength
CopperAlloyConductor,600-VoltWire,Electrical,Fluoropolymer-Insulated,ExtrudedTFE,PolyimideCoated,Nickel-CoatedHighStrength
CopperAlloyConductor,600-VoltWire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,Lightweight,Tin-CoatedCopper,
150°C,600-VoltWire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,Lightweight,Silver-CoatedHigh
StrengthCopperAlloy,150°C,600-VoltWire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,NormalWeight,Tin-CoatedCopper,150°C,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,NormalWeight,Silver-CoatedHighStrengthCopperAlloy,150°C,600-VoltWire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,NormalWeight,Nickel-CoatedCopper,200°C,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,NormalWeight,Nickel-CoatedHighStrengthCopperAlloy,200°C,600-Volt

SAE
AS22759/43AS22759/44AS22759/45AS22759RevisionA-4-
Wire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,NormalWeight,Silver-CoatedCopper,200°C,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,LightWeight,Silver-CoatedCopper,200°C,600-Volt
Wire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,LightWeight,Nickel-CoatedCopper,200°C,600-Volt
AS22759/46
AS22759/80AS22759/81AS22759/82AS22759/83--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
AS22759/84
AS22759/85AS22759/86AS22759/87
AS22759/88AS22759/89AS22759/90AS22759/91AS22759/92AS50881AS9003
Wire,Electrical,Fluoropolymer-Insulated,Cross-linkedModifiedETFE,LightWeight,Nickel-CoatedHighStrengthCopperAlloy,200°C,600-Volt
Wire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,LightWeight,TinCoated,Copper
Conductor,150°C,600VoltsWire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,LightWeight,SilverCoated,HighStrengthorUltraHighStrengthCopperAlloy,200°C,600Volts
Wire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,LightWeight,NickelCoated,HighStrengthorUltraHighStrengthCopperAlloy,260°C,600Volts
Wire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,NormalWeight,SilverCoated,CopperConductor,200°C,600Volts
Wire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,NormalWeight,NickelCoated,CopperConductor,260°C,600Volts
Wire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,NormalWeight,TinCoated,Copper
Conductor,150°C,600VoltsWire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,NormalWeight,SilverCoated,CopperConductor,200°C,600Volts
Wire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,NormalWeight,NickelCoated,CopperConductor,260°C,600Volts
Wire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,NormalWeight,TinCoated,Copper
Conductor,150°C,600VoltsWire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,NormalWeight,SilverCoated,High
StrengthorUltraHighStrengthCopperAlloy,200°C,600VoltsWire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,NormalWeight,NickelCoated,High
StrengthorUltraHighStrengthCopperAlloy,260°C,600VoltsWire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,LightWeight,SilverCoated,Copper
Conductor,200°C,600VoltsWire,Electrical,Polytetrafluoroethylene/PolyimideInsulated,LightWeight,NickelCoated,Copper
Conductor,260°C,600VoltsWiring,AerospaceVehicleInspectionandTestQualitySystem

SAE
2.2
U.S.GovernmentPublications
AS22759RevisionA-5-
AvailablefromtheDocumentAutomationandProductionService(DAPS,Building4/D,700RobbinsAvenue,Philadelphia,PA19111-5094,Tel:215-697-6257,http://assist.daps.dla.mil/quicksearch/.MIL-STD-104LimitsforElectricalInsulationColorMIL-STD-129MarkingforShipmentandStorage
MIL-STD-202ElectronicandElectricalComponentsParts
MIL-STD-681MIL-STD-2223MIL-PRF-5606MIL-DTL-5624--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
MIL-DTL-12000MIL-PRF-23699MIL-C-43616MIL-PRF-87252MIL-PRF-7808MIL-A-8243
MIL-DTL-83133MIL-PRF-87937MIL-W-29606
SD6H4/H8IdentificationCodingandApplicationofHookupandLeadWireTestMethodsforInsulatedElectricWire
HydraulicFluid,PetroleumBase;Aircraft,MissileandOrdnanceTurbineFuel,Aviation,GradesJP-4andJP-5Cable,Cord,andWire,Electric;Packagingof
LubricatingOil,AircraftTurbineEngine,SyntheticBaseCleaningCompound,AircraftSurfaceCoolantFluid,HydrolyticallyStable,Dielectric
LubricatingOil,Aircraft,TurbineEngine,SyntheticBaseAnti-icingandDeicingDefrostingFluid
TurbineFuel,Aviation,KeroseneTypes,NATOF-34(JP-8andNATOF-35CleaningCompound,AerospaceEquipmentWire,Electrical,Stranded,UninsulatedCopper,CopperAlloy,orAluminum,orThermocouple
Extension,GeneralSpecificationFor
ProvisionsGoverningQualification
CatalogofCommercialandGovernmentEntities(CAGE
(BattleCreekCustomerContactCenter,DefenseLogisticsInformationService,74WashingtonAvenueN.,BattleCreek,MI49017-3084

SAE
2.3Non-GovernmentPublications
AS22759RevisionA-6-
Publicationsareavailableattheaddressindicatedforthetypeofspecificationlisted(see6.2.2.3.1ASTMPublications
AvailablefromASTMInternational,100BarrHarborDrive,WestConshohocken,PA19428-2959,Tel:610-832-9585,www.astm.org.ASTMB286ASTMD149ASTMD471ASTMD491ASTMD770ASTMD792ASTMD882
CopperConductorsforUseinHookupWireforElectronicEquipment
StandardTestMethodforDielectricBreakdownVoltageandDielectricStrengthofSolidElectricalInsulatingMaterialsatCommercialPowerFrequenciesStandardTestMethodforRubberProperty
StandardTestMethodforDeterminingTemperaturesandHeatsofTransitionsofFluoropolymersbyDifferentialScanningCalorimetry
StandardSpecificationforIsopropylAlcohol
StandardMethodsofTestforSpecificGravityandDensityofPlasticsbyDisplacementStandardTestMethodsforTensilePropertiesofThinPlasticSheeting
ASTMD1153MethylIsobutylKetone(forUseinOrganicCoatingsASTMD1655StandardSpecificationforAviationTurbineFuelsASTMD3032HookUpWireInsulationStandardTestMethodFor
ASTMD4591TemperatureandHeatsDeterminingofTransitionofFluoropolymersbyDifferentialScanningCalorimetryASTMD4814Gasoline,Automotive,Combat
ASTMD4895StandardSpecificationforPolytetrafluoroethylene(PTFEResinProducedFromDispersion2.3.2ANSIPublications
AvailablefromAmericanNationalStandardsInstitute,25West43rdStreet,NewYork,NY10036-8002,Tel:212-642-4900,www.ansi.org.
ANSI-Z540.1Laboratories,CalibrationandMeasuringandTestEquipment2.3.3ASQPublications
AvailablefromAmericanSocietyforQuality,600NorthPlankintonAvenue,Milwaukee,WI53203,Tel:800-248-1946
(NorthAmericaor+1-414-272-8575(International,www.asq.org.ASQC-Z1.4
SamplingProceduresandTablesforInspectionbyAttributes
ASQC-A8402QualityManagementandQualityAssurance-Vocabulary

SAE
2.3.4
AS22759RevisionA
IPC-AssociationConnectingElectronicsIndustriesPublications
-7-
AvailablefromIPC,3000LakesideDrive,Bannockburn,IL60015,Tel:847-597-2862,www.ipc.org.J-STD-002
ComponentLeads,Terminations,Lugs,wires,SolderabilityTestsFor
3.REQUIREMENTS
3.1AcquisitionSpecificationandDetailSpecifications
Therequirementsfortheindividualwiresunderthisacquisitionspecificationshallbeasspecifiedhereinandinaccordancewiththeapplicabledetailspecification(see2.1.1.Unlessotherwisespecifiedbelow,anyconflictbetweentherequirementsofthisspecificationandthoseofthedetailspecification,therequirementsofthedetailspecificationshallgovern.Iftheacquisitionspecificationrefertoadetailspecificationforarequiredvalueandthatvalueisnotspecifiedinthedetailspecification,theacquisitionspecificationrequirementdoesnotapplytothatdetailspecification.Unlessotherwisespecifiedbycontractorpurchaseorder,productpurchasedtothisspecificationshallbesuppliedtothelatestrevisionineffectatissuanceofthecontractorpurchaseorder(see6.3.3.1.13.1.23.2
Alldetailspecificationprovisionsforresistancetotapeabrasionarenotrequired.Alldetailspecificationprovisionsforacidresistancearenotrequired.Qualification(see4.4
Thewiresfurnishedunderthisspecificationshallbeproducts,whichareauthorizedbythequalifyingactivityforlistingontheapplicablequalifiedproductslistatthetimesetforopeningofcontractbidsorpurchaseorders.QualificationrequirementsareinaccordancewithTable4andthedetailspecification.3.2.1
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
ConformitytoQualifiedSample
Exceptforchangesapprovedbythecontract,itisunderstoodthatwiresuppliedundercontractshallbethesamematerialformulations,materialsources,andmanufacturingprocessesasapprovedbythequalifyingactivity.Anyunapprovedchangesmadeafterthequalificationapprovaldate,unlessacceptedbythequalifyingactivity,mayconstitutecauseforrejection.3.3Materials
Wirematerialsshallbeasspecifiedhereinorasspecifiedinthedetailspecification.3.3.1
ConductorMaterial(see4.5.1.1
AllconductorsshallmeetthematerialrequirementsofMIL-W-29606.3.3.2
InsulationMaterial(see4.5.1.2
Allfluoropolymersusedinanytypeofinsulationshallbeasspecifiedhereinandinthedetailspecificationandshallcontainnoadditivesexceptthoserequiredaswettingagentsinsuspensoids,pigmentationforcolors,andlubricantsusedinextrusion.Fillersshallbeaddedonlywhenrequiredbytheapplicabledetailspecification.Theuseofreclaimedorrecycledinsulationmaterialsisnotprohibited,butifused,therecycledmaterialsshallnothavebeendegraded,arefreeofcontaminants,andareidenticalwithmaterialsinperformance.ThephysicalpropertiesofthefluoropolymerinsulatingmaterialsshallbeasspecifiedinTable1.
3.3.2.1Polytetrafluoroethylene(PTFEResinMaterial
Unlessotherwisespecifiedinthedetailspecification,thePTFEresinshallconformtoASTMD4895.

