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Sae As4373

The AS4373E standard outlines test methods for insulated electric wire, with the latest revision adding new methods such as adhesion of nickel coating and smoke resistance. It includes a comprehensive table of contents detailing various test groups and procedures. The document serves as a technical guideline for ensuring the quality and performance of insulated electric wires in aerospace applications.

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Sae As4373

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AEROSPACE AS4373 REV.

E
STANDARD
Issued 1993-08
Revised 2012-02

Superseding AS4373D
Test Methods for Insulated Electric Wire

RATIONALE

This revison adds the following new test methods: Adhesion of Nickel Coating, Spark Test of Finished Wire Insulation,
Smoke Resistance, Fluoride Offgassing, Nitric Acid Immersion, Circumferential Insulation Elongation, Wrap (mandrel
wrap) and High Temperature Endurance. Figures and tables were also modified to accomodate the new test methods.

TABLE OF CONTENTS

1. SCOPE .......................................................................................................................................................... 5

1.1 Contents ........................................................................................................................................................ 5

1.2 Test Method Numbering ............................................................................................................................... 5

2. APPLICABLE DOCUMENTS ........................................................................................................................ 5

2.1 SAE Publications........................................................................................................................................... 6

2.2 ASTM Publications ........................................................................................................................................ 6
2.3 ANSI Publications ......................................................................................................................................... 7
2.4 U.S. Government Publications ...................................................................................................................... 7

3. INDEX OF SECTIONS AND TEST METHODS............................................................................................ 7

3.1 Test Methods Group 100 - Assembly, Handling, and Repair Tests ............................................................. 7
3.2 Test Methods Group 200 - Chemical, Biological, Radiological/Nuclear, Biological, Chemical (CBR/NBC) 8
3.3 Test Methods Group 300 - Physical Damage Tests ..................................................................................... 8
3.4 Test Methods Group 400 - Conductor Tests ................................................................................................ 8
3.5 Test Methods Group 500 - Electrical Tests .................................................................................................. 8
3.6 Test Methods Group 600 - Environmental Tests .......................................................................................... 9
3.7 Test Methods Group 700 - Mechanical Tests ............................................................................................... 9
3.8 Test Method Group 800 - Thermal Tests...................................................................................................... 9
3.9 Test Methods Group 900 - Weight and Dimensional Tests ........................................................................ 10
3.10 Test Methods Group 1000 - Wire Identification Marking and Evaluation ................................................... 10

4. TEST METHODS AND TEST PROCEDURES .......................................................................................... 10

4.1 Test Methods Group 100 - Assembly, Handling and Repair Tests ............................................................ 10
4.1.1 Method 101, Concentricity and Wall Thickness .......................................................................................... 10
4.1.2 Method 102, Insulation Bonding to Potting Compounds ............................................................................ 11
4.1.3 Method 103, Insulation Pull-Off Force ........................................................................................................ 12
4.1.4 Method 104, Insulation Shrinkage/Expansion ............................................................................................ 12
4.1.5 Method 105, Solderability ........................................................................................................................... 13
4.1.6 Method 106, Thermal/Mechanical Resistance - Single Wire ...................................................................... 14
4.1.7 Method 107, Thermal/Mechanical Resistance - Bundle ............................................................................. 17
__________________________________________________________________________________________________________________________________________
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SAE AS4373E Page 2 of 103

4.1.8 Method 108, Solder Pot Test for Insulation Shrinkage ............................................................................... 18
4.1.9 Method 109, Percent Overlap of Insulating Tapes ..................................................................................... 18
4.1.10 Method 110, Outer Layer Insulation Smoothness ...................................................................................... 20
4.2 Test Methods Group 200 - Chemical, Biological and Radiological Tests/Nuclear,
Biological and Chemical (CBR/NBC) .......................................................................................................... 21
4.3 Test Methods Group 300 - Physical Damage Tests ................................................................................... 22
4.3.1 Method 301, Needle Abrasion Test ............................................................................................................ 22
4.4 Test Methods Group 400 - Conductor Tests .............................................................................................. 24
4.4.1 Method 401, Conductor Diameter ............................................................................................................... 24
4.4.2 Method 402, Conductor Elongation and Tensile Breaking Strength .......................................................... 24
4.4.3 Method 403, Conductor Resistance ........................................................................................................... 26
4.4.4 Method 404, Conductor Strand Blocking .................................................................................................... 27
4.4.5 Method 405, Adhesion of Nickel Coating .................................................................................................... 28
4.5 Test Methods Group 500 - Electrical Tests ................................................................................................ 29
4.5.1 Method 501, Dielectric Constant ................................................................................................................. 29
4.5.2 Method 502, Corona Inception and Extinction Voltages............................................................................. 30
4.5.3 Method 503, Impulse Dielectric................................................................................................................... 30
4.5.4 Method 504, Insulation Resistance ............................................................................................................. 31
4.5.5 Method 505, Spark Test of Finished Wire Insulation .................................................................................. 32
4.5.6 Method 506, Surface Resistance ................................................................................................................ 33
4.5.7 Method 507, Time/Current to Smoke .......................................................................................................... 34
4.5.8 Method 508, Dry Arc Propagation Resistance............................................................................................ 34
4.5.9 Method 509, Wet Arc Propagation Resistance ........................................................................................... 41
4.5.10 Method 510, Voltage Withstand (Wet Dielectric) ........................................................................................ 45
4.5.11 Method 511, Wire Fusing Time ................................................................................................................... 46
4.5.12 Method 512, Voltage Rating: TO BE DETERMINED................................................................................. 46
4.5.13 Method 513, Smoke Resistance ................................................................................................................. 46
4.6 Test Methods Group 600 - Environmental Tests ........................................................................................ 48
4.6.1 Method 601, Fluid Immersion ..................................................................................................................... 48
4.6.2 Method 602, Forced Hydrolysis .................................................................................................................. 49
4.6.3 Method 603, Humidity Resistance .............................................................................................................. 50
4.6.4 Method 604, Weight Loss Under Temperature and Vacuum ..................................................................... 51
4.6.5 Method 605, Propellant Resistance ............................................................................................................ 52

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4.6.6 Method 606, Weathering Resistance.......................................................................................................... 52
4.6.7 Method 607, Wicking .................................................................................................................................. 53
4.6.8 Method 608, Fluoride Offgassing ................................................................................................................ 54
4.6.9 Method 609, Nitric Acid Immersion ............................................................................................................. 56
4.7 Test Methods Group 700 - Mechanical Tests ............................................................................................. 57
4.7.1 Method 701, Abrasion ................................................................................................................................. 57
4.7.2 Method 702, Cold Bend .............................................................................................................................. 57
4.7.3 Method 703, Dynamic Cut-Through ............................................................................................................ 58
4.7.4 Method 704, Flex Life.................................................................................................................................. 58
4.7.5 Method 705, Insulation Tensile Strength and Elongation ........................................................................... 61
4.7.6 Method 706, Notch Propagation ................................................................................................................. 62
4.7.7 Method 707, Stiffness and Springback ....................................................................................................... 63
4.7.8 Method 708, Mandrel and Wrapback Test.................................................................................................. 66
4.7.9 Method 709, Wrinkle Test ........................................................................................................................... 67
4.7.10 Method 710, Durability of Wire Manufacturer's Color and/or Identification ................................................ 68
4.7.11 Method 711, Durability and Legibility of Wire Installer's Identification ........................................................ 69
4.7.12 Method 712, Bend Test ............................................................................................................................... 72
4.7.13 Method 713, Circumferential Insulation Elongation .................................................................................... 73
4.7.14 Method 714, Wrap (Mandrel Wrap) ............................................................................................................ 76
4.8 Test Methods Group 800 - Thermal Tests .................................................................................................. 77
4.8.1 Method 801, Flammability ........................................................................................................................... 77
4.8.2 Method 802, High Pressure/High Temperature Air Impingement (Burst Duct) .......................................... 78
4.8.3 Method 803, Smoke Quantity ..................................................................................................................... 80
4.8.4 Method 804, Relative Thermal Life and Temperature Index ...................................................................... 80
4.8.5 Method 805, Thermal Shock Resistance .................................................................................................... 81
4.8.6 Method 806, Property Retention After Thermal Aging ................................................................................ 82
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4.8.7 Method 807, Multi-day Heat Aging Test (Life Cycle) .................................................................................. 82
4.8.8 Method 808, Blocking ................................................................................................................................. 84
4.8.9 Method 809, Lamination Sealing ................................................................................................................ 85
4.8.10 Method 810, Topcoat Cure ......................................................................................................................... 85
4.8.11 Method 811, Cross-link Proof Test ............................................................................................................. 86
4.8.12 Method 812, Flame Resistance .................................................................................................................. 88
4.8.13 Method 813, Insulation State of Sinter ........................................................................................................ 91
4.8.14 Method 814, High Temperature Endurance ............................................................................................... 92
4.9 Test Methods Group 900 - Wire Diameter and Weight .............................................................................. 95
4.9.1 Method 901, Finished Wire Diameter ......................................................................................................... 95
4.9.2 Method 902, Finished Wire Weight ............................................................................................................. 96
4.10 Test Methods Group 1000 - Wire Identification Marking and Evaluation ................................................... 96
4.10.1 Method 1001, Wire Marking Contrast ......................................................................................................... 96

