SAE AS22759/191:2010 download.WIRE. ELECTRICAL POLYTETRAFLUOROETHYLENEIPOIYIM IDE INSULATED. SMOOTH SURFACE. LIGHT WEIGHT. SILVER-COATED COPPER CONDUCTOR. 200 C. 600 VOLTS.
THIS SPECIFICATION HAS BEEN DEVELOPED AT THE REQUEST OF NAVAL AIR SYSTEMS COMMAND AND THE
UNITED STATES AIR FORCE. THIS PRODUCT IS BASED ON AS22759191 WITH ADDITIONAL REOUIREMENTS
INCLUDING A SMOOTH OUTER FLUOROPOLYMER SURFACE.
NOTICE
THE REQUIREMENTS FOR ACQUIRING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS SPECIFICATION
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 SOUCITAT1ON: A522759
TEMPERATURE RATiNG: 200 C (392 F) MAXIMUM CONTINUOUS CONDUCTOR TEMPERATURE. VOITAGE RATiNG: 600 VOLTS (RMS) AT SEA LEVEL.
I.
ADf)ITIONAL REQUIREMENTS:
DRY ARC PROPAGATION RESISTANCE (TEST REQUIRED FOR IIITIAL 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 ARE MET:
1. A MINIMUM OF 70 WIRES PASS THE DIELETRIC TEST.
2. TWO WIRES OR LESS FAIL THE DIELECTRIC TEST IN ANY ONE BUNDLE.
3. ACTUAL DAMAGE TO THE WIRE IS NOT MORE THAN 1.0 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 UMITS BELOW. FOR WIRE TESTiNG ASSOCIATED WITH QUALIFICATION. RETENTION OF
QUALIFICATION AND QUALITY CONFORMANCE. CONFORMITY OF COLOR SHALL NOT BE REQUIRED AFTER OVEN EXPOSURE
FLAMMABIUTY: TEST IN ACCORDANCE WiTH AS4373. METHOD 801
REQUIREMENTS:
DURATION AFTER-FLAME 3.0 SECONDS (MAXIMUM)
FLAME TRAVEL 3.0 INCHES (MAXIMUM))
NO FLAMING OF TISSUE
FORCED HYDROLYSIS: (TEST REQUIRED FOR INITIAL QUALiFICATION ONLY) 5000 HOURS AT 70 C. TEST 5 UNCONDITIONED AND 5 CONDITiONED SAMPLES OF 20 AWG WIRE.
HIGK FREQUENCY SPARK TEST: (WHEN USED IN LIEU OF THE IMPULSE DIEI..ECTR)C TEST) 5.7 KILOVOLTS (RMS). TEST 100 PERCENT OF THE WIRE
HUMIDITY RESISTANCE: REQUIRED. AFTER HUMIDITY EXPOSURE. THE WIRE SHALL MEET THE REQUIREMENTS FOR INITIAL INS.AT1ON RES1STANCE.
IDENTIFICATION OF PRODUCT: NOT REQUIRED FOR SIZE 26. COLOR CODE DESIGNATOR NOT REQUIRED. IDEN’TIFICATION DURABIUTY: 125 CYCLES (250 STROKES) 250 GRAM WEIGHT.
IMMERSION: (TEST REQUIRED FOR INTITAL QUALIFICATION ONLY) TEST IN ACCORDANCE WITH AS4373. METHOD 601. USE MANDRELS
AND WEIGHTS USTED IN TABLE 6 FOR BEND TESTING. DIELECTRIC TEST. 2500 VOLTS (RUS). 60 HZ. FOR TURBINE FUEL IMMERSION
TEST OF AS43T3. EITHER JP-4 OR ML-DTL-83133 TYPE P-B (NATO TYPE F-34) MAY BE USED.
IMPULSE DIELECTRIC TEST: 8.0 KILOVOITS (PEAK). TEST 100 PERCENT OF THE WiRE
INSULATION RESISTANCE: 5000 MEGOHMS PER 1000 FEET (MINIMUM)
INSULATiON STATE OF SINTER: (QUALIFICATION AND QUALITY CONFORMANCE INSPECTiON PERFORMED ON ONE SAMPLE PER LOT)
EVALUATE FLUOROPOLYMER LAYERS ONLY. THE DIFFERENCE IN ENERGY TO MELT BETWEEN FIRST AND SECOND HEATS SHALL. BE
LESS THAN OR EQUAL TO 3 JOULES PER GRAM.