AS22759RevisionA
t
n0000%a-0050tsdor5215ie3sloleiuelRFfnlaeElF004narrty0484oeehT2-ittP-snye(48-440-ail2126-1%%050716211-44-21rMob(PeezAiSl-yeed2eziS
n0isvnir5teoF0ey2lduV00koilcFP(aPziSJr-ooennroeoeunE50illet5flF00ayayT01lhutrhttE5sEee(nTIdeddeueetnrtanel0xnelyP05Eiry1ohpE0utoF0r(2lFEP0000000050
0522a-43-etrneoreEtlFyoylu8olhTftPPe(00540224181-8-8-0-82-21121e005021162118-84-0-211ezizddeerSiSsde00eziS00eut0500niprn3tiaxs1TEEFTPd77m5.1
nx00ia00mmetroppusnUts00a00C033ndUe00v0027325112..22x000na000iik03725mmS4221152..22
eschgsitaltsgriireelaenevmyegigtgesrtithtgncealrnanna/ralarteaoo1tieiereierSmslimgvarrtttaSvniavtravnculi5algri.headganeefgaertmmmi/55dciClin2usintinncmnnccfnmi/goioirns.itonilleeltace(bnlemreupcrempeml3oTo((vot66ei(i..pLCD035S
.1elbaTnislairetamrehtorofelbacilppatonsitsetnoitagnolelaitnerefmucricehT/1-8-
-
--`,,`,`,,`,,`-`-````,,`,,,`,`,,``,,`,`,`,,,``--
SAE

TABLE1-PHYSICALPROPERTIESOFINSULATIONCOMPONENTS



SAE
3.3.2.2
AS22759RevisionA
PTFECoatedFibrousGlassYarnsMaterial
-9-
Unlessotherwisespecifiedinthedetailspecification,allfibrousglassyarnsusedinbraidingshallbecoatedwithPTFEresintotheextentofnotlessthan15%byweightofthecoatedyarn.Inaddition,aftereachbraidapplication,thebraidshallbecoatedwithPTFE.ThiscoatingshallbeaPTFEfinisher,PTFEextrusion,orPTFEunsupportedtape.3.3.2.3
PTFECoatedFibrousGlassTapesMaterial
Unlessotherwisespecifiedinthedetailspecification,allfibrousglasstapesusedininsulationshallcontainnotlessthan50%ofPTFEbyweightofthecoatedtape.3.3.2.4
Fluoropolymer/Polyimide/FluoropolymerTapesMaterial
Unlessotherwisespecifiedinthedetailspecification,fluoropolymer/polyimide/fluoropolymertapesshallbeasspecifiedherein.3.43.4.1
FinishedWireConstruction(see4.5ConductorConstruction(see4.5
AllconductorsshallbeconstructedinaccordancewithMIL-W-29606.3.4.1.13.4.1.1.1
ConductorElongationandTensileStrengthofFinishedWire(see4.5.12ConductorSoftorAnnealedCopper(see4.5.12.1
Theindividualstrandsremovedfromfinishedwireswithsoftorannealedcopperconductors,wiresizes20andlarger,orthewholesoftorannealedcopperconductorremovedfromfinishedwire,sizes22andsmaller,shallhavethefollowingminimumelongation:
Sizes24andsmaller-6%(minimumSizes22andlarger-10%(minimum
Thereshallbenotensilestrengthrequirementsforsoftorannealedcopperconductors.3.4.1.1.2
ConductorHighStrengthAlloyCopper(see4.5.12.2
Unlessotherwisespecifiedinthedetailspecification,thewholeconductorremovedfromfinishedwireswithhighstrengthandultrahighstrengthalloycopperconductorsshallexhibitelongationof6%minimum,andtensilebreakingstrengthconformingtoMIL-W-29606.3.4.1.2
ConductorStranding(see4.5
Conductorstrandingshallbeasspecifiedinthedetailspecification.3.4.1.3
ConductorDiameter(see4.5.2
Thediameteroftheconductorshallbeasspecifiedinthedetailspecification.3.4.1.4
ConductorResistance(see4.5.11
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
Conductorresistanceshallbeasspecifiedinthedetailspecification.

SAE
3.4.2
InsulationConstruction(see4.5
AS22759RevisionA-10-
Insulationconstructionshallbeasspecifiedinthedetailspecification.3.4.2.1
InsulationTapeSplices
3.5FinishedWireDesign(see4.5
Thefinishedwireshallbeconstructedasspecifiedinthedetailspecification.3.5.1
PrimaryInsulationFlaws(see4.5.1.3
Unlessotherwisespecifiedinthedetailspecification,onehundredpercentofthewire,followingapplicationoftheprimaryinsulation,shallbesubjectedtothesparktest,impulsedielectrictest,orthehighfrequencysparktest.Thisevaluationshallbeperformedbeforetheapplicationofanyadditionallayerstothewire.3.5.2
InsulationStripping(4.5.4
Allinsulationshallbereadilyremovablebyconventionalwirestrippingdeviceswithoutdamagetotheconductor.Unlessotherwisespecifiedinthedetailspecification,theinsulationshallberemovedinaccordancewiththerecommendedtoolinAS5457andtheconductorshallbefound“acceptable”asdefinedbyAS5457.Thereshallbenoevidenceofinsulationontheconductorwhenviewedusingnormalorcorrectivevision,withoutmagnification.3.5.2.1
InsulationStripForce(4.5.4.1
Forwiresize26through14,thestripforceshallbeinaccordancewiththedetailspecification.3.5.3InsulationConcentricityandWallThickness(see4.5.13
Theconcentricityrequirementshallapplytoboththeprimaryinsulationandthefinishedwire.Theconcentricityrequirementshallnotapplytotape-wrapconstructions.Whenrequiredinthedetailspecification,theminimumwallthicknessshallbeasspecifiedinthedetailspecification.3.5.4
FinishedWireInsulationFlaws(see4.5.6
Onehundredpercentofthefinishedwireshallpasseithertheimpulsedielectrictestorthehighfrequencysparktest.Thistestshallbeperformedduringthefinalwindingofthewireonshipmentspoolsorreels.
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
Splicesshallbepermittedintheinsulationtapesprovidedtheperformancecharacteristicsofthefinishedwirearenotaffected.Nospliceinonelayerofinsulationtapeshallbesopositionedonthewireastooverlapanypartofaspliceinanotherlayerofinsulationtape.Themeasuredmaximumdiameterofthefinishedwireataspliceintheinsulationtapeshallnotexceedthemeasureddiameterofthefinishedwirewherenotapespliceispresentbymorethanfivetimesthenominalthicknessofthetapeinwhichthespliceoccurs(seventimesforsingle-tapeinsulations.Splicesoftheouterinsulationtapeshallnotbelongerthan1inchandnotmorethanonespliceoftheouterinsulationtapeshalloccurinany150feetofthefinishedwire.

SAE
3.5.5
InsulationColorMarking(see4.5
AS22759RevisionA-11-
Thecolorofthefinishedwireshallbeasindicatedbytheinsulationcolordesignator(see1.1ofthewirepartnumber.Thefirstdigitofthedesignatorshallindicatethebackgroundinsulationcolorandthesucceedingdigits,ifany,shallindicatethecolorsofthestripes,bands,ortracers.TheinsulationcolordesignatorofthewireshallbelistedinMIL-STD-681,SystemI(differentiationcolorcodingforchassiswiring.Thepreferredcolorandanyapplicablerestrictionsonavailablecolorsareindicatedintheindividualdetailspecification.Unlessotherwisespecifiedinthedetailspecification,thecolorofthebackgroundinsulationshallbeinaccordancewithMIL-STD-104,Class1.AlternateMunsellcolorlimitsforthebackgroundinsulationmaybeusedforlasermarkingwhenspecifiedinthedetailspecification.Thecolorofstripes,bands,ortracersshallbeinaccordancewithMIL-STD-104,Class1.ThedesignationcodeforcolormarkingofstripesorbandsshallbeinaccordancewithMIL-STD-681.3.5.6InsulationIdentificationPrintedMarking(see4.5
Unlessotherwisespecifiedinthedetailspecification,thefinishedwireshallbeidentifiedbyaprintedmarkingappliedtotheoutersurfaceofthewire.Theprintedidentificationshallbeatintervalsof6to60inches,asmeasuredfromtheendofonecompletemarkingtothebeginningofthesucceedingcompletemarking.Theidentificationmarkshallnotbeappliedbyhotstampmarkingorothermethodsthatsignificantlypenetratetheinsulation.3.5.6.1
PartNumberMarking(see1.1
Thefirstmarkingonthewireshallbethepartnumber.3.5.6.1.1
ColorMarkingCodeExemption
Thecolorcodeportionofthepartnumberisnotrequiredintheprintedmarkingbutisrequiredinallreferencedocumentation.Attheoptionofthewiresupplier,thecolorcodeportionofthepartnumber(see1.1maybeincludedbut,ifincluded,itshallbeincludedinitsentirety,notinpart.3.5.6.2ManufacturerIdentification
Thesecondmarkingonthewireshallbethemanufacturer’sidentificationinaccordancewiththemanufacturer’sCommercialandGovernmentEntity(CAGElistedinpublicationH4/H8.3.5.6.3
DetailSpecificationRevisionLetter
Thethirdmarkingonthewireshallbethelatestrevisionletterspecifiedforthedetailspecification.Ifthedetailspecificationhasnorevisionletter,therevisionletterisnotrequired.3.5.6.3.1
SupplyofLatestRevision
Unlessotherwisespecifiedinthepurchaseorder,thesupplierhas12monthsfromthedateoftherevisionofaspecificationsheettosupplyproducttothatlatestrevisionor12monthsfromissuanceofthisdocument(revisionAforexistingdetailspecificationsdatedpriortothisdocumentrevision.3.5.6.4
WirePrintedMarkingExample
Anexampleofhowthemarkingappearsonthewireisasfollows(forcolormarkingoptionsee3.5.6.1:M22759/1-2212814REVA