5. NOTES ...................................................................................................................................................... 101

APPENDIX A UNIQUE OR CRITICAL TEST EQUIPMENT ........................................................................................... 102

FIGURE 1 THERMAL/MECHANICAL RESISTANCE TEST SETUP ........................................................................... 15

FIGURE 2 TWO SUGGESTED PLACEMENTS FOR SNAP SWITCH TO START TIMER ........................................ 15
FIGURE 3 CONTINUITY DETECTION CIRCUIT FOR SOLDER IRON RESISTANCE TEST ................................... 16
FIGURE 4 FORMULA FOR CALCULATING PERCENT OVERLAP ........................................................................... 19
FIGURE 5 MEASUREMENT BASED ON AN INSULATED WIRE CROSS-SECTION ............................................... 21
FIGURE 6 ABRASION DURABILITY TEST FIXTURE AND NEEDLE ........................................................................ 23
FIGURE 7 TYPICAL 7-STRAND CONDUCTOR AFTER BIRDCAGING (NO STRANDS BLOCKED) ....................... 28
FIGURE 8 BLADE ........................................................................................................................................................ 38
FIGURE 9 ALUMINUM BLADE SHARPENING FIXTURE........................................................................................... 38

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FIGURE10 BUNDLE CONFIGURATION ...................................................................................................................... 39
FIGURE11 BUNDLE TYING.......................................................................................................................................... 39
FIGURE 12 TEST FIXTURE........................................................................................................................................... 40
FIGURE 13 ELECTRICAL CONNECTION..................................................................................................................... 40
FIGURE 14 BALL SLIDE BLADE FIXTURE................................................................................................................... 41
FIGURE 15 BUNDLE CONFIGURATION ...................................................................................................................... 43
FIGURE 16 BUNDLE TYING.......................................................................................................................................... 43
FIGURE 17 ELECTRICAL CONNECTION..................................................................................................................... 44
FIGURE 18 FORMULA FOR VOLTAGE TO CURRENT RATIO ................................................................................... 47
FIGURE 19 FLEX LIFE TEST SETUP ........................................................................................................................... 60
FIGURE 20 NOTCHING TOOL ...................................................................................................................................... 63
FIGURE 21 TEST FIXTURE FOR STIFFNESS AND SPRINGBACK TEST ................................................................. 64
FIGURE 22 STIFFNESS AND SPRINGBACK TEST FIXTURE BASE PLATE ............................................................. 65
FIGURE 23 WRAP BACK TEST .................................................................................................................................... 67
FIGURE 24 CLAMP DEVICE FOR PRINT DURABILITY TEST .................................................................................... 71
FIGURE 25 CIRCUMFERENTIAL ELONGATION APPARATUS .................................................................................. 75
FIGURE 26 TEST MANDREL FOR CIRCUMFERENTIAL ELONGATION ................................................................... 75
FIGURE 27 SPECIMEN HOLDING BLOCK................................................................................................................... 76
FIGURE 28 ELECTRICAL CONNECTIONS FOR TEST METHOD 802 ....................................................................... 79
FIGURE 29 TYPICAL SAMPLE ARRANGEMENT ........................................................................................................ 83
FIGURE 30 TYPICAL SAMPLE ARRANGEMENT ........................................................................................................ 87
FIGURE 31 FLAME RESISTANCE TEST FIXTURE ..................................................................................................... 89
FIGURE 32 BURNER DETAILS ..................................................................................................................................... 90
FIGURE 33 HIGH TEMPERATURE ENDURANCE TEST SETUP................................................................................ 95
FIGURE 34 LIGHTING EQUIPMENT ............................................................................................................................. 98
FIGURE 35 CONTRAST MEASUREMENT ON WIRE SPECIMEN MARKINGS ........................................................ 100

TABLE 1 GROUP 100 TEST METHODS..................................................................................................................... 7

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TABLE 2 GROUP 300 TEST METHODS..................................................................................................................... 8

TABLE 3 GROUP 400 TEST METHODS..................................................................................................................... 8
TABLE 4 GROUP 500 TEST METHODS..................................................................................................................... 8
TABLE 5 GROUP 600 TEST METHODS..................................................................................................................... 9
TABLE 6 GROUP 700 TEST METHODS..................................................................................................................... 9
TABLE 7 GROUP 800 TEST METHODS..................................................................................................................... 9
TABLE 8 GROUP 900 TEST METHODS................................................................................................................... 10
TABLE 9 GROUP 1000 TEST METHODS................................................................................................................. 10
TABLE 10 SOLDERABILITY TEST CONDITIONS ...................................................................................................... 13
TABLE 11 ELECTRICAL CONNECTION..................................................................................................................... 36
TABLE 12 CIRCUIT RESISTANCE ............................................................................................................................. 36
TABLE 13 ELECTRICAL CONNECTION..................................................................................................................... 44
TABLE 14 CIRCUIT RESISTANCE ............................................................................................................................. 44
TABLE 15 FLUID TABLE ............................................................................................................................................. 49
TABLE 16 STIFFNESS AND SPRINGBACK LOADS .................................................................................................. 65
TABLE 17 WRINKLE TEST MANDREL SIZE .............................................................................................................. 68
TABLE 18 BEND TEST MANDRELS AND LOADS ..................................................................................................... 73
TABLE 19 WRAP TEST MANDRELS .......................................................................................................................... 77
TABLE 20 MAXIMUM RECOMMENDED VALUES ..................................................................................................... 82
TABLE 21 AGING TEST SPECIMEN LENGTH REQUIREMENTS............................................................................. 82
TABLE 22 BLOCKING MANDRELS AND TENSIONS ................................................................................................ 84
TABLE 23 HIGH TEMPERATURE ENDURANCE CURRENT FOR CONDITIONING................................................ 94
TABLE 24 HIGH TEMPERATURE ENDURANCE MANDRELS AND LOADS ............................................................ 94

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SAE AS4373E Page 5 of 103

1. SCOPE

This standard describes test methods for insulated, single conductor, electric wire intended for aerospace applications.
Particular requirements for the wire being tested need to be specified in a procurement document or other detail
specification. Suggested minimum requirements are included in the notes at the end of some of the test methods. SAE
Performance Standard AS4372 uses some of the tests in this document for evaluating comparative performance of
aerospace wires.

1.1 Contents

This document is comprised of the following Sections:

a. Scope including Contents and Numbering System

b. Applicable Documents

c. Index of Sections and Test Methods

d. Test Methods and Test Procedures

1.2 Test Method Numbering

The test methods are assigned numbers, such as 101, 102, etc., from the applicable group as follows:

a. Group 100: Assembly, Handling, and Repair Tests

b. Group 200: Chemical, Biological, Radiological (CBR) Tests

c. Group 300: Physical Damage Tests

d. Group 400: Conductor Tests

e. Group 500: Electrical Tests

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f. Group 600: Environmental Tests

g. Group 700: Mechanical Tests

h. Group 800: Thermal Tests

i. Group 900: Weight and Dimensional Tests

j. Group 1000: Wire Identification Marking and Evaluation

2. APPLICABLE DOCUMENTS

The following publications form a part of this document to the extent specified herein. The latest issue of SAE
publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase
order. In the event of conflict between the text of this document and references cited herein, the text of this document
takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific
exemption has been obtained.

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2.1 SAE Publications

Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside
USA and Canada) or 724-776-4970 (outside USA), www.sae.org.