LAMINATION SEALING: (QUALIFICATION AND GROUP II QUALITY COMFORMANCE TEST) WHEN TESTED IN ACCORDANCE WITH AS4373.
METHOD 809 AT 260 C ±2 C (500 F ± 3.6 F) FOR 6 HOURS. THERE SHALL BE NO EVIDENCE OF TAPE SEPARATiON OR LIFTING. THREE
SAMPLES PER LOT SHALL BE TESTED.
LIFE CYCI..E: 500 HOURS AT 230 C ±2 C (446 F ± 3.6 F). DIELECTRIC TEST. 2500 VOLTS (RUS). 60 HZ. USE MANDRELS COATED WITH
POLYTETRAFLUOROETHYLENE SUCH THAT THE DIAMETER OF THE MANDRELS. AFTER COATING. STiLL CONFORM TO THE REQUIRED
TEST MANDRELS DLAMETERS 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 (45 F ± 3.6 F). DIELECTRIC TEST, 2500 VOLTS (RMS). 60 HZ.
OUTER INSULATION LAYER SURFACE SMOOTHNESS: (QUALIFICATiON AND GROUP II QUALITY CONFORMANCE TEST) WHEN TESTED IN
ACCORDANCE WiTH AS4373. METHOD 110. THE DIFFERENCE IN WALL. THICKNESS OF THE OUTER PTFE INSULATION LAYER AT THE
DISCERNABLE TAPE EDGE SHALL NOT EXCEED 10.0 PERCENT.
SCRAPE ABRASION (NEEDLE): (INITIAL QUALIFICATION AND RETENTION OF QUALIFICATION) WiRE SIZE 20 ONLY. WHEN TESTED IN
ACCORDANCE WiTH AS4373, METHOD 301. THE AVERAGE CYCLES TO FAILURE ON 8 READINGS. AFTER DROPPING THE HIGHEST AND
LOWEST VALUE OF THE 10 READINGS TESTED. SHALL NOT BE LESS THAN THE VALUES LISTED BELOW WHEN APPLYiNG A 1.10 LB * 0.01
LB LOAD.
STRIPPABILITY: (QUALIFICATION AND GROUP II QUALITY CONFORMANCE TEST) AFTER STRIPPING. NO FRAGMENTS OF ANY LAYER
SHALL EXTEND MORE THAN 0.031 INCHES BEYOND THE END OF THE POLYIMIDE TAPE LAYER.
TAPE OVERLAP: TEST IN ACCORDANCE WITH AS4373. METHOD 109.
TENSILE MODULUS: TEST COMPOSITE FILM IN ACCORDANCE WITH ASTM 0882. METHOD A.
THERMAL INDEJ( (TEST REQUIRED FOR INITiAL OUAUFICAT1ON ONLY). TEST WIRE SIZE 20 ONLY. 200 °C (392 °F) MINIMUM FOR 10 000 HOUR$.
THERMAL SHOCK RESISTANCE: OVEN TEMPERATURE. 200 C ±2 C (392 F ± 3.6 F). MAXIMUM CHANGE IN MEASUREMENT, 0.091 INCH. NO CRACKING.
UV LASER MARKING: (QUALiFICATiON AND GROUP I QUALITY CONFORMANCE TEST) APPLICABLE TO WHITE INSULATION ONLY. TEST IN ACCOkOANCE WiTH AS4373. METHOD 1001. CONTRAST SHALL BE A 62 PERCENT MINIMUM AVERAGE ON SIX READINGS.
UV LASER CONTRAST AFTER THERMAL AGING: (INITIAL OUAUFICATION AND RETENTION OF QUALIFICATION) WIRE SIZE 20 ONLY.
PREPARE SAMPLE IN ACCORDANCE WITH AS4373 METHOD 1001. PLACE SAMPLE IN AN AIR CIRCULATING OVEN AT 230 °C ± 2°C
(446 °F ± 3.6 °F) FOR 168 HOURS. MINIMUM AVERAGE CONTRAST AFTER AGING SHALL NOT BE LESS THAN 40 PERCENT.