SAE
3.5.6.5
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
AS22759RevisionA
IdentificationMarkingColor
-12-
Unlessotherwisespecifiedinthedetailspecification,theprintingshallbegreenincolorinaccordancewithMIL-STD-104,Class1,exceptthatwhenthewireisanycoloragainstwhichgreenisdifficulttodistinguish,theprintingshallbewhite.Identificationprintingshallbeappliedwiththeverticalaxesoftheprintedcharacterslengthwiseofthewirewhenthenominaldiameterofthefinishedwireis0.050inchesorsmaller.Theverticalaxesoftheprintedcharactersmaybeeithercrosswiseorlengthwiseofthewirewhenthenominaldiameterofthewireexceeds0.050inch.Allprintedcharactersshallbecompleteandlegible.3.5.6.6StripeIdentification
Thecoloredstripesorbands,ifused,shallbeinaccordancewithMIL-STD-681.3.5.7
InsulationCircumferentialElongationfor(extrudedPTFEorabrasionresistantPTFEinsulation(see4.5.1.2.3
Thethininsulationslugshallnotsplitorcrack.3.5.8
InsulationResistance(see4.5.7
Theinsulationresistanceshallbeasspecifiedinthedetailspecification.3.5.9
Diameter(see4.5.3
Thefinishedwirediametershallbeasspecifiedinthedetailspecification.3.5.10Weight(see4.5.5
Thefinishedwireweightshallbeasspecifiedinthedetailspecification.3.5.11InsulationStateofSinter(see4.5.37
Layersofinsulationsshallmeetthestateofsinterrequirementasspecifiedinthedetailspecification.3.5.12Workmanship(see4.5
Alldetailsofworkmanshipshallbeinaccordancewithhighgradeaircraftwiremanufacturingpractice.Theinsulationshallbefreeofcracks,splits,irregularities,andimbeddedforeignmaterial.3.63.6.1
FinishedWirePerformanceRequirements(see4.5MarkingDurability(see4.5.9
Identificationofproductprinting(see3.5.5and3.5.6,whenappliedtotheoutersurfaceofthefinishedwire,shallbecapableofwithstandingthedurabilitytestforthenumberofcyclesandwiththeweightspecifiedinthedetailspecification.Thistestshallnotberequiredwhentheidentificationmarking(see3.5.5and3.5.6isunderaclearjacket,oronbraidedtracers.3.6.23.6.2.1
InsulationWrap(see4.5.8
ExtrudedInsulation("wrapbacktest"
Wireinsulationcomposedentirelyofextrudedmaterialorpolyimide-coatedextrudedmaterialshallshownocrackingoftheinsulation.

SAE
3.6.2.2
AS22759RevisionA
TapeorBraidInsulation(MandrelTest
-13-
Wirewithtapes,braids,orbothtapesandbraidsascomponentsoftheinsulationshallshownoinsulationcrackingordielectricbreakdown.3.6.3
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
InsulationBlocking(see4.5.10
Adjacentturnsorlayersofthewireshallnotsticktooneanother.3.6.4
ConductorStrandAdhesion(see4.5.30
Whenrequiredbythedetailspecification,theconductorshallcontainthetotalnumberofstrandsspecifiedinthedetailspecification.When19-strandconductors(wiresizes26through12takenfromfinishedwiresareexaminedinaccordancewith4.5.30,thetotalnumberofunbondedsinglestrandsplusthenumberofmetallicbondedpairsandmetallicbondedgroupsofstrandsinthespecimenshallbenotlessthan13.Forallotherconductors(7strands,etc.thetotalcountofunbondedsinglestrandsmetallicbondedpairsofstrands,andmetallicbondedgroupsofstrandsshallnotbelessthan0.70timesthenumberofstrandsintheconductor.3.6.5
ConductorSolderability(see4.5.29
Unlessotherwisespecifiedinthedetailspecification,conductorsoffinishedwiresthathavetincoatedorsilvercoatedstrandsshallbetestedforsolderability.TherequirementforacceptablesoldercoverageofthestrandedconductorshallbeasdefinedinJ-STD-002.Thetestisnotapplicabletofinishedwireswithnickelcoatedstrands(see6.1.3.6.6
InsulationShrinkage(see4.5.14
Insulationshrinkageshallnotexceedthatspecifiedintheinthedetailspecification.3.6.7
InsulationLowTemperatureResistance(see4.5.16
Theinsulationshallhavenovisiblecracksordielectricbreakdown.3.6.8
InsulationThermalShock(see4.5.17
Theinsulationshallnotshrinkorelongategreaterthanthatspecifiedintheinthedetailspecification.Thereshallbenoflaringoftheinsulationlayers.3.6.9
Wicking(see4.5.15
Thewireshallnotexceedtheweightgainortravelbeyonddyelengthspecifiedinthedetailspecification.3.6.10LifeCycle(see4.5.19
Unlessotherwisespecifiedintheinthedetailspecification,thereshallbenochangeincoloroftheinsulation.Changeinmarkingcolorshallnotbeconsidered.Thereshallbenoobservedcracksorsplitswhensubjectedtothebendtestandnodielectricbreakdownoftheinsulation.3.6.11FluidImmersion(see4.5.24
Thefinishedwireshallnotexceedthediameterspecifiedintheinthedetailspecificationbymorethan5%.Thewireshallexhibitnocrackingorinsulationdielectricbreakdown.3.6.12HumidityResistance(see4.5.25
Thefinishedwireshallbeinaccordancewiththeinsulationresistancespecifiedintheinthedetailspecification.

SAE
3.6.13SurfaceResistance(see4.5.26
AS22759RevisionA-14-
Thefinishedwireshallbeinaccordancewiththesurfaceresistancespecifiedinthedetailspecification.3.6.14SmokeResistance(see4.5.27Thefinishedwireshallexhibitnovisiblesmoke.3.6.15FlameResistance(see4.5.18
Unlessotherwisespecifiedinthedetailspecification,thewireinsulation,oncetheflamehasbeenremoved,shallbeselfextinguishingpriortothetimespecifiedinthedetailspecificationandflametravelshallnotexceedthespecifiedlength.Whenspecifiedinthedetailspecification,theinsulationdielectricshallnotbreakdown.Breakingofthewirespecimensinsizes24andsmallershallnotbeconsideredasafailureprovidedtherequirementforflametravellimitsanddurationofflamerequirementismet.
3.6.16WetArcPropagationResistance(see4.5.31
Whenwetarcpropagationresistanceisrequiredinthedetailspecification,aminimumof67totalwiresformediumweightwireand64totalwiresforlightweightwireshallpassthewetdielectrictest.Nomorethanthreewiresshallfailthewetdielectrictestinanyonebundle.Theactualdamageareashallnotbemorethan3inchesinanyonewire.3.6.17DryArcPropagationResistance(see4.5.32
Whenthefinishedwiredryarcpropagationisrequiredinthedetailspecification,aminimumof67totalwiresformediumweightwireand64totalwiresforlightweightwireshallpassthewetdielectrictest.Nomorethanthreewiresshallfailthewetdielectrictestinanyonebundle.Theactualdamageareashallnotbemorethan3inchesinanyonewire.3.6.18DynamicCut-through(see4.5.33
Whendynamiccut-throughisrequiredinthedetailspecification,theminimumaveragedynamiccut-through(poundsatagiventemperatureshallbetestedinaccordancewith4.5.33exceptthatthecuttingbladeedgeshallbea0.005inchradius±0.001inchradius.
3.6.19ForcedHydrolysis(see4.5.34
Whentheforcedhydrolysisisrequiredinthedetailspecification,theinsulationshallexhibitnodielectricbreakdown.3.6.20InsulationCrosslinkProofandAcceleratedAging(see4.5.21
Whentheinsulationcrosslinkproofandacceleratedagingisrequiredinthedetailspecification,changeinmarking,color,orpittingshallnotbeconsidered.Thereshallbenoobservedcracksorsplitswhensubjectedtothebendtestandnodielectricbreakdownoftheinsulation.3.6.21ThermalIndex(see4.5.35
Whenthethermalindexisrequiredinthedetailspecification,thefinishedwireshallhavethethermalindexratingatthetimeandtemperaturespecified.3.6.22UVLaserMarking(see4.5.36
WhentheUVlasermarkingisrequiredinthedetailspecification,thefinishedwireoutersurfaceshallbeultraviolet(UVlasermarkable.Unlessotherwisespecifiedinthedetailspecification,themarkshallmeetaminimumcontrastlevelof55%.
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---

SAE
3.6.23ContinuousLengths(see4.5.28
AS22759RevisionA-15-
TheindividualcontinuouslengthsofwireineachqualificationlotshallbeofsuchfootagethatwheninspectedthequalificationlotshallconformtotheScheduleAcontinuouslengthrequirementsofTable2ortotheScheduleBcontinuouslengthrequirementsofTable3,asapplicable.Unlessthecontractororderthatwasusedtoproducethequalificationlotspecifiesotherwise,thefootageoftheindividualcontinuouslengthsineachspoolorreelshallbemarkedonthespoolorreelinthesequenceinwhichthelengthswillbeunwoundfromthespool.Forproductionlots(see5.1.1,theapplicablescheduleshallbeasspecifiedinthedetailspecification.
TABLE2-MINIMUMCONTINUOUSWIRELENGTHS(SCHEDULEAREQUIREMENTS
RequiredMinimumPercentoftheTotalInspection
WireSizeLotFootageinContinuousLengthsGreaterThan(Range300ft100ft50ft25ft30-2050%80%100%—18-1430%80%100%—12-10—50%80%100%8-4—20%50%100%2-1——50%100%0-0000——30%100%
TABLE3-MINIMUMCONTINUOUSWIRELENGTHS(SCHEDULEBREQUIREMENTS
RequiredMinimumPercentoftheTotalInspectionWireSizeLotFootageinContinuousLengthsGreaterThanRange500ft250ft100ft50ft25ft30-685%—100%——4-2—85%—100%—1-0000——85%—100%
4.QUALITYASSURANCEPROVISIONS:4.1
ResponsibilityforInspection
Unlessotherwisespecifiedinthecontractorpurchaseorder,thesupplierisresponsiblefortheperformanceofall
contractinspectionrequirementsasspecifiedherein.Exceptasotherwisespecifiedinthecontractorpurchaseorder,thesuppliermayuseanyfacilitiessuitablefortheperformanceoftheinspectionrequirementsspecifiedherein.Thepurchaserorqualifyingactivityhastherighttoperformanyoftheinspectionssetforthinthestandardwheresuchinspectionsaredeemednecessarytoassuresuppliesandservicesconformtoprescribedrequirements.4.1.1
ResponsibilityforCompliance
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
Allitemsmustmeetallapplicablerequirementsofthisproductstandard.Theinspectionsetforthinthisstandardshallbecomeapartofthesupplier’soverallinspectionsystemorqualityprogram.Theabsenceofanyinspectionrequirementsinthestandardshallnotrelievethesupplieroftheresponsibilityofassuringthatallproductscomplywithallrequirementsofthecontract.Samplinginqualityconformancedoesnotauthorizesubmissionofknowndefectivematerial,eitherindicatedoractual,nordoesitcommitthepurchasertoacceptanceofdefectivematerial.