AMS1424 Anti-Icing and Deicing-Defrosting Fluid

AS1241 Fire Resistant Phosphate Ester Hydraulic Fluid for Aircraft

AS3320 Stud - Straight, Ring Locked, CRES AMS 5731, .250-20UNJC X .250-28UNJF

AS4372 Performance Requirements for Wire, Electric, Insulated Copper or Copper Alloy

AS4851 Relative Thermal Life and Temperature Index for Insulated Electric Wire

AS5649 Wire and Cable Marking Process, UV Laser

AS22759/35 Wire, Electrical, Fluoropolymer-Insulated, Crosslinked Modified ETFE, Normal Weight, Silver-Coated,
High-Strength Copper Alloy, 200°C, 600 Volt

AS25244 Circuit Breaker, Trip-Free, Push-Pull, 5 Thru 50 Amp, Type I

AS25281 Clamp, Loop, Plastic, Wire Support

AS58091 Circuit Breaker, Trip Free, Aircraft, General Specification for

AS50881 Wiring, Aerospace Vehicle

J1966 Lubricating Oils, Aircraft Piston Engines (Non-Dispersant Mineral Oil)

2.2 ASTM Publications

Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel:
610-832-9585, www.astm.org.

ASTM B 355 Nickel-Coated Soft or Annealed Copper Wire

ASTM D 412 Rubber Properties in Tension, Standard Test Method for

ASTM D 471 Standard Test Fluids

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ASTM D 638 Tensile Properties of Plastics, Test Method for

ASTM D 910 Aviation Gasoline, Standard Specification for

ASTM D 1153 Methyl Isobutyl Ketone, Standard Specification for

ASTM D 1868 Detection and Measurement of Partial Discharge (Corona) Pulse in Evaluation of Insulation Systems,
Standard Test Method for

ASTM D 3032 Hookup Wire Insulation, Standard Test Method for

ASTM D 4814 Gasoline, Automotive, Combat

ASTM F 814 Specific Optical Density of Smoke Generated by Solid Materials for Aerospace Applications Standard
Test Method for

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ASTM G 53 Operating Light- and Water-Exposure Apparatus (Fluorescent UV-Condensation Type) for Exposure of
Non-metallic Materials, Standard Practice for

2.3 ANSI Publications

Available from American National Standards Institute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-
4900, www.ansi.org.

TT-I-735 Isopropyl Alcohol

2.4 U.S. Government Publications

Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue,
Philadelphia, PA 19111-5094, Tel: 215-697-6257, http://assist.daps.dla.mil/quicksearch/.

MIL-C-43616 Cleaning Compound, Aircraft Surface

MIL-DTL-5624 Turbine Fuel, Aviation Grades JP-4, JP-5 and JP-5/JP-8 ST

MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene Types, NATO F-34(JP-8) and NATO F-35

MIL-PRF-5606 (Inactive for New Design) Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance
Hydrocarbon Base, Aircraft, Metric, NATO Code Number H-537

MIL-PRF-7808 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base, NATO Code Number 0-148

MIL-PRF-23699 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base, NATO Code Number 0-156

MIL-PRF-87252 Coolant Fluid, Hydrolytically Stable, Dielectric

MIL-PRF-87937 Cleaning Compounds, Aircraft Exterior Surfaces, Water Dilutable

MIL-STD-202 Test Methods for Electronic and Electrical Component Parts

MIL-STD-704 Aircraft Electric Power Characteristics

3. INDEX OF SECTIONS AND TEST METHODS

3.1 Test Methods Group 100 - Assembly, Handling, and Repair Tests

TABLE 1 – GROUP 100 TEST METHODS

Method
No. Title
101 Concentricity and Wall Thickness
102 Insulation Bonding to Potting Compounds
103 Insulation Pull-off Force
104 Insulation Shrinkage/Expansion
105 Solderability
106 Thermal/Mechanical Resistance - Single Wire
107 Thermal/Mechanical Resistance - Bundle
108 Solder Pot Test for Insulation Shrinkage
109 Percent Overlap of Insulating Tapes
110 Outer Layer Insulation Smoothness

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3.2 Test Methods Group 200 - Chemical, Biological, Radiological/Nuclear, Biological, Chemical (CBR/NBC)

No test methods have been adopted for Group 200 - CBR/NBC. The United States military have done extensive testing
on materials in a CBR/NBC environment. This information remains classified but is available to prime contractors. This
section is reserved for industry CBR/NBC tests that may be developed or instituted in the future.

3.3 Test Methods Group 300 - Physical Damage Tests

No test methods have been adopted for Group 300 – Physical Damage Tests. This section is reserved for physical
and/or in-service damage tests that may be developed or instituted in the future.

TABLE 2 – GROUP 300 TEST METHODS

Method
No. Title
301 Needle Abrasion Test

3.4 Test Methods Group 400 - Conductor Tests

TABLE 3 – GROUP 400 TEST METHODS

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Method
No. Title
401 Conductor Diameter
402 Conductor Elongation and Tensile Breaking Strength
403 Conductor Resistance
404 Conductor Strand Blocking
405 Adhesion of Nickel Coating

3.5 Test Methods Group 500 - Electrical Tests

TABLE 4 – GROUP 500 TEST METHODS

Method
No. Title
501 Dielectric Constant
502 Corona Inception and Extinction Voltages
503 Impulse Dielectric
504 Insulation Resistance
505 Spark Test of Finished Wire Insulation
506 Surface Resistance
507 Time/Current to Smoke
508 Dry Arc Propagation Resistance
509 Wet Arc Propagation Resistance
510 Voltage Withstand (Wet Dielectric)
511 Wire Fusing Time
512 Voltage Rating
513 Smoke Resistance

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3.6 Test Methods Group 600 - Environmental Tests

TABLE 5 – GROUP 600 TEST METHODS

Method
No. Title
601 Fluid Immersion
602 Forced Hydrolysis
603 Humidity Resistance
604 Weight Loss Under Temperature and Vacuum
605 Propellant Resistance
606 Weathering Resistance
607 Wicking
608 Fluoride Offgassing
609 Nitric Acid Immersion

3.7 Test Methods Group 700 - Mechanical Tests

TABLE 6 – GROUP 700 TEST METHODS

Method
No. Title
701 Abrasion
702 Cold Bend
703 Dynamic Cut Through
704 Flex Life
705 Insulation Tensile Strength and Elongation
706 Notch Propagation
707 Stiffness and Springback
708 Mandrel and Wrapback Test
709 Wrinkle Test
710 Durability of Wire Manufacturer's Color/Identification
711 Durability of Wire Installer's Identification
712 Bend Test
713 Circumferential Insulation Elongation
714 Wrap, (Mandrel Wrap)

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3.8 Test Method Group 800 - Thermal Tests

TABLE 7 – GROUP 800 TEST METHODS

Method
No. Title
801 Flammability
802 High Pressure/High Temperature Air Impingement (Burst Duct)
803 Smoke Quantity
804 Relative Thermal Life and Temperature Index
805 Thermal Shock Resistance
806 Property Retention After Thermal Aging
807 Multi-day Heat Aging Test (Life Cycle)
808 Blocking
809 Lamination Sealing
810 Topcoat Cure
811 Cross-link Proof Test
812 Flame Resistance
813 Insulation State of Sinter
814 High Temperature Endurance (Fire-Resistant Wire)
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3.9 Test Methods Group 900 - Weight and Dimensional Tests

TABLE 8 – GROUP 900 TEST METHODS

Method
No. Title
901 Finished Wire Diameter
902 Finished Wire Weight

3.10 Test Methods Group 1000 - Wire Identification Marking and Evaluation

TABLE 9 – GROUP 1000 TEST METHODS

Method
No. Title
1001 Wire Marking Contrast

4. TEST METHODS AND TEST PROCEDURES

4.1 Test Methods Group 100 - Assembly, Handling and Repair Tests

4.1.1 Method 101, Concentricity and Wall Thickness

4.1.1.1 Scope

This test is to be used to determine the wall thickness and concentricity of an insulated wire.

4.1.1.2 Specimen

A wire specimen of not less than 6 in (152 mm) shall be tested.

4.1.1.3 Test Equipment

4.1.1.3.1 Magnifying Device

A microscope or optical comparator equipped with devices capable of making measurements reproducible to at least
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0.0005 in (0.013 mm) shall be used.

4.1.1.4 Test Procedure

4.1.1.4.1 Wholly Tape Wrapped Constructions

Measurements of wall thickness shall be by measuring the finished wire insulation at its thinnest point. The wall thickness
measurement shall be the shortest distance between the outermost rim of the finished wire and the outer rim of the
outermost strand of the conductor.

4.1.1.4.2 Other Constructions

All other constructions shall have wall thickness measurements performed in accordance with section 16 of ASTM D
3032.

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4.1.1.4.2.1 Concentricity

Of other than wholly tape wrapped constructions shall be calculated from the wall thickness as shown below:

a. Size 30 through 10:

Minimum wall thickness u 100

% Concentricity (Eq. 1)
Maximum wall thickness

b. Size 8 through 0000:

Minimum wall thickness u 100

% Concentricity (Eq. 2)
Average wall thickness of
4 measuremen ts taken 90q apart

4.1.1.5 Results

Report wall thickness measurements for all constructions. Report concentricity for those constructions that are not wholly
tape wrapped.

4.1.1.6 Information Required in Detail Specification

Number and wire size of specimens to be tested and number of measurements.

4.1.1.7 Precision Bias

A minimum concentricity of 70% is usually desirable.

4.1.2 Method 102, Insulation Bonding to Potting Compounds

4.1.2.1 Scope

This test is to be used to measure the bonding between potting compounds and wire insulation.

4.1.2.2 Specimen

See section 19.3 of ASTM D 3032 for specimen preparation.

4.1.2.3 Test Equipment

See section 19.2 of ASTM D 3032 for test apparatus.

4.1.2.4 Test Procedure

See section 19.4 of ASTM D 3032 for the test procedure and section 19.5 of ASTM D 3032 for the calculation of the pull-
out strength.

4.1.2.5 Results

Report the average pull-out strength, specific identification of the potting compound, and surface preparation of the wire
insulation.

4.1.2.6 Information Required in the Detail Specification

Description of the potting compound, primer (if applicable), surface preparation, and number of specimens to be tested.
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4.1.2.7 Precision Bias

See section 19.7 of ASTM D 3032 for precision bias. Potting compounds can vary in property between manufacturer's
and location of testing facilities. Care should be taken in drawing conclusion from single test results

4.1.3 Method 103, Insulation Pull-Off Force

4.1.3.1 Scope

This test method is to be used to determine the force required to remove the insulation material from the conductor of a
finished wire.

4.1.3.2 Specimen

See section 27.4 of ASTM D 3032.

4.1.3.3 Test Equipment

See ASTM D 638 and section 27.3 of ASTM D 3032.

4.1.3.4 Test Procedure

4.1.3.4.1 Perform sections 27.5.1 through 27.5.5 of ASTM D 3032.

4.1.3.5 Results

Report results of pull test in pounds-force (Newton).

4.1.3.6 Information Required in Detail Specification

Number of specimens to be tested.

4.1.3.7 Precision Bias

This test method of ASTM D 3032 has not had the benefit of round-robin testing to determine precision.

4.1.4 Method 104, Insulation Shrinkage/Expansion

4.1.4.1 Scope

This test is to determine the longitudinal shrinkage or expansion experienced by a wire insulation after brief heat aging.

4.1.4.2 Specimen

The specimen shall be a 13 in (330 mm) length of wire cut flush on both ends.

4.1.4.3 Test Equipment

4.1.4.3.1 A razor blade or equivalent device to remove an insulation slug from conductor.

4.1.4.3.2 A device capable of measurement to 0.001 in (0.025 mm).

4.1.4.3.3 An air oven capable of maintaining the specified temperatures and tolerances.

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4.1.4.4 Test Procedure

Strip 1/2 in (12.7 mm) of insulation shall be from each end of the finished wire specimen. Use a razor blade (or
equivalent) held perpendicular to the axis of the wire to remove the insulation. The length of the exposed conductor at
each end of the specimen shall be measured to the nearest 0.005 in (0.13 mm). The specimen shall be exposed for 6 h to
a minimum temperature of 30 °C ± 3 °C (86 °F ± 5 °F) above the rated temperature of the specimen. An air circulating
oven shall be used for this exposure. At the end of 6 h, remove the specimen from the oven and allow it to return to room
temperature. Each end of the specimen shall be measured to the nearest 0.005 in (0.13 mm). The longitudinal shrinkage
or expansion of the insulation shall be the greatest distance any layer of insulation has moved on either end of the
specimen.

4.1.4.5 Results

Report oven temperature and greatest shrinkage or expansion of insulation.

4.1.4.6 Information Required in Detail Specification

Number and wire size of specimens to be tested, temperature rating of the insulated wire and limit of allowable shrinkage
or expansion.

4.1.4.7 Precision Bias

A maximum longitudinal shrinkage or expansion of 0.125 in (3.13 mm) is usually desirable for sizes 12 and smaller. A
maximum shrinkage or expansion requirement of 0.250 in (6.25 mm) is usually desirable for sizes 10 and larger.

4.1.5 Method 105, Solderability

4.1.5.1 Scope

This test is to be used to determine the solderability of tin coated copper conductor. At present, the solderability of wires
with other coatings has not been validated to this or other test methods.

4.1.5.2 Specimen

A wire specimen of not less than 10 in (254 mm) shall be used.

4.1.5.3 Test Equipment

See Sections 2 and 3 of Method 208, MIL-STD-202.

4.1.5.4 Test Procedure

See Section 4 of Method 208, MIL-STD-202. One of the three test conditions listed in Table 10 shall be used.

TABLE 10 – SOLDERABILITY TEST CONDITIONS

Hours of
Condition Steam Aging Flux
A 8 R
B 1 R
C 0 R

4.1.5.5 Results

Report the actual and average results of the solderability test and the condition used.

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4.1.5.6 Information Required in Detail Specification

Number and wire size of specimens to be tested, test condition required, and soldering pot or soldering iron method.

4.1.5.7 Precision Bias

This is a new method that has not had the benefit of any round-robin testing to determine precision.

4.1.6 Method 106, Thermal/Mechanical Resistance - Single Wire

4.1.6.1 Scope

This test is to be used to determine the combined thermal/mechanical cut-through resistance of an individual insulated
wire and to simulate possible wire damage during removal of overbraids from wire bundles.

4.1.6.2 Specimen

A wire specimen of not less than 12 in (305 mm) shall be tested.

4.1.6.3 Test Equipment

4.1.6.3.1 A solder iron or system capable of controlling tip temperatures to 398 °C ± 3 °C (750 °F ± 5 °F), 343 °C ±
3 °C (650 °F ± 5 °F), and 288 °C ± 3 °C (550 °F ± 5 °F). The solder iron is to be equipped with a screwdriver
tip approximately 0.105 in (2.67 mm) wide by 0.05 in (1.27 mm) thick.

4.1.6.3.2 A temperature-measuring device capable of providing an accurate measurement of the solder iron tip
described in 4.1.6.3.1.

4.1.6.3.3 A scale capable of measuring a 5 lb (2.27 kg) ±3%, weight.

4.1.6.3.4 Moment external limit switch.

4.1.6.3.5 60 min standard timer.

4.1.6.3.6 Continuity detector box.

4.1.6.3.7 Test setup, fixture, and procedure.

4.1.6.4 Test Procedure

4.1.6.4.1 Test Setup

A recommended test setup is shown in Figure 1 and described in the following paragraphs. Use of equivalent, alternate
fixtures to hold the soldering iron or boxes to detect continuity are acceptable.

4.1.6.4.1.1 Build a test fixture to hold the soldering iron in a vertical position. Figure 1 shows a clamp attached to a
lever arm with no friction. The solder iron shall be weighted via the lever arm to provide a 5 lb (2.27 kg)
load to the soldering iron tip. A 1 in (25.4 mm) minimum thickness PTFE sheet will provide a non-heat-
conducting surface for the wire to rest on and a small groove in the PTFE sheet will help to keep the wire
specimen in place during test. The limit switch used to start the timer shall be placed in either of the two
locations shown in Figure 2. The first location is attached to the vertical stand so that the limit switch is
activated by the lever arm as it is lowered onto the wire. The second location is beneath the PTFE sheet so
that the force associated with the soldering iron resting on the wire activates the switch.

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FIGURE 1 - THERMAL/MECHANICAL RESISTANCE TEST SETUP

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FIGURE 2 - TWO SUGGESTED PLACEMENTS FOR SNAP SWITCH TO START TIMER

Copyright SAE International

4.1.6.4.1.2 The schematic for a suggested continuity tester box with a timer circuit is shown in Figure 3.

FIGURE 3 - CONTINUITY DETECTION CIRCUIT FOR SOLDER IRON RESISTANCE TEST

4.1.6.4.1.3 Check for the 5 lb (2.27 kg) load at solder iron tip by lowering the solder iron tip onto the scale and adding
weights to the control arm until scale registers 5 lb (2.27 kg).

4.1.6.4.2 Test Procedure

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4.1.6.4.2.1 Place wire specimen in groove of 1 in (25.4 mm) PTFE sheet and secure with tape.

4.1.6.4.2.2 Connect iron-constantan thermocouple to solder iron tip, and temperature measuring device described in
4.1.6.3.2. Measure the exact temperature of the solder iron tip and adjust solder iron to obtain required
initial temperature of 398 °C ± 3 °C (750 °F ± 5 °F).

4.1.6.4.2.3 Connect continuity detector circuit using size 20 lead wire with alligator clips to solder iron and to the end of
the wire specimen.