SAE
4.1.2
ClassificationofInspections
AS22759RevisionA-16-
Theinspectionrequirementsunderthisspecificationareclassifiedasfollows:a.Supplierprocessinspections(see4.3b.Qualificationinspections(see4.4
c.Qualityconformanceinspections(see4.4.3d.Inspectionofpackaging(seeSection54.2
StandardTestConditions
Unlessotherwisespecifiedhereinorinthedetailspecification,allmeasurementsandtestsshallbemadeattemperaturesof15to35°C(59to95°Fatairpressureof650to800millimetersofmercury,andarelativehumidityof45to75%.Whenevertheseconditionsmustbecloselycontrolledinordertoobtainmorereproducibleresults;forrefereepurposes,temperature,relativehumidity,andatmosphericpressureconditionsof25+0,-2°C(77+0,-3.6°F,50%±12%RelativeHumidity,and650to800millimetersofmercuryshallbeused.4.2.1
TestEquipmentandInspectionFacilities
Testandmeasuringequipmentandinspectionfacilitiesofsufficientaccuracy,quality,andquantitytopermitperformanceoftherequiredinspectionshallbeestablishedandmaintainedbythesupplier.TheestablishmentandmaintenanceofacalibrationsystemtocontroltheaccuracyofthemeasuringandtestequipmentshallbeinaccordancewithANSI/NCSLZ540-1orequivalentstandards.4.3ProcessControls
ThesuppliershallcontrolallprocessesinaccordancewithAS9003orequivalent.Independentcertificationoftheprocessesisnotrequired,howeverthequalifyingactivityreservestherighttoinspectanyofthesupplier’sprocessesinaccordancewithAS9003.Failuretocomplybecauseofthequalifyingactivityinspectionmayresultinqualificationdisapproval.

SAE
AS22759RevisionA
TABLE4-QUALIFICATIONANDQUALITYCONFORMANCEREQUIREMENTS
-17-
Group1,2&3In-process
RequirementTestMethodQualityQuality
InspectionTestsParagraphParagraphConformanceConformance
Conductormaterial3.3.14.5.1.14.4.3.1Insulationmaterial3.3.24.4.5.24.4.3.1Conductorandinsulationsplices3.4.1&3.4.24.4.3.2.34.4.3.1Primaryinsulationflaws3.5.14.4.3.2.44.4.3.1Insulationcircumferentialelongation3.5.74.4.3.2.54.4.3.1

Conductorconstruction3.4.14.51Conductorelongation3.4.1.1.14.4.121Conductortensilebreakstrength3.4.1.1.24.4.12.21Conductorstranding3.4.1.34.51Conductordiameter3.4.1.44.5.21Conductorresistance3.4.1.54.5.111Insulationconstruction3.4.24.51Finishedwireconstruction3.54.51Insulationstripping3.5.24.5.41Insulationcolormarking3.5.54.51Insulationidentificationprintedmarking3.5.64.51Insulationresistance3.5.84.5.71Diameter3.5.94.5.31Weight3.5.104.5.51Insulationstateofsinter3.5.114.5.371Workmanship3.5.124.51Markingdurability3.6.14.5.91

Insulationconcentricityandwallthickness3.5.34.5.132Insulationblocking2/3.6.34.5.102Conductorstrandadhesion3.6.44.5.302Conductorsolderability4/3.6.54.5.292Insulationshrinkage3.6.64.5.142Insulationlowtemperatureresistance3.6.74.5.162Insulationthermalshock3.6.84.5.172Insulationcrosslinkproofandacceleratedaging3.6.204.5.212Wicking3.6.94.5.152Insulationwrap3.6.24.5.82

Finishedwireinsulationflaw3.5.44.5.63

Continuouslength3.6.234.3.4.1.3&4
4.5.28

Lifecycle3.6.104.5.19Fluidimmersion1/3.6.114.5.24Humidityresistance2/3.6.124.5.25Surfaceresistance3.6.134.5.26Smokeresistance2/3.6.144.5.27Flameresistance2/3.6.154.5.18Wetarcpropagation1/3.6.164.5.31Dryarcpropagation1/3.6.174.5.32

SAE

AS22759RevisionA-18-
TABLE4-QUALIFICATIONANDQUALITYCONFORMANCEREQUIREMENTS(Continued

Group1,2&3In-process
RequirementTestMethodQualityQuality
InspectionTestsParagraphParagraphConformanceConformance
Dynamiccut-through1/3.6.184.5.33Forcedhydrolysis1/3.6.194.5.34Thermalindex1/3/3.6.214.5.35UVlasermarking1/3.6.224.5.361/Notrequiredforretentionofqualificationunlessmaterialshavebeenchangedsinceinitialqualification.
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2/Requiredtobeperformedatfouryearintervalsafterinitialqualificationunlessmaterialshavebeenchangedsinceinitialqualification.
3/Initialqualificationapprovalshallnotbewithheldduringthethermalindextestperiod.Attherequestofthequalifyingactivity,thesupplierwillprovideasummaryofresultsatregularintervals.
4/Forsilvercoatedconductor,requiredtobeperformedonlyatfouryearintervalsafterinitialqualificationunlessmaterialshavebeenchangedsinceinitialqualification.4.4QualificationInspections
Qualificationinspectionsincludetheinitialqualificationinspection(4.4.1andinspectionforretentionofqualification(4.4.2.4.4.1
InitialQualificationInspection
Initialqualificationinspectionshallconsistofallthetestsandexaminationsofthisspecificationexcepttheexaminationofpackaging.Performanceoftheinspectionshallbetheresponsibilityofthequalificationapplicantunderauthorizationofthequalifyingactivity(see6.3.Thequalifyingactivityshallauthorizetotheapplicanttobeginqualificationtestingbyawrittennoticethatdescribestherequirementsofsubmissioninaccordancewiththisspecification.Thequalificationapplicantshallfurnishtestresults,certifications,andtestedsamplesoruntestedproduct(whenrequestedtothequalifyingactivity(see4.4.1.3.CertificationsshallbeprovidedongovernmentformDDForm1718,“CertificationofQualifiedProducts”orequivalent.Detailtestresultsneededtoconfirmcertificationrequirementsshallbeprovideduponrequestfromthequalifyingactivity(see6.1.4.4.1.1
SamplingforInitialQualificationInspection
Afinishedwirelengthshallbeobtainedfromthecontinuouslengthqualificationlot(see3.6.20.Exceptasprovidedunderqualificationbysimilarityin4.4.1.2,afinishedwiresampleoftherequiredlengthshallbeselectedfromTableVforeachsizerangeforwhichqualificationisdesiredintheapplicabledetailspecification.Thesamplemaybeanysizewirewithinthespecifiedsizerange.
TABLE5-QUALIFICATIONWIRELENGTHREQUIREMENTS
WireSizeRange30through2826through2018through1412through108through42andlarger

Feet200200200100100100

SAE
4.4.1.2
AS22759RevisionA
SamplesforInitialQualificationbySimilarity
-19-
Qualificationbysimilarityisapplicablewhereagroupoftwoormoredetailspecificationscoverwireswhichareidenticalinmaterialsandconstructionexceptthattheconductorisdifferentineachdetailspecification.Insuchevent,thequalificationapplicantmayselectthesamplesspecifiedin4.4.1.1foranysizerangeorrangesofanydetailspecificationinthesimilargrouplistedinTable6.Approvalofthefinishedwirequalificationsampleshallalsoqualifythesamewiresizerangeorrangesineachoftheotherdetailspecificationsforwhichonlytheconductorisdifferent.Also,wherearequirementismorerigorousforawirebeingqualifiedbysimilaritythanforthewireundergoingcompletetest,thesampleundergoingcompletetestmustmeetthemorerigorousrequirementofthesimilarwireinordertoqualifythesimilarwire(e.g.,ifthefinishedwiresampleisa150°Cratedwireandthewirebeingqualifiedbysimilarityisratedat200°C,thefinishedwiresamplemustpassthethermalshocktestat200°Cinordertoqualifythe200°Cwire.Changesinthepropertiesofthelessrigorousconductorconstructionshallnotbeconsideredaspartofthemorerigoroustestresults.SimilaritygroupsnotdefinedinTable6shallbecoordinatedwiththequalifyingactivitypriortotesting.
TABLE6-WIREQUALIFICATIONSIMILARITYGROUPS
Detail
GroupSpecificationGroup1/1,/272/5,/683/7,/894/9,/10,/20,/21105/11,/12,/22,/23116/14,/1512
Detail
SpecificationGroup/16,/1713/18,/1914/28,/29,/30,/3115/32,/33,/44-/4616/34,/35,/41-/4317/80,/91,/92
Detail
Specification/81,/82/83-/88/89,/90

NOTE:Forpurposesofdeterminingidentityofconstructionindetail,specificationsunderthesimilarityprovision,small
differencesinspecifiedfinishedwirediameterorweightthatareobviouslyduetodifferencesinthespecifiedconductorshallnotbeconsideredasconstitutingdifferencesintheconstructionofthewires.4.4.1.3
SubmissionofQualificationResultsandSamples
Unlessotherwisespecifiedbythequalifyingactivity(see6.1,thesuppliershallonlyprovidethetestresultswithcopiesofallcertifications.Theformatofthetestreportshallbespecifiedbythequalifyingactivity.Whenrequestedbythequalifyingactivity,thesuppliershallprovidetestedand/oruntestedsamples.Thequalifyingactivityshallspecifywhattypesoftestedsamplesshallbeprovided,andhowthetestedsamplesshallbeidentifiedandpackaged.Untestedsamplesshallbetakenfromthesamelotorlotsastestedbythesupplierandplainlyidentifiedbysecurelyattacheddurabletagsmarkedwiththeinformationlistedbelow.Thetagsmustbestampedbythesupplier’sand/orqualifyingactivitydesignatedQualityAssuranceRepresentative(QARinspectorasrepresentativesamplesofthemanufacturer’snormalproductioncapability.Samplessubmittedwithoutthestampwillnotbeaccepted.
Sampleforqualificationtests:WIRE,ELECTRICAL,FLUOROPOLYMER-INSULATED,COPPERORCOPPERALLOYDetailSpecificationpartnumber:
Manufacturer’snameandcodenumber(PublicationH4/H8:Manufacturer’spartnumber:
Placeanddateofmanufactureofsample:
Submissioninformation:Submittedby(name(dateforqualificationtestsinaccordancewiththerequirementsofAS22759underauthorization(referenceauthorizingletter.
Materialcomposition:Whenspecificallyrequested,acomprehensivedescriptionandprimemanufacturer’snameandformulationnumberofthebasematerialsfromwhichtheproductismadeshallbeprovided(Thisinformationwillnotbedivulgedbythequalifyingactivity.4.4.2
RetentionofQualification
Inspectionsofproductforretentionofqualificationshallbemadeattwo-yearintervalsafterthesupplier’sinitialacceptancedateforqualificationapproval.Thequalifyingactivitymayestablishadifferentretentionofqualificationduedate.Failureofthesuppliertosubmitretentionofqualificationtestreportorcertificationwithin30daysaftertheendofthetwo-yearreportingperiodmayresultintheremovaloftheproductorproductsfromtheQualifiedProductsList(QPL.