Copyright SAE International

4.1.6.4.2.4 Lower the solder iron onto the wire specimen. Record the time it takes the solder iron to penetrate through
the wire insulation as measured by the timer. Repeat test four times on each wire specimen. Rotate the
specimen 90 degrees and index 0.5 in (12.7 mm) along specimen length for each repeat test. If penetration
does not occur within 1 min, stop the test. Continue with next specimen.

4.1.6.4.2.5 Clean solder iron tip by lightly buffing with emery paper to remove residues after each test.

4.1.6.4.2.6 If failure occurs at 398 °C (750 °F), repeat same test at 343 °C (650 °F) on same wire specimen. If failure
occurs at 343 °C (650 °F), repeat same test at 288 °C (550 °F) on same wire specimen.

4.1.6.5 Results

The time recorded as the time required for penetration of the solder iron to the inner conductor shall be the average time
of the measurements taken.

4.1.6.6 Information Required in Detail Specification

Number and wire size of specimens to be tested.

4.1.6.7 Precision Bias

This is a new method that has not had the benefit of any round-robin testing to determine precision.

4.1.7 Method 107, Thermal/Mechanical Resistance - Bundle

4.1.7.1 Scope

This test is to be used to determine the ability of a bundle of insulated wire specimens to withstand the heat of a soldering
iron when the iron rests on the bundle.

4.1.7.2 Specimen

Ten 12 in (305 mm) insulated wire specimens of the same size shall be used for each bundle to be tested. The bundle
shall be formed by string-tying the grouped wires every 3 in (76 mm) from either end.

4.1.7.3 Test Equipment

The test equipment used, including monitoring/timing circuitry and excluding the test fixture, shall be as described in
Method 106 of this document.

4.1.7.4 Test Procedure

Connect the stripped end of all wires to a common lead and use this lead to detect continuity between the iron and any
conductor. See Figure 3 of Method 106 for a continuity detection circuit. Limit switch location similar to the second
location of the limit switch shown in Figure 2 of Method 106 may be used. Lay the barrel of the soldering iron
perpendicularly across the bundle so that it does not touch any string tie. If necessary, elevate the bundle to achieve
contact. Measure the time for the iron to make contact with any conductor in the bundle. The test may be terminated if no
penetration occurs within 5 min. Test with the soldering iron at 398 °C (750 °F), 343 °C (650 °F), and 288 °C (550 °F).
Test three locations for each temperature, making sure that each point of contact is at least 0.5 in (13 mm) from any
previous contact. It is not necessary to test at lower temperatures if no penetration occurs at 398 °C (750 °F).

4.1.7.5 Results

Report the time to penetration at all test temperatures.

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4.1.7.6 Information Required in Detail Specification

Number and wire size of specimens to be tested.

4.1.7.7 Precision Bias

This is a new method that has not had the benefit of any round-robin testing to determine precision.

4.1.8 Method 108, Solder Pot Test for Insulation Shrinkage

4.1.8.1 Scope

This test is to be used to assess the insulation shrinkage of a wire after exposure to hot solder.

4.1.8.2 Specimen

The specimen shall be a length of insulated wire not less than 6 in (152 mm).

4.1.8.3 Test Equipment

4.1.8.3.1 A suitable container of molten (63/37 tin/lead) solder maintained at a temperature of approximately 320 °C
(608 °F).

4.1.8.3.2 Mandrels of the sizes needed in 4.1.8.4.

4.1.8.4 Test Procedure

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The specimen shall be taken from a point at least 6 in from the end of an inspection unit and shall be prepared for testing
by removing 0.5 in of insulation from one end. At a point 0.5 in from the end of the insulation on the stripped end, the
specimen shall be given a 90 degree bend over a mandrel of its own diameter. This end shall then be immersed in the
solder for 5 s, to within 1/8 in of the insulation. There shall be no flux used in preparing the specimen. The insulation
shall not flare away from the conductor nor open up over the bent portion. The shrinkage shall be measured as the
greatest distance any layer of insulation has moved.

4.1.8.5 Results

Record the amount of shrinkage to the nearest 1 mm (1/32 in).

4.1.8.6 Information Required in Detail Specification

Number and wire size of specimens to be tested and limit of allowable shrinkage.

4.1.8.7 Precision Bias

This is a process control test.

4.1.9 Method 109, Percent Overlap of Insulating Tapes

4.1.9.1 Scope

This test determines the percent overlap of the insulating tape or tapes used in a finished wire.

4.1.9.2 Specimen

The specimen shall be not less than a 6 in (152 mm) length of wire cut flush on both ends.

Copyright SAE International

4.1.9.3 Test Equipment

4.1.9.3.1 Insulation stripping tool with precision blades.

4.1.9.3.2 A single edged razor blade or equivalent cutting tool.

4.1.9.3.3 A microscope or equivalent optical device providing a magnification of 15 diameters minimum (preferably one
with an eyepiece of similar means to measure angles).

4.1.9.4 Test Procedure

The test sample shall consist of at least three specimens. Specimens shall be prepared by stripping an insulation slug
approximately 0.50 inch in length using the precision stripping tool. With the razor blade or cutting tool, cut the edge of
each insulation slug to be examined. The cut faces of the specimen must be smooth, perpendicular to the slug axis, and
perpendicular to each other. The cut edge of the insulation slug to be examined shall be positioned under the microscope
or suitable optical device. Inspect the cut cross section under the microscope or suitable device at a magnification of 15
diameters, minimum. Measure, in degrees of rotation, the total length of the spiral edge displayed by the innermost
insulation tape (wrap 1) in the cross section. Using the formula noted in Figure 4, convert the degrees of rotation to
percent overlap of the tape in the insulation. Repeat the determination for any additional tape (wrap 2, etc.) in the cross
section.

§ (N ( x / 360 )) 1 ·
% overlap ¨¨ ¸¸ u 100
© (N ( x / 360)) ¹
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N = number of complete 360° overlaps

x = additional degrees of overlap past 360°

FIGURE 4 - FORMULA FOR CALCULATING PERCENT OVERLAP

4.1.9.5 Results

Report the degrees of rotation observed and the percent tape overlap of each tape in the insulation of each specimen

4.1.9.6 Information Required in Detail Specification

Specifications for wires with tape wrapped insulation shall list the minimum tape overlap of each insulating tape used in
the finished wire.

4.1.9.7 Precision Bias

This test is only applicable to tape wrapped wire to provide verification of insulation overlap and is typically performed as
an in-process test.

Copyright SAE International

EXAMPLE:

N2 is the top layer (360 degree wrap)

N1 is the bottom layer (360 degree wrap)

“x” additional overlap in degrees

Example: If x = 25 degree in the above picture the results would be:

§ (2 (25 / 360 )) 1 ·
% overlap ¨¨ ¸¸ u 100
© (2 (25 / 360)) ¹

1.069
% overlap u 100 51.7%
2.069

4.1.10 Method 110, Outer Layer Insulation Smoothness

4.1.10.1 Scope

This test method is to be used to determine the outer insulation wall smoothness and presence of an outer edge or
internal wrap lines in a wrapped insulation construction.

4.1.10.2 Specimen

A wire specimen of not less than 6 inches (152 mm) shall be tested.

4.1.10.3 Test Equipment

4.1.10.3.1 Equipment for grinding and polishing mounted samples for metallurgical inspection.

4.1.10.3.2 Magnifying Device: A microscope or optical comparator equipped with devices capable of making

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measurements reproducible to at least 0.25 mils (6.4 um) shall be used.

4.1.10.4 Test Procedure

4.1.10.4.1 The finished wire should be micro-sectioned using the basic guidelines in ASTM 3E, Standard Guide for
Preparation of Metallographic Specimens. Cut approximately a 1 inch (25 mm) section of finished wire from
the test specimen and place it vertically and perpendicularly to the flat surface in a round casting mount. Fill
the mold containing the wire specimen with a castable two part resin that hardens at low temperature (similar
to Buehler casting epoxy, Part Number 208130). Grind mounted sample using wettable sandpaper
(preferably SiC) starting with 180 grit to reach the specimen and an area not damaged by the sample cutting
process. Use successfully finer grit of 240, 320, 400, and 600. Rotate specimen 90 degrees during the
grinding process and clean and dry the sample after the last grinding step. Grind mounted sample using
wettable sandpaper (preferably SiC) starting with 180 grit to reach the specimen and an area not damaged by
the sample cutting process. Use successfully finer grit of 240, 320, 400, and 600. Rotate specimen 90
degrees during the grinding process and clean and dry the sample after the last grinding step.

Copyright SAE International

4.1.10.4.2 The sample shall be inspected using up to 200X optical magnification and the outer PTFE layer shall be
smooth and homogenous with no voids or visible internal wrap lines. The outer insulation layer should have
no discernible tape edge. If an edge is discernible, divide the outer tape edge thickness ((difference between
maximum outer insulation wall thickness (line 2) and the minimum outer layer insulation wall thickness (line
1)), by the maximum outer layer insulation wall thickness (line 2)) multiplied by 100. The result shall be less
than 10% or as required by the detailed specification. The maximum allowable distance between line 1 and
line 2 at the outer surface of the insulation wall shall be 3.0 mils. Figure 5 shows how to make the
measurement. There shall be no discernible separation or lifting of a detectable tape edge.

4.1.10.5 Results

Report if a discernible edge exists and if so, the percentage of the edge with respect to the outer wall thickness and if
there is a discernible separation or lifting of a detectable tape edge. Calculation shall be performed as noted below:

Percent Edge = (Larger Wall Thickness (Line 2) - Smaller Wall Thickness (Line1)) X 100
(Larger Wall Thickness (Line 2))

4.1.10.6 Information Required in Detail Specification

Number and wire size of specimens to be tested and the number of measurements to be recorded.

4.1.10.7 Precision Bias

This test is only applicable to tape wrapped wire to provide verification of outer layer insulation smoothness.

FIGURE 5 - MEASUREMENT BASED ON AN INSULATED WIRE CROSS-SECTION

NOTE: Discernible edge must be less than 10%. Divide the tape edge thickness (line 2 minus line 1) by the outer layer
PTFE thickness at the discernible edge (line 2) then multiply by 100 to get the percent value.

For above example, the discernible edge percentage was calculated as ((Line 2 - Line 1) / Line2) X 100% = ((3.4mm -
3.1mm) / 3.4mm) X 100%= 8.8%.

4.2 Test Methods Group 200 - Chemical, Biological and Radiological Tests/Nuclear, Biological and Chemical
(CBR/NBC)
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4.2.1 When required by a user, specimens of insulation material shall be tested to the CBR/NBC requirements. Note
that the Air Force has established an extensive data base on the chemical compatibility of materials for use in
aerospace vehicles. While this database as a whole is classified information, it has been made available to prime
aerospace contractors. Current contact for this database is at WL-MLSA, Wright Patterson AFB, Ohio. In
addition, the Army has done extensive testing of a number of materials and should be consulted before testing to
determine if a candidate insulation material has already been tested. Contact for this is NBC Survivability Office,
Army CR&D, Edgewood, MD.

The intent of this material testing is to assure inertness of a material to the CBR/NBC exposure. The Air Force
and the Army has established over a dozen qualified laboratories to do this type of CBR/NBC testing. However,
these laboratories are not empowered to determine the suitability of an item, such as a wire, after exposure, but
only to determine if there is an effect on the materials used for insulation. It is not recommended that handling of
items after exposure be done outside of these qualified labs due to personnel safety considerations.

4.3 Test Methods Group 300 - Physical Damage Tests

4.3.1 Method 301, Needle Abrasion Test

4.3.1.1 Scope

This test method is designed to evaluate an insulated wire’s resistance to cyclic abrasion under various temperatures.
The results of this test are not related to the specific survivability time frame of a wire in an air vehicle environment."

4.3.1.2 Specimen

The specimen for each test condition shall be a 20 AWG 45 inch ± 1 inch (1143 mm ±25 mm) insulated wire or as defined
in the detailed specification.

4.3.1.3 Test Equipment

4.3.1.3.1 The abrasion durability test fixture (see figure 6) shall be a Wellman (P/N 158L238G1) or equivalent. It will be
designed to hold the wire specimen firmly clamped in a horizontal position with the upper longitudinal surface
of the specimen fully exposed. The durability apparatus shall be capable of rubbing a rigid needle with a
diameter of 20 mils ± 1.0 mil (0.5 mm ± 0.03 mm) in diameter (see Figure 6), repeatedly over the upper
surface of the wire. The longitudinal axis of the needle and the specimen shall be at right angles to each
other and the abrading edge of the needle set in a 90° support with a half cylindrical groove machined to
conform to the needle. A weight affixed to a jig above the needle shall control the weight normal to the
surface of the insulation. A motor-driven mechanism and counter shall be used to deliver an accurate
number of abrading strokes in a direction parallel to the axis of the specimen. The system shall have an
automatic stop when the abrading surface reaches the wire sample conductor. The length of the stroke shall
be 0.4 inches ± 0.05 inches (10 mm ± 1.0 mm) and the frequency of the stroke shall be 110 strokes (55
cycle’s ± 10) per minute. A cycle consists of one forward stroke and one backward stroke. Average
frequency shall be specified with the test data. The fixture shall also contain an enclosure around the
specimen to regulate the temperature of the test environment during elevated temperature testing.

4.3.1.3.2 The abrasion needle shall be made from a polished nickel coated steel sewing needle or equivalent.

4.3.1.3.3 After ten tests the needle shall be replaced or moved to a new area.

4.3.1.4 Test Procedure

4.3.1.4.1 Install the wire specimen into the test fixture and apply a 1.10 lb ± 0.01 lbs (500 grams ± 5.0 grams) load or
the load specified in the detailed specification. Strip one end of the test specimen and attached to the circuit
detection device. Verify ambient temperature of 23 ºC ± 2 ºC (72 ºF ± 5 ºF). Begin the oscillation and allow
the test to continue until continuity is detected between the insulated wire’s conductor and the abrading
needle. Each specimen shall undergo ten tests and be moved 4 inches ± 0.4 inches (100 mm ± 10mm)
between each test and turned at an angle of 90 degrees always in the same direction.
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4.3.1.4.2 For each test record the number of cycles (two stokes/cycle) required for penetration to the conductor.

4.3.1.4.3 Apply a heat source to an enclosure around the abrading fixture and using thermocouples, maintain the
temperature at 70 °C ± 2 ºC (158 °F ± 5 ºF) or the temperature defined in the detailed specification in the
enclosure. The thermocouple shall be placed within one inch of the wire abrasion site. Allow the enclosure
to stabilize for 5 minutes at the prescribed temperature prior to starting the test. Once stabilized, begin the
oscillation and allow the test to continue until continuity is detected between the insulated wire’s conductor
and the needle. Record the number of cycles required for penetration to the conductor.

4.3.1.4.4 Repeat abrasion test at all weights and temperatures specified in the detailed specification.

4.3.1.5 Results

The high and low values from each set of ten data points collected shall be dropped and the average and standard
deviation reported for the remaining values for each test condition. Report the equipment model used to conduct test or
provide a description of equipment. Abrasion may be accomplished with a sliding arm or arm on a cam which can
produce different results. The type of fixture should be reported in case labs are attempting to compare results. Report
the average stroke frequency.

4.3.1.6 Information Required in Detail Specification

Number and wire size of specimens to be tested and the number of measurements to be recorded.

4.3.1.7 Precision Bias

This test method has not had the benefit of any round-robin testing to determine precision.

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FIGURE 6 - ABRASION DURABILITY TEST FIXTURE AND NEEDLE

4.4 Test Methods Group 400 - Conductor Tests

4.4.1 Method 401, Conductor Diameter

4.4.1.1 Scope

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This test is to be used to determine the diameter of conductors.

4.4.1.2 Specimen

An insulated wire of not less than 24 in (610 mm) shall be used.

4.4.1.3 Test Equipment

4.4.1.3.1 Micrometer

A micrometer or equivalent device capable of measuring to the nearest 0.0001 in (0.0025 mm).

4.4.1.4 Test Procedure

Remove the insulation without damaging or distorting the conductor. Determine the conductor diameter by measuring the
outer diameter in at least three locations, approximately equally spaced along the length of the specimen. Each
measurement shall consist of the average of two micrometer readings at the same location along the conductor, but taken
90 degrees from each other.

4.4.1.5 Results

Report measured conductor diameters and the average diameter for each specimen tested.

4.4.1.6 Information Required in Detail Specification

Number and wire size of specimens to be tested and number of measurement locations, if greater than three.

4.4.1.7 Precision Bias

This is a process control test.

4.4.2 Method 402, Conductor Elongation and Tensile Breaking Strength

4.4.2.1 Scope

This test is to be used to determine the tensile breaking strength and elongation of soft (annealed) copper strand or
conductor, or copper alloy conductor.

4.4.2.2 Specimen

4.4.2.2.1 The specimen shall be a conductor or a wire strand from a multi-strand conductor removed from an insulated
wire and shall be at least 12 in long.