SAE
4.4.2.1
AS22759RevisionA
RetentionofQualificationTestsandSamples
-20-
OnewiresizefromeachinitialqualificationapprovedsimilaritygrouplistedinTable6shallbetested.ThesamplesshallbefromcurrentproductionandshallbeinspectedinaccordancewithTable4.4.4.2.2
ProcedureforRetentionofQualificationInspection
Itisthesupplier’sresponsibilitytosubmitretentionqualificationdataattherequiredinterval.Unlessotherwisenotifiedbythequalifyingactivity,thedatashallbeprovidedinthesameformatasprovidedforinitialqualification.Thequalifyingactivityisnotrequiredtoprovideanauthorizationnoticetobeginretentionofqualificationtesting.Thequalifyingactivityreservestherighttomonitorthetesting,andrequesttestedand/oruntestedsamples,buttherequestmustbereceivedbythesuppliersixmonthspriortotheretentionofqualificationinterval.4.4.2.3
EffectofFailureinRetentionofQualificationInspection
Ifafailureoccursinthetestsforretentionofqualification,nowirerepresentedbythesample,noranyotherwiremanufacturedwiththesamematerialsandprocesses,whichhasnotalreadybeensubmittedforqualityconformanceinspection,shallbeofferedforacceptanceuntilthecauseforfailurehasbeendeterminedandconcurredwithbythequalifyingactivityasnotaffectingtheabilityofthewiretomeetqualificationinspectionrequirements.4.4.2.4
RetentionofQualificationbyCertification
Iftherehasbeennoproductionsincethelastretentionofqualificationinterval,retentionofqualificationshallconsistofacompletedgovernmentDDForm1718,“CertificationofQualifiedProducts”.Theformshallbesubmittedtothequalifyingactivitybytheperiodicqualificationduedate.Whenproductionresumesfollowingacertificationsubmission,themanufacturershallperformqualificationretentiontestsontheproductionlotandsubmitinaccordancetheretentionofqualificationrequirements.Retentionofqualificationbycertificationshallnotbepermittedfortwosuccessiveretentionofqualificationperiods.4.4.34.4.3.1
QualityConformanceProcessControlInspectionsQualityConformanceProcessControlInspection
Thisinspectioncomprisesqualityconformancetestsandexaminationsofsuchanaturethattheyareimpossibleorimpracticaltoperformonthefinishedwireandthereforeareconductedatthemostappropriatestageofthereceivingorthemanufacturingoperations.TherequiredprocesscontrolinspectiontestsarelistedinTable4.Processcontrolinspectionshallbeperformedoneverylotofwireacquiredunderthisspecification.ForqualityconformanceofconductorsprocuredtoMIL-C-22909,useASQCZ-1.4inlieuofMIL-STD-105,ASQCA8402inlieuofMIL-STD-109,andANSI-Z540.1inlieuofMIL-STD-45662.4.4.3.24.4.3.2.1
SamplingforQualityConformanceProcessControlInspectionConductorMaterialSample
Threeten-footlengthsofconductor,priortoinsulation,shallbeselectedinsuchmannerastoberepresentativeofthematerialtobeusedineachinspectionlotoffinishedwire.4.4.3.2.2
InsulationMaterialSample
Whenextrudedinsulationisused,threesamplesrepresentativeofeachinspectionlotshallbeselectedafterextrusion.Whenunsupportedtape,coatedglasstape,orcoatedglassyarnisused,threesamplesrepresentativeofeachinspectionlotshallbeselectedbeforeapplicationtothewire.

SAE
4.4.3.2.3
SpliceSamples(see4.5.1.4
AS22759RevisionA-21-
Theconductorandinsulationtapesamplesshallbesubjecttoexaminationforconformityofsplice,ifpresent.Forqualificationpurposes,thesupplier’ssplicingmethodsmaybeobservedduringtheinsulationprocessatthediscretionofthequalifyingactivityrepresentative.Theoptionsof4.1arealsoapplicable.4.4.3.2.4
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
PrimaryInsulationFlawsSample(see4.5.1.3
Whenatestforflawsoftheprimaryinsulationisrequired,test100%ofthewireafterapplicationoftheinsulationandpriortotheapplicationofanyadditionallayers.Portionsshowingdielectricbreakdownundertestshallbecutoutorremovedandtestingofthebalanceofproductionshallberesumed.4.4.3.2.5CircumferentialElongationSample(see4.5.1.2.3
Whenpolytetrafluoroethylene(PTFEorabrasionresistant(mineralfilledPTFEisused,fivesamplesrepresentativeofeachinspectionlotshallbeselectedafterextrusion.Circumferentialelongationtestingisnotrequiredforotherinsulationtypes.4.4.3.3
RejectionandRetestinProcessControlInspection
Therequirementsofthisparagraphdonotapplytoincomingconductororinsulationmaterialrequirementspriortowireprocessingortoprimaryinsulationflaws.Whenaprocesscontrolsampleselectedduringaproductionrunfailstomeetthespecifiedrequirements,furtherprocessingofthatlotshallceaseuntiltheextentandcauseofthefailurehavebeendeterminedandresolved.Ifcorrectiveactionistakenonthesamelotinwhichthefailureoccurred,theappropriateprocesscontroltestsshallberepeated.Correctiveactionstakenonfailinglotsshallbecommunicatedtothepurchaser.4.4.4
QualityConformanceInspectionofFinishedWire
ThequalityconformanceinspectionoffinishedwireshallconsistoftheexaminationsandtestslistedinTable4(Groups1-4.Unlessotherwisespecified,theinspectionshallbeperformedoneverylotofwireacquiredunderthespecification.4.4.4.1
SamplingforQualityConformanceInspectionofFinishedWire(Group1and2Tests
Forpurposesofthisspecification,thefollowingshallapply:
a.Lot:TheInspectionlotshallincludeallwireofonepartnumbersubjectedtoinspectionatonetime.
b.Unitofproduct:Theunitofproductfordetermininglotsizeforsamplingshallbeonecontinuouslengthofwireas
offeredforinspection.c.Sampleunit(GroupsIandIItestsofTable4:ThesampleunitforGroups1and2tests,exceptfortheGroupI
insulationresistancetest,shallconsistofasinglepieceoffinishedwirechosenatrandomfromtheinspectionlotandofsufficientlengthtopermitallapplicableexaminationsandtests.Unlessotherwisespecified,thelengthofthesampleunitforGroupItestsofTable4,otherthaninsulationresistance,shallbe20feetandthelengthofthesampleunitforGroupIItestsshallbe25feet.Notmorethanonesampleunitforeachgroupoftestsshallbetakenfromasingleunitofproduct.d.Sampleunitforinsulationresistancetest(Table4Group1:ThesampleunitfortheGroupIinsulationresistancetest
shallbeaspecimenatleast26feetinlengthselectedatrandomfromfinishedwirewhichhaspassedtheGroup3dielectrictest.Itisoptionalwhetherthespecimenistestedonthereelorremovedfromthereelforthetest,providedthelengthofthespecimencanbedetermined.4.4.4.1.1
FinishedWireInspectionLevelsandAcceptableQualityLevels(AQL(Groups1and2Tests
ForGroupIcharacteristics,includingtheinsulationresistancetest,theinspectionlevelshallbeS-2andtheAQLshallbe6.5%defectiveunitsinaccordancewithASQC-Z1.4andthedefinitionsherein(see6.2.ForGroupIIcharacteristics,theinspectionlevelshallbeS-3andtheAQLshallbe1.5%defectiveunits.

SAE
4.4.4.1.2
AS22759RevisionA
SamplingandAcceptanceInsulationFlawsTest(Group3ofTable4
-22-
Onehundredpercentofthefinishedwire,andeverylengthofthewireshallbesubjectedfullytothetestforinsulationflaws.Insulationbreakdownsresultingfromthetest,andendsorportionsnotsubjectedtothetestshallbemarkedorcutoutofthefinishedwire.Whenspecifiedinthecontractororder,dielectricfailure,untestedportions,orportionsthathavebeenexposedtofewerormorethanthespecifiednumberofpulsesorcyclesarepermittedtobemarkedbystrippingtheinsulationoranyothermethodspecifiedinthecontractinlieuofbeingcutoutthewire.4.4.4.1.3
SamplingandAcceptabilityLevelsforContinuousLengths(Group4
Theinspectionlevelandacceptablequalitylevelforthisexaminationshallbeasrequiredfortheapplicableprocedureof4.5.28.4.4.4.2
EffectofaQualityConformanceProcessControlFailureonFinishedWire
Qualityconformancetestingoffinishedwiremaybecontinuedduringtheinvestigationofthefailureofaprocesscontrolsample,butthereshallbenofinalacceptanceofthefinishedproductuntilitisdeterminedthatthelotmeetsallthequalityconformancerequirementsofTable4.4.4.4.3
NonconformingInspectionLots
DispositionofinspectionlotsfoundunacceptableunderqualityconformanceinspectionshallbeinaccordancewithASQC-Z1.4.
4.5TestMethods
Unlessotherwisespecifiedallsamplesshallbeexaminedcarefullytodetermineconformancetothisspecificationandtotheapplicabledetailspecificationswithregardtorequirementsnotcoveredbyspecifictestmethods.Certificationtotherequirementsnotcoveredbyspecifictestmethodsisrequiredforqualification.Thequalifyingactivityreservestherighttorequestdocumentationtosubstantiatethecertification.4.5.1
ProcessControlInspectionTestMethods
4.5.1.1ConductorMaterial
Testdataorcontrolprocessesusedtodemonstratecompliancetoconductormaterialrequirementsshallbeprovidedtothequalifyingactivityuponrequest.Certificationfromtheoriginalmaterialsuppliermaybesubmittedasanalternativetoperformingthetest.
4.5.1.2InsulationMaterial
Samplesofinsulationmaterialshallbesubjectedtothefollowingtests.Certificationfromtheoriginalmaterialsuppliermaybeacceptedasanalternativetoperformingthesetests.4.5.1.2.1
TensileStrengthandElongationofUnsupportedTapes
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UnsupportedtapesshallbesubjectedtothetensilestrengthtestsandelongationtestsofASTMStandardD882,MethodAorB,exceptthatthereshallbenolimitationastowidthofthetape.4.5.1.2.2
TensileStrengthandElongationofExtrudedFluoropolymerPrimaryInsulationorJacket
Unlessotherwisespecified,specimensofextrudedfluoropolymerprimaryinsulationorjacketshallbecarefullyremovedfromtheconductorandtestedfortensilestrengthandelongationinaccordancewithMIL-STD-2223method2001,exceptthattherateoftravelofthepower-actuatedgripofthetensilemachineshallbe10inchesperminute±2inchesperminutefortestsofpolyvinylidenefluoridespecimens.