4.4.2.2.2 For copper wire sizes 22 AWG and smaller, the specimen shall be the whole stranded conductor removed
from the finished wire. For all wire sizes of high strength copper alloys, the specimen shall be the whole
stranded conductor removed from the finished wire.

Copyright SAE International

4.4.2.3 Test Equipment

4.4.2.3.1 A testing machine that meets the following requirements:

The machine shall be power-driven.

A dial, scale, or automatic recorder capable of indicating the applied tension to within ±1% when properly calibrated.

The indicator shall remain at the point of maximum force after rupture of the specimen. A spring-balanced type of
machine is satisfactory if equipped to prevent recoil of the spring.

The machine, when used for a given specimen, should be of such capacity that the maximum load required to break the
specimen is not greater than 85% nor less than 15% of the rated capacity.

The machine shall accommodate specimens of 10-in bench length.

The grips of the machine shall be designed to produce as nearly as possible uniformly distributed pure axial tension in the
specimen. Older testing machines may have spool-type grips for specimens less than 0.208 in and wedge-type grips for
specimens 0.208 in and larger. Newer testing machines will have power-actuated or mechanical vise grips.

4.4.2.3.2 A strip chart recorder or digital indicator that can be used in conjunction with the testing machine to measure
the applied load and travel distance of the specimen grip.

4.4.2.3.3 Steel scale graduated to 1/32 in or finer or its decimal equivalent.

4.4.2.4 Test Procedure

Two parallel bench marks 10 in ± 1/32 in apart shall be placed on the specimen without damage to the copper. The
specimen shall be placed in the testing machine so that the bench marks are between the spools but not in contact with
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the surface of the spools when spool grips are used. When using the usual wedge-type grip there shall be a distance of
at least 1 in between each bench mark and the adjacent grip. The speed of the power-actuated grip shall be 10 in ± 2 in
per minute under no load for a copper wire specimen and 2 in ± 0.5 in for a copper alloy wire specimen. If the jaw
separation is more than 10 in, adjust the jaw speed for constant strain force. The tensile breaking strength shall be
measured as the total tensile force indicated by the testing machine at break of the individual strand or first strand of the
stranded conductor. If the specimen breaks outside the bench marks or within 1 in of either bench mark, the results shall
be discarded and additional specimens tested until breaks are obtained within the prescribed portion. The elongation
shall be calculated from the increased distance of the bench marks. The elongation shall be measured when the first
strand of the stranded conductor or individual strand breaks as indicated on the recording device.

4.4.2.5 Results

Report the tensile breaking strength and elongation, as required by the Detail Specification, for each specimen of strand
or conductor.

4.4.2.6 Information Required in Detail Specification

Number and wire size of specimens to be tested.

4.4.2.7 Precision Bias

This is a process control test.

Copyright SAE International

4.4.3 Method 403, Conductor Resistance

4.4.3.1 Scope

This test is to be used to measure or calculate the DC resistance per unit length of a conductor at 20 °C (68 °F). A
correction formula is provided to allow for when resistance measurements are taken at other than 20 °C (68 °F).

4.4.3.2 Specimen

A wire specimen of at least 36 in (914 mm) shall be used.

4.4.3.3 Test Equipment

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4.4.3.3.1 A suitable DC current source for the resistance measurements.

4.4.3.3.2 A suitable bridge or potentiometer with the accessory equipment necessary for the measurement of
resistance with an accuracy of 0.2%.

4.4.3.3.3 Temperature measuring equipment that will measure the temperature of the conductor to within 0.5 °C (1 °F).

4.4.3.3.4 A steel tape graduated to 1/64 in or finer or its decimal equivalent or other apparatus which will measure the
length of the specimen to an accuracy of 0.2%.

4.4.3.4 Test Procedure

4.4.3.4.1 If a Kelvin double bridge is used, both current and potential leads shall be used. The current leads shall be
attached in such a manner as to give assured contact with all the wires of the conductor. The potential leads
should be attached by encircling clamps on the bared conductor or to a binding of fine copper wire wrapped
tightly for several turns about the bare conductor.

4.4.3.4.2 The test shall be made by a method using both current and potential leads if the resistance of the specimen is
less than 1 :. Where potential leads are used, the distance between each lead and the corresponding
current lead shall be at least 3 times the diameter of the conductor.

4.4.3.4.3 The length of the specimen between potential leads shall be measured to an accuracy of 0.2% and the value
recorded as L. In order to avoid raising the temperature of the specimen, the magnitude of the current shall
be kept low and the time of its flow through the conductor shall be kept short to minimize the change in
resistance due to rise in temperature of the specimen.

4.4.3.4.4 The resistance of the specimen shall be measured and the value recorded in ohms as R after indications
have been steady for not less than 1 min. The ambient temperature shall be measured to an accuracy of
0.5 °C and the value recorded as T.

4.4.3.4.5 The resistance of the conductor per 1000 ft shall be calculated as follows:

R
Resistance, ohms per 1000 ft u 1000 (Eq. 3)
L

where:
R = Resistance of the specimen or the length of specimen between potential conductors, ohms
L = Length of the specimen or the length of specimen between potential conductors, feet

4.4.3.5 Results

Report measured resistance of specimen, measured length of specimen, calculated resistance per 1000 ft (305 m), and
test temperature.

Copyright SAE International

4.4.3.6 Information Required in Detail Specification

Number and wire size of specimens to be tested and acceptable resistance values.

4.4.3.7 Temperature Correction

See ASTM B 193 to normalize the resistance to 20 °C when the actual measurement is taken at a temperature other than
20 °C. In addition to the temperature coefficients listed therein, the temperature coefficient of copper alloy PD135 is
0.00342 and that of copper alloy CS95 is 0.00198.

4.4.3.8 Precision Bias

This is a process control test.

4.4.4 Method 404, Conductor Strand Blocking

4.4.4.1 Scope

This test provides a method to determine if conductor strands of 7 and 19 strand conductors will block (adhere) to each
other in the finished wire. This test was developed as a process control test for silver coated copper conductors of MIL-
DTL-81381 polyimide insulated wires, but it may be applied to other conductors and insulation types when strand blocking
is a potential problem.

4.4.4.2 Specimen

The specimen shall be a 6 in (152 mm) length of finished wire.

4.4.4.3 Test Equipment

4.4.4.3.1 Wire insulation stripping tool.

4.4.4.3.2 Fine needle or thin blade.

4.4.4.3.3 Device to sever conductor strands.

4.4.4.4 Test Procedure

4.4.4.4.1 Preparation of Specimen

With the insulation stripping tool, initiate a stripping action 2 in (51 mm) from one end of the specimen and, without kinking
or otherwise damaging the conductor, move the insulation slug endwise until approximately 3/4 in (19 mm) of the
conductor is exposed. Remove the specimen from the stripping tool and proceed.

4.4.4.4.2 Procedure

4.4.4.4.2.1 For 19 Strand Unidirectional Lay and All 7 Strand

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a. Grip the insulation with the fingers at both ends of the exposed portion of the conductor and rotate one end of the
specimen so as to untwist the exposed strands and make them parallel with the conductor axis. The use of rubber pads
or similar holding aids is permitted.

b. Retain the grip position used to untwist the strands and carefully push the ends of the exposed portion of the conductor
toward each other in the conductor axis, causing the strands to spread apart in a "bird cage" effect. See Figure 7.

c. Gently probe non-separated strands with a fine needle or thin blade to determine whether they are fused together by
metallic bonding or simply lying side by side. Metallic-bonded pairs or groups of strands which cannot be separated
along the whole "bird cage" length, without forcing the needle or blade between the strands, shall each be counted as
one in step d.
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d. Count the number of unbonded single strands plus the number of metallic-bonded pairs or groups of strands in the
conductor.

FIGURE 7 - TYPICAL 7-STRAND CONDUCTOR AFTER BIRDCAGING (NO STRANDS BLOCKED)

4.4.4.4.2.2 For 19 Strand "True Concentric" Lay

a. Perform step a as for unidirectional lay, but use only the rotation needed to untwist the 12-strand outer layer.

b. Perform step b as for unidirectional lay, using pressure needed to "bird cage" the outer layer. See Figure 7.

c., d. On the "bird cage" outer layer, perform steps c and d as for unidirectional lay.

e. Using a suitable tool, snip through each unbonded single strand and each bonded pair or group of strands of the outer
layer approximately in the center of the "bird cage" and fold the snipped ends back toward the respective ends of the
specimen. Do not cut the 7-strand core of the conductor.

f. Repeat steps a, b, c, and d with the 7-strand core.

g. Add the count of unbonded single strands and bonded pairs or groups of strands in the core to the count previously
derived from the outer layer. This total is the count applicable to the entire 19 strand conductor.