SAE
AS22759RevisionA-23-
4.5.1.2.3CircumferentialElongation(extrudedPTFEorabrasionresistantPTFEinsulationonly
Thetestmeasurestheelongationofathinslugofwireinsulationinthecircumferential(radialdirection.ThecircumferentialelongationshallbeperformedinaccordancewithMIL-STD-2223method2005.4.5.1.2.4DielectricStrengthofUnsupportedTapes
Samplesoftapeshallbesubjectedtotheshort-timetestofASTMStandardD149.Stainlesssteelelectrodes1/4inchindiameterandhavingedgesroundedto1/32-inchradiusshallbeused.Theradiusmustbeaccurate,andshouldbecheckedonanopticalcomparator.Voltageshallbeincreasedatapproximately500voltspersecond.Tapesshallbetestedwithoilasthemedium.TheoilshallbeasspecifiedinMIL-L-23699.4.5.1.2.5SpecificGravityofUnsupportedTapes
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SamplesoftapesshallbesubjectedtoTestMethodAofASTMStandardD792.Asuitablewettingagentshallbeaddedtothewatertoassistincompletewettingofthesurfacesofthespecimen.4.5.1.2.6
PTFEContentofCoatedFibrousGlassYarnsandTapes
Aweighedspecimenofthecoatedfibrousglassshallbeignitedfor4hoursinamufflefurnaceat700°C.TheresidueshallbecooledandweighedandthelossinweightcalculatedasPTFEcontentofthecoatedtapeoryarn.4.5.1.3
PrimaryInsulationFlaws
Oneofthefollowingmethodsshallbeusedtodeterminethepresenceoffaultyareasintheprimaryinsulation.Onehundredpercentofthewireshallbetested,andanyportionshowinginsulationbreakdownshallbecutoutofthewireoneachsideofthefailure.Thetestvoltageshallbespecifiedinthedetailspecification.4.5.1.3.1
SparkTestofPrimaryInsulation
Thewire,aftertheapplicationoftheprimaryinsulationandpriortotheapplicationofanyothermaterial,shallbepassedthroughachainelectrodesparktestdeviceusingthevoltageandfrequencyspecifiedintheapplicabledetailspecification.Theelectrodeshallbeofabeadchainorfinemeshconstructionthatwillgiveintimatemetalliccontactwithmostoftheinsulationsurface.Electrodelengthandspeedofwiremovementshallbesuchthattheinsulationissubjectedtothetestvoltageforaminimumof0.2second.4.5.1.3.2
ImpulseDielectricTestofaPrimaryInsulation
Performinaccordancewithimpulsedielectrictest(see4.4.6.1.Unlessotherwisespecifiedonthedetailspecifications,performtheimpulsedielectrictestat6.0kV(peak.4.5.1.3.3
HighFrequencySparkTestofPrimaryInsulation
Performinaccordancewithhighfrequencysparktest(see4.4.6.2.Unlessotherwisespecifiedinthedetailspecification.Performthehighfrequencysparktestat4.2kV(rms.4.5.1.4
ConductororInsulationSplices
Certificationofconformitytothesplicingrequirementsisrequired.Testdataorcontrolprocessesusedtodemonstratecompliancetoconductororinsulationsplicerequirementsshallbeprovidedtothequalifyingactivityorpurchaseruponrequest.
4.5.2ConductorDiameter
TheconductordiametershallbemeasuredinaccordancewithMIL-STD-2223method5001.

SAE
4.5.3Diameter
AS22759RevisionA-24-
4.5.4InsulationStripping
TheinsulationshallberemovedinaccordancewiththerecommendedtoolspecifiedinAS5457.Withouttouchingtheconductoraftertheinsulationisremoved,theconductorshallbeexaminedinaccordancewithAS5457.4.5.4.1
InsulationStripForce
A0.25inchinsulationslugshallbestrippedfromthewireandthestripforcemeasuredinaccordanceASTMD3032Section27.4.5.5Weight
TheweightofeachlotoffinishedwireshallbedeterminedbyProcedureIofMIL-STD-2223method6002.LotsfailingtomeetthewireweightrequirementoftheapplicabledetailspecificationwhentestedinaccordancewithProcedureIshallbesubjectedtoProcedureIIofMIL-STD-2223method6002.Allreelsorspoolsfailingtomeettherequirementsoftheapplicabledetailspecificationshallberejected.ThequalityconformancesamplingplansarenotapplicablewhenProcedureIIisused.Eithermethodmaybeusedtosubmitqualificationdataincludingcorrectiveaction(ifapplicable.4.5.6
FinishedWireInsulationFlaws
Oneofthefollowingmethodsshallbeused.Onehundredpercentofthefinishedwireshallbetested,andanyportionshowinginsulationbreakdownshallbecutoutofthewireincludingatleast2inchesofwireoneachsideofthefailure.4.5.6.1
ImpulseDielectricTest
FinishedwireshallbetestedinaccordancewithMIL-STD-2223method3002atthevoltagespecifiedintheapplicabledetailspecification.Unlessotherwisespecifiedinthedetailspecifications,performtheimpulsedielectrictestat8.0kV(peakforfinishedwire.4.5.6.2
HighFrequencySparkTest
Asanalternativetotheimpulsedielectrictest,the3KHzhighfrequencysparktestinaccordancewithMIL-STD-2223method3008ispermittedforthedetectionofflawsinfinishedwire,unlessotherwisespecifiedinthedetailspecifications,performthehighfrequencysparktestat5.7kV(rmsforfinishedwire.4.5.7InsulationResistance
TheinsulationresistancetestshallbeperformedinaccordanceMIL-STD-2223method3003.4.5.8InsulationWrap
Thewraptestshallbeperformedinaccordancewiththefollowingmethods:4.5.8.1
ForExtrudedInsulation("wrapbacktest"
ThewireshallbetestedinaccordancewithMIL-STD-2223method2003exceptwiressize4andsmallershallbewrappedbackonitself.Forsizetwoandlargerthemandrelsizeshallbeasspecifiedinthedetailspecification.Theairoventemperatureshallbeasspecifiedinthedetailspecification.
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
ThefinishedwirediametershallbemeasuredinaccordancewithMIL-STD-2223method6001.Forqualification,anin-processmethodformeasurethediametermaybeusedprovidedasummaryoftheresultsissubmittedtothequalifyingactivity.

SAE
4.5.8.2
AS22759RevisionA
ForTapeorBraidInsulation(mandreltest
-25-
ThewraptestshallbeperformedinaccordancewithMIL-STD-2223method2002exceptthemandrelsizeshallbespecifiedinthedetailspecification.Eachspecimenshallbesubjectedtoawetdielectrictest.4.5.9MarkingDurability
Thedurabilityofproductidentificationandcolormarkingsappliedtothewireforcodingshallbeevaluatedat20to25°C(68to77°FinaccordancewithMIL-STD-2223method6004.Ifthereisacontinuouslineoferasureorobliterationthroughthestripe,band,orprintedidentificationmarkingexposingtheprimaryinsulation,thespecimenshallbeconsideredashavingfailed.Threespecimensshallbetestedfromeachsampleunitandfailureofanyspecimenshallconstitutefailureofthesampleunit.4.5.10InsulationBlocking
TheblockingtestshallbeperformedinaccordancewithMIL-STD-2223method4007.Thetemperatureshallbeasspecifiedinthedetailspecification.4.5.11ConductorResistance
TheDCresistanceoftheconductorshallbemeasuredinaccordancewithMIL-STD-2223method5003exceptthatthewireshallbetesteddrywithoutimmersion.
4.5.12ConductorElongationandTensileBreakStrength
Theconductorelongationshallbeperformedinaccordancewiththefollowingtestmethod:4.5.12.1SoftorAnnealedCopper
ElongationtestsofsoftorannealedcopperconductorsshallbeperformedinaccordancewithMIL-STD-2223method5002
4.5.12.2HighStrengthCopperAlloy
ElongationandtensilebreakstrengthtestsofhighstrengthalloyconductorsshallbeperformedinaccordancewithMIL-STD-2223method5002.
4.5.13InsulationConcentricityandWallThickness
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TheconcentricityandwallthicknessoftheprimaryinsulationandofthefinishedwireshallbedeterminedinaccordancewithMIL-STD-2223method6003.4.5.14InsulationShrinkage
TheshrinkagetestshallbeperformedinaccordancewithMIL-STD-2223method4005.Unlessotherwisespecifiedinthedetailspecification,theshrinkageoftheinsulationshallthenbemeasuredasthegreatestadditionaldistancethatanylayeroftheinsulation,includingjacketifpresent,hasrecededfromeitherendoftheconductor;thatis,themeasurementobtainedattheendshowingthegreatershrinkageshallbeconsideredtheshrinkageofthespecimen.4.5.15Wicking
WickingshallbeperformedinaccordancewithMIL-STD-2223method1005.ProcedureI(BorII(Ashallbespecifiedintheapplicabledetailspecification.

SAE
4.5.16InsulationLowTemperatureResistance
Thelowtemperature(coldbendtestshallbeperformedinaccordancewithMIL-STD-2223method2004.4.5.17InsulationThermalShock
ThethermalshockresistanceshallbeperformedinaccordancewithMIL-STD-2223method4004.Forpurposesofthistest,insulationisdefinedasalllayersofnon-conductingmaterialcoveringtheelectricalconductor,e.g.,primaryinsulation,alltapesandbraids,andthejacket.4.5.18Flammability
Theflammabilityshallbeperformedinaccordancewiththefollowingtestmethod:4.5.18.1Apparatus
Theflammabilitytestchambershallbeapproximately1footsquareby2feetinheight,andshallbeopenattopandfronttoprovideadequateventilationforcombustionbutpreventdrafts.Meansshallbeprovidedinthechambertoholdthetestspecimentautatanangleof60degreesfromhorizontalinaverticalplaneparalleltoandabout6inchesinfrontoftherearwallofthechamber.ThetestburnershallbeaBunsentypegasburnerhavinga1/4inchinlet,aneedlevalveinthebaseforgasadjustment,aboreof3/8inchnominal,andalengthofapproximately4inchesabovetheairinlets.Theburnershallbefittedwithawingtopflamespreaderhavinga1/16inchby2inchopening.4.5.18.2Procedure
A24-inchspecimenofwire,markedatadistanceof8inchesfromthelowerendtoindicatethepointofcontactforthetestflame,shallbeclampedtautly,at60degreesfromhorizontal,inthespecimenholderofthetestchamber.Theburnershallbeadjustedtodeliveranall-blueflame,2incheshigh,atatemperatureof955°C±30°C(1751°F±54°F,asmeasuredwithathermocouplepyrometer.Withtheburnerheldata90degreeangletothewirespecimenandthelongdimensionoftheflamespreaderparalleltotheaxisofthespecimen,thehottipoftheflameshallbeappliedtothewiresothatthemidpointoftheflametouchesthe8-inchmarkonthespecimen.Theperiodofflameapplicationshallbe15secondsforwiresizes30through18,30secondsforsizes16through12,1minuteforsizes10through4,and2minutesforlargersizes.Atthecloseoftheapplicationperiod,theflameshallbewithdrawnandthedurationoftheafterflameinthespecimenshallbenoted.Whenrequiredbytheapplicabledetailspecification,theburnedsectionofthewirespecimenshallbesubjectedtothepost-flamedielectrictestof4.5.18.3aremet.Breakingofthewirespecimensinsizes24andsmallershallnotbeconsideredasfailureprovidedtherequirementforflametravellimits,whenspecifiedintheapplicabledetailspecification,anddurationofflamerequirementaremet.4.5.18.3Post-flameDielectricTest
Whenapost-flamedielectrictestisrequired,thespecimenfromtheflametestshallbeclampedfirmlyinahorizontalposition,leavingtheburnedportionofthewireaccessibletoacontactplatejigequaltothatshowninFigure4.Thebottomcontactplateshallbeplacedunderneaththewireandshallmakecontactwiththecenter1/2-inchareaoftheburnedsectionofthewireonthesideoftheinsulationthathasbeennearesttheflame.Theuppercontactplateshallbeplacedontopofthespecimen,directlyoverthebottomplate,anda1/4-poundweightshallbeplacedontheupperplate,directlyoverthespecimen,toinsurecontactwiththeburnedarea.Thevoltagespecifiedintheapplicabledetailspecificationshallthenbeappliedbetweentheconductorofthespecimenandthecontactplatesofthejig.Thevoltageshallbegraduallyincreasedatauniformratefromzerotothespecifiedvoltagein1/2minute,maintainedatthatvoltagefor1minute,andgraduallyreducedtozeroin1/2minute.Thereshallbenodielectricfailureofthespecimenunderthistest.
--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
AS22759RevisionA-26-

SAE
AS22759RevisionA-27-

--``,,,`,`,`,,``,,`,`,,,`,,````-`-`,,`,,`,`,,`---
FIGURE4-CONTACTPLATEJIGFORPOST-FLAMEDIELECTRICTEST
4.5.19LifeCycle
ThelifecycletestshallbeperformedinaccordancewithMIL-STD-2223method4001for120hours(unlessotherwisespecifiedatthetemperaturespecifiedinthedetailspecification.Themandrelsizesandweightsshallbeasspecifiedinthedetailspecification.Thespecimenshallbeexaminedforcolorretention(3.5.5priortothebendtest.Thebendtestshallbeperformedinaccordance4.5.22.Thedielectrictestshallbeperformedinaccordancewith4.5.23.4.5.20ConductorPitting
Afterthepost-flamedielectrictest,theinsulationshallberemovedfromthespecimenandtheconductorshallbeexaminedforpitting(see6.2.3.
4.5.21InsulationCrosslinkProofandAcceleratedAging
ThecrosslinkprooftestoracceleratedagingtestshallbeperformedinaccordancewithMIL-STD-2223method4003forthehoursandtemperaturespecifiedinthedetailspecification.Themandrelsizesandweightsshallbeasspecifiedinthedetailspecification.Thebendtestshallbeperformedinaccordance4.5.22.Thedielectrictestshallbeperformedinaccordancewith4.5.23.

SAE
4.5.22BendTest
AS22759RevisionA-28-
ThebendtestshallbeperformedinaccordancewithMIL-STD-2223method2006.Usethemandrelsandweightspecifiedinthedetailspecification.4.5.23DielectricTest
ThedielectrictestshallbeperformedinaccordancewithMIL-STD-2223method3005atthewithstandvoltagespecifiedinthedetailspecification.4.5.24FluidImmersion
Unlessotherwisespecifiedinthedetailspecification,theimmersiontestshallbeperformedinaccordancewithMIL-STD-2223method1001exceptthefluidsspecifiedinTable7shallbeused.4.5.25HumidityResistance
ThehumiditytestshallbeperformedinaccordancewithMIL-STD-2223method1004.4.5.26SurfaceResistance
ThesurfaceresistancetestshallbeperformedinaccordancewithMIL-STD-2223method3004.4.5.27SmokeResistance
ThesmoketestshallbeperformedinaccordancewithMIL-STD-2223method4008.Thereshallbenoindicationofvisiblesmoke.
4.5.28ContinuousLengths
Therequirementsforcontinuouswirelengthsshallbesatisfiedbythesupplier’scertificateofconformityforthequalificationlot(see4.4.1andfortheproductionlot(4.4.4.However,thequalifyingactivityreservestherighttoexaminewirelotsorsupplierprocesses,ifdeemednecessarytoassurethatthelengthsactuallyconformtotherequirement.Inmeasuringcontinuouswirelengthswherethewirehasbeenmarkedorstrippedofinsulationinlieuofbeingcuttomarkinsulationfailuresoridentifyuntestedorimproperlytestedareas,suchmarkingorstrippingshallbeconsideredequivalenttocompleteseveranceofthewireatthetwoendsofeachmarkedorstrippedarea.4.5.29ConductorSolderability
ThesolderabilitytestshallbeperformedinaccordancewithMIL-STD-2223method5004.Unlessotherwisespecifiedinthedetailspecification,fivespecimens,AWG10andsmaller,shallbetested.ThesolderedareashallbeexaminedinaccordancewithJ-STD-002.4.5.30ConductorStrandAdhesion
TheconductorstrandadhesiontestshallbeinaccordancewithMIL-STD-2223method5005.4.5.31WetArcPropagationResistance
PerformthetestinaccordancewithMIL-STD-2223method3006.Measurethedamageofthewiresalongaxisofthebundle.
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SAE
AS22759RevisionA
TABLE7-FINISHEDWIRETESTFLUIDS
-29-
MIL-A-8243D,dated26October1985,isherebycancelled.FutureacquisitionforthisitemshouldrefertoAMS1424.TheU.S.AirForceendorsestheuseofAMS1424inlieuofMIL-A-8243;however,theU.S.AirForceshallnotprocureanydeicing/anti-icingfluidsthatcontainethyleneglycol(USAF/CE;March31,1992;"ProhibitiononPurchaseofEnvironmentallyHazardousDeicingChemicals".ProposedchangesbyDoDactivitiesmustbesubmittedtotheDoDAdoptingActivity,U.S.AirForce,ASC/ENOI,2530LoopRoadWest,Wright-PattersonAFB,OH45433-7101.
TestFluids
A.MIL-A-8243Anti-icingandDeicingDefrostingFluid,Undiluted
B.MIL-A-8243Anti-icingandDeicingDefrostingFluid,Diluted60/40(fluid/waterratio
C.MIL-C-43616CleaningCompound,AircraftSurface,TypeI
D.ASTMD1153MethylIsobutylKetone(ForUseInOrganicCoatings
E.SAEAS1241FireResistantHydraulicFluidforAircraft
F.MIL-L-7808LubricatingOil,Aircraft,TurbineEngine,SyntheticBase
G.MIL-C-87937CleaningCompound,AerospaceEquipment,TypeIIorTypeIV,undiluted
H.MIL-C-87937CleaningCompound,Aerospace
Equipment,TypeIIorTypeIV,diluted25/75(fluid/waterratio
I.ASTMD471StandardTestMethodforRubberProperty,FuelA
J.ASTMD471StandardTestMethodforRubberProperty,FuelD
K.ASTMD471StandardTestMethodforRubberProperty,OilNumber1
LSilicateesterperMIL-C-47220TypeIVorequivalentM.MIL-G-3056,Gasoline,Automotive,Combat
N.Lubricatingoil,aircraft,turbineengine,syntheticbase,MIL-L-23699
O.Hydraulicfluid,petroleumbase,aircraftmissile,andordnance,MIL-PRF-5606
P.Isopropylalcohol,ASTMD770
Q.Turbinefuel,aviation,GradeJP-4,MIL-DTL-5624orturbinefuel,aviation,kerosenetype,JP-8,MIL-T-83133orJetA,ASTMD1655StandardSpecificationforAviationTurbineFuels
TestTemperature°C(°F
48-50(118-12248-50(118-12248-50(118-12220-25(68-7748-50(118-122118-121(244-250
63-68(145-15463-68(145-15420-25(68-7720-25(68-7720-25(68-7720-25(68-7720-25(68-7748-50(118-122

48-50(118-122

18-20(64-7218-20(64-72
ImmersionTime(h20
2020168200.5202016816816816816820202020
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SAE
4.5.32DryArcPropagationResistance
AS22759RevisionA-30-
PerformthetestinaccordancewithMIL-STD-2223method3007.Measurethedamageofthebundlesalongtheaxis.4.5.33DynamicCut-throughResistance
PerformthetestinaccordancewithASTMD3032section22.4.5.34ForceHydrolysis
PerformthetestinaccordancewithdetailspecificationandAS4373method602.4.5.35ThermalIndex
PerformthetestinaccordancewithASTMD3032section14onawiresize20.4.5.36UVLaserMarking
PerformthetestwithaUVlasersourceoperatingatafluenceof0.9Joules/cm2±0.1Joules/cm².Thecontrastlevelshallbeevaluatedinaccordancewithmethod711ofAS4373.Thecontrastlevel(CLshallbecalculatedusingthefollowingformula:
CL=
(Reflectanceofthebackgroundinsulation-Reflectanceofthelasermark×100
(Eq.1
Reflectanceofthebackgroundinsulation
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4.5.37InsulationStateofSinter
PerformthetestinaccordancewithASTMD4591.5.PACKAGING5.1
Packaging(see6.3
ThepackagingofmaterialsreadyforshipmentshallbeexaminedtodetermineconformitytotherequirementsofSection5.Unlessotherwisespecified,wirepackagingcontainersshallbemarkedasfollows:PartNumber:M22759/1-22-9
Manufacturer’sidentificationcode:12814DetailspecificationRevision:ADetailspecificationdate:2001-075.1.1
ContinuousLengthPackage
Unlessotherwisespecifiedbycontractorpurchaseorder,theapplicablescheduleforcontinuouslengthshallbeasspecifiedinthedetailspecification.Unlessotherwisespecifiedinthecontractororder,thefootageoftheindividualcontinuouslengthsineachspoolorreelshallbemarkedonthespoolorreelinthesequenceinwhichthelengthswillbeunwoundbytheuser.Inmeasuringcontinuouswirelengthswherethewirehasbeenmarkedorstrippedofinsulationinlieuofbeingcuttomarkinsulationfailuresoridentifyuntestedorimproperlytestedareas,suchmarkingorstrippingshallbeconsideredequivalenttocompleteseveranceofthewireatthetwoendsofeachmarkedorstrippedarea.

SAE
5.1.2GovernmentAcquisition
AS22759RevisionA-31-
Foracquisitionbythegovernment,thepackagingrequirementsshallbeasspecifiedinthecontractororder.UnlessotherwisespecifiedthebarreldiameterofthespoolsshallbeinaccordancewithTable8.WhenactualpackagingofmaterialistobeperformedbyDoDpersonnel,thesepersonnelneedtocontacttheresponsiblepackagingactivitytoascertainrequisitepackagingrequirements.PackagingrequirementsaremaintainedbytheInventoryControlPoint’spackagingactivitywithintheMilitaryDepartmentorDefenseAgency,orwithintheMilitaryDepartment’sSystemCommand.PackagingdataretrievalisavailablefromthemanagingMilitaryDepartmentorDefenseAgency’sautomatedpackagingfiles,CD-ROMproducts,orbycontactingtheresponsiblepackagingactivity.
TABLE8-BARRELDIAMETEROFSPOOLSANDREELS
MinimumDiameterofBarrel
(asTimesMinimumDiameterofFinishedWire,
Exceptsee5.1.1.1
50X40X30X20X
5.2Non-governmentAcquisition
Fornon-governmentalacquisition,productshallbesuppliedinaccordancewiththepurchaseorder.6.NOTES
Thissectioncontainsinformationofageneralorexplanatorynaturethatmaybehelpful,butisnotmandatory.6.1IntendedUse
Theelectricwirescoveredbythisspecificationareintendedforuseinanyapplicationwheretheirperformancecharacteristicsareappropriate.ThewiresaresuitableforinstallationonaerospaceelectricalsystemsinaccordancewithAS50881withinthelimitationsofapplicableperformancerequirements.6.2Definitions:
6.2.1TemperatureRating
Temperatureratingsaslistedindetailspecificationsrepresentthelowerofthemaximumrecommendedoperatingtemperatureofeithertheconductorortheinsulationsystem.Themaximumambienttemperatureshouldbetheratedmaximumtemperatureofthewirediminishedbytheoperatingriseintemperatureoftheconductor.Theseratingsaretheacceptedupperlimitsfortheuseoftherespectivewiretypes.Usersneedtoconsiderthetime-temperaturerelationshipofthesetemperatureratingsfortheirapplication.AS50881isadocumentthatprovidesrecommendationsfortheapplicationoftemperatureratings.6.2.2SizeDesignations
Theconductorsizesandthecorrespondingwiresizedesignationsofthisspecificationareinaccordancewithestablishedusageforstrandedcopperconductorsforhookupwireintheelectronicandaircraftindustries(seeASTMB286,CopperConductorsforUseinHookupWireforElectronicEquipment.ItshouldbenotedthatthesesizesandsizedesignationsarenotidenticalwithAmericanWireGage(AWGsizesforsolidwireandstrands.Thediametersandcross-sectionalareasofthestrandedconductorsofthisspecificationare,inmostsizes,onlyroughlyapproximatetothoseofAWGsolidconductorsofthesamenumericalsizedesignation.Forthepurposesofmatingwithterminationcomponents,theCircularMilarea(CMAoftheconductormustbeconsideredaswellastheconductordiameter.ConductorsdefinedinaccordancewithMIL-W-29606arecompatiblewithSAEaerospaceterminationstandards.
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WireSize30-1412-108-10-0000

SAE
6.2.3Pitting
AS22759RevisionA-32-
Pittingisdefinedassmallholesorcavitiesintheconductorsurfacethatarelargeenoughtobeseenwiththeunaidedeye.Discoloration(suchastheformationofinter-metalliccompoundsorsurfacechangescausedbytheflowoftinarenotconsideredpitting.
6.2.4MarkingIdentification
Inadditiontothemarkingidentification,requiredhere-in,otheridentificationmaybeimposedbythepurchaser(seeAS50881.
6.2.5WireSolderability
Theconductorasspecifiedhereinisexpectedtobesolderableafterapplicationoftheinsulation.SeeAS4461forfurtherguidance.
6.2.6CriticalDefect
Acriticaldefectisadefectthatjudgmentandexperienceindicatewouldresultinhazardousorunsafeconditionsforindividualsusing,maintaining,ordependingupontheproduct,oradefectthatjudgmentandexperienceindicateislikelytopreventperformanceoftheactualfunctionofamajorenditemsuchasaship,aircraft,tank,missile,orspacevehicle.6.2.7Defect
Adefectisanynonconformanceoftheunitofproductwithspecifiedrequirements.6.2.8MajorDefect
Amajordefectisadefect,otherthancritical,thatislikelytoresultinfailure,ortoreducetheusabilityoftheunitofproductforitsintendedpurpose.6.2.9MinorDefect
Aminordefectisadefectthatisnotlikelytoreducemateriallytheusabilityoftheunitofproductforitsintendedpurpose,orisadeparturefromestablishedstandardshavinglittlebearingontheeffectiveuseoroperationoftheunit.6.3OrderingData:6.3.1
AcquisitionInformation(see5.1
Unlessotherwisespecified,productwillbesuppliedtothelatestrevisionineffectatissuanceofpurchaseorder(see3.5.6.3.1.6.3.2
Acquisitiondocumentsshouldspecifythefollowing:
a.Title,numberincludingrevisionletter,anddateofthisspecification
b.Applicabledetailspecificationnumberincludingrevisionletter,title,anddatec.Applicabledetailspecificationpartnumber(see1.2.1d.Colorrequired(see3.6.4
e.Quantityofwirerequired(see5.1.1.
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SAE
f.Packagingandpackingrequired
AS22759RevisionA-33-
g.Exceptions,ifany,totheoptionalprovisionsofthisspecificationsuchas:
(1
Responsibilityforinspection,ifotherthanspecifiedin4.1
(2Statement,ifapplicable,thatcertificationofconformity(see4.6.2.1,4.6.2.3.4,and4.6.3.20willnotbe
accepted.Statementshouldincludetestingscheduletobesubstituted.(3(46.4
Markingofdielectrictestfailuresorirregularitiesbystrippingofinsulationorbyothermethodspecifiedinthecontractinlieuofcuttingofthewire,ifapplicable(see4.6.3.1.3.
Specialpreparationfordeliveryrequirements,ifapplicable(seeSection5
Documentation(alternatesources
Documentsmayalsobeobtainedatthefollowingwebsites:a.ForSAEdocuments:http://www.sae.org
b.Formostgovernmentdocuments:http://assist.daps.dla.mil/quicksearch/
c.ForH4/H8CAGEcodes:https://www.bpn.gov/ccr/scripts/index.htmforUnitedStatesmanufacturingsitesand
http://www.dlis.dla.mil/ccr/ccr_cageinfo.htmforinternationalmanufacturingsites.d.ForIPCdocuments:http://www.ipc.org6.5Qualification
Withrespecttoproductsrequiringqualificationbythegovernment,awardswillbemadeonlyforproducts,whichareatthetimesetforopeningofbids,qualifiedforinclusionintheapplicableQualifiedProductsList(QPL,whetherornotsuchproductshaveactuallybeensolistedbythatdate.Theattentionofthecontractorsiscalledtotheserequirements,andmanufacturersareurgedtoarrangetohavetheproductsthattheyproposetooffertotheFederalGovernmenttestedforqualificationinorderthattheymaybeeligibletobeawardedcontractsfortheproductsdelineatedinthisspecification.QualificationisrequiredforU.S.Governmentprocurement.TheQPLEvaluatingActivity,forU.S.DepartmentofDefenseprocurementpurposes,istheNavalAirSystemsCommand(Code4.4.4.3,22229ElmerRoad,Building2360,PatuxentRiver,MD20670.ApplicationforqualificationtestsshallbemadeinaccordancewithprovisionsgoverningqualificationinSD-6(see2.1.2.6.5.1
ConformitytoQualifiedSample
Itisunderstoodthatwiresuppliedundercontractshouldbeidenticalineveryrespecttothequalificationsampletestedandfoundsatisfactory,exceptforchangespreviouslyapprovedbytheGovernment.Anyunapprovedchangesfromthequalificationsampleshallconstitutecauseforrejection.6.6SupersessionInformation
AS22759wasadoptedbythegovernmentandsupersedesMIL-W-22759.Thepartnumberformatremainsunchanged.6.7KeyWords
Aerospacewireelectrical,finishedwire,conductormaterial,insulatingmaterial,concentriclaystranding,ropelaystranding

SAE
6.8
AS22759RevisionA
TheobjectiveofAS22759RevisionAisthefollowing:
-34-
a.ProvideacompleteeditedchangeinaccordancewithARP5578(draft.b.Anupdateofallreferences
c.ReferencetestmethodsinaccordancewithMIL-STD-2223
d.ReferenceconductorrequirementsinaccordancewithMIL-C-29606e.AddAS22759-A1requirements
f.Combineallqualificationandqualityconformancetablesintoonetable.
g.Makealltechnicalrequirementsreferenceatestmethodparagraphoracertificationrequirement.h.Addaninsulation-striptestmethod.i.j.6.9
ModifythequalificationrequirementstoreflectthepresentNAVAIRqualifyingactivitypolicy.Addthenewwiretestrequirementsofthehybridwirefromthedetailspecifications.
Thechangebar(llocatedintheleftmarginisfortheconvenienceoftheuserinlocatingareaswheretechnicalrevisions,noteditorialchanges,havebeenmadetothepreviousissueofthisdocument.An(Rsymboltotheleftofthedocumenttitleindicatesacompleterevisionofthedocument.

PREPAREDBYSAESUBCOMMITTEEAE-8D,WIREANDCABLEOF
COMMITTEEAE-8,AEROSPACEELECTRICAL/ELECTRONICDISTRIBUTIONSYSTEMS
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