4.4.4.5 Results

Report the count of unbonded single strands and metallic bonded pairs or groups in the conductor.
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4.4.4.6 Information Required in Detail Specification

Number of specimens, conductor size of specimens, and the minimum number of unbonded strands.

4.4.4.7 Precision Bias

This is a new method that has not had the benefit of any round-robin testing to determine precision.

4.4.5 Method 405, Adhesion of Nickel Coating

4.4.5.1 Scope

This test determines the ability of nickel plating or coating to adhere properly to the underlying copper or high strength
copper alloy material. This test is generally used as a process control test.

4.4.5.2 Specimen

Two six inch specimens of uninsulated conductor strands.

4.4.5.3 Test Equipment

4.4.5.3.1 Thermal shock chamber or air oven capable of maintaining 250 ± 3 °C.

Copyright SAE International

4.4.5.3.2 Materials as required for continuity of coating test of ASTM B 355.

4.4.5.4 Test Procedure

4.4.5.4.1 One strand specimen shall be wrapped over its own diameter for eight close turns. The second strand
specimen shall remain in its straight form. The specimens shall then be subjected to ten continuous cycles
of temperature change. Each cycle shall consist of 4 hours at 250° ± 3 °C followed by 4 hours at room
temperature. Upon completion of the thermal cycling, the straight specimen shall be wrapped over its own
diameter for eight close turns in a manner identical to that of the first specimen. Both wrapped specimens
shall then be tested for continuity of plating in accordance with ASTM B 355.

4.4.5.5 Results

Report the results of the continuity of coating test on each specimen.

4.4.5.6 Information Required in Detail Specification

The detailed specification shall list the applicability of this test.

4.4.5.7 Precision Bias

This method has been actively used in aerospace specification sheets for 30 years.

4.5 Test Methods Group 500 - Electrical Tests

4.5.1 Method 501, Dielectric Constant

4.5.1.1 Scope

This test is to be used to determine the dielectric constant of an insulation.

4.5.1.2 Specimen

A specimen of at least 15 ft (4.6 m) of size 22 wire shall be used.

4.5.1.3 Test Equipment

4.5.1.3.1 A suitable capacitance bridge that shall be capable of measuring the capacitance within a limit of error of
1 picofarad. It shall be capable of measuring the capacitance of a specimen, one side of which is grounded.
Provisions shall be made for connecting and disconnecting the specimen at the specimen end of the leads
connecting the specimen to the bridge.

4.5.1.3.2 A water bath in which the specimen can be immersed.

4.5.1.4 Test Procedure

4.5.1.4.1 The conductor diameter (d) shall be measured using Method 401 of AS4373.

4.5.1.4.2 The insulation diameter (D) shall be measured using Method 901 of AS4373.

4.5.1.4.3 The middle 10 ft (3.05 m) of the specimen shall be immersed in distilled water for the required period of time.
A 2.5 ft (0.76 m) portion of each end of the specimen shall be kept well above the surface of the water as
leakage insulation. The capacitance of the insulation shall be determined at a frequency of either 1000 or 60
cycles, using a suitable capacitance bridge. The voltage impressed upon the conductor shall be sufficient to
give the required sensitivity of measurement, except that the impressed voltage on the conductor shall not be
greater than 40 V per mil of insulation thickness. The specimen shall be immersed to the same depth, and
the temperature of the water bath shall be the same, at the time readings are taken after each immersion
period. --```,``,,,`,,,,,`,,`,`,``,`,,,-`-`,,`,,`,`,,`---

Copyright SAE International

4.5.1.4.4 The dielectric constant (e) of the insulation shall be calculated after each immersion period as follows:

e 13,600 C Log10 D / d (Eq. 4)

where:
C = Capacitance in microfarads of the immersed 10 ft (3.05 m) of the specimen
D = Diameter over the insulation, inch(es)
d = Diameter over the conductor, inch(es)

4.5.1.5 Results

Record capacitance (C), conductor diameter (d), and insulation diameter (D). Report dielectric constant.

4.5.1.6 Information Required in the Detail Specification

Report the dielectric constant.

4.5.1.7 Precision Bias

This is a material dependent test.

4.5.2 Method 502, Corona Inception and Extinction Voltages

4.5.2.1 Scope

This test is to be used to determine the corona inception and extinction voltages (CIV and CEV) for an insulated wire
specimen.

4.5.2.2 Specimen

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Specimens shall be selected in accordance with Section 25.3.2.1 of ASTM D 3032 and shall be prepared as described in
Section 25.3.2.2.

4.5.2.3 Test Equipment

The test equipment required for this test is described in Section 7 of ASTM D 1868.

4.5.2.4 Test Procedure

See Section 25.4 of ASTM D 3032.

4.5.2.5 Results

Report dimensions of specimen, type of ground electrode used, CIV, CEV, and test conditions, if other than ambient.

4.5.2.6 Information Required in Detail Specification

Number of specimens to be tested, wire size of specimens, and test conditions other than ambient.

4.5.2.7 Precision Bias

See ASTM D 3032.

4.5.3 Method 503, Impulse Dielectric

4.5.3.1 Scope

This test describes a method for detecting defects in finished wire insulation with an impulse dielectric test.
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4.5.3.2 Specimen

See Section 13.5 of ASTM D 3032.

4.5.3.3 Test Equipment

See Sections 13.3 and 13.4 of ASTM D 3032.

4.5.3.4 Test Procedure

See Section 13.6 of ASTM D 3032.

4.5.3.5 Results

Report impulse voltage used.

4.5.3.6 Information Required in Detail Specification

Peak impulse voltage for test.

4.5.3.7 Precision Bias

A minimum peak impulse voltage of 6.5 kV is recommended.

4.5.4 Method 504, Insulation Resistance

4.5.4.1 Scope

This test is to be used to determine the insulation resistance of a finished wire specimen. Insulation resistance is of
interest in high impedance circuits and as a measure of quality control. Changes in insulation resistance may indicate
deterioration of other properties.

4.5.4.2 Specimen

See Section 6.3 of ASTM D 3032.

4.5.4.3 Test Equipment

See Section 6.2 of ASTM D 3032. A measuring apparatus that can measure at least 40,000 M: or as little as 12.5 pA
(for current measurements) is needed to measure the desirable minimum insulation resistance as stated in the prevision
bias.

4.5.4.4 Test Procedure

See Section 6.4 of ASTM D 3032. The last sentence of Section 6.4.1, "Discard any specimen with a gross defect...", shall
not be applicable. Calculation of insulation resistance shall be as described in Section 6.5 of ASTM D 3032.

4.5.4.5 Results

Report the measured resistance, the immersed length, and the calculated insulation resistance.

4.5.4.6 Information Required in Detail Specification

Number and wire size of specimens.

4.5.4.7 Precision Bias

A minimum insulation resistance of 1000 M: - 1000 ft, is usually desirable.

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Copyright SAE International

4.5.5 Method 505, Spark Test of Finished Wire Insulation

4.5.5.1 Scope

This test describes a method for detecting defects in finished wire insulation with a spark test. This method can also be
utilized to verify defects in interior insulation walls of multi-layered insulation systems as an in-process test when required
by the detailed specification sheet. The high frequency waveform (3000 Hz) is the preferred method and identified is
Method 1. A 60 Hz or 50 Hz waveform may be used as an alternate method and is identified as Method 2.

4.5.5.2 Specimen

4.5.5.2.1 Method 1: See Section 13.10 of ASTM D 3032.

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4.5.5.2.2 Method 2: Unless otherwise specified, the specimen shall be the entire length of wire or cable offered for
inspection.

4.5.5.3 Test Equipment

4.5.5.3.1 Method 1: See Sections 13.8 and 13.9 of ASTM D 3032.

4.5.5.3.2 Method 2:

Spark Tester: A spark tester will provide essentially sinusoidal voltage.

Transformer: A transformer of sufficient capacity to maintain the test voltage specified in the detail specification under all
normal conditions of leakage current. The core of the transformer and one end of the secondary winding shall be
connected to ground.

Voltmeter: A voltmeter shall be so located in the circuit that it will indicate at all times the actual test voltage applied. The
spark tester shall not be simultaneously connected to more than one electrode.

Electrode: An electrode, such as a bead-chain or wire brush, which makes direct mechanical contact with the surface of
the insulation of the wire or cable undergoing test. A pipe, coiled spring, or the like shall not be acceptable. If the link or
bead-chain type of electrode is used, the bottom of the metal electrode enclosure shall be V-shaped. The chains shall
have a length appreciably greater than the depth of the enclosure. The width of the trough shall be approximately 1 ½
inches greater than the diameter of the largest wire or cable to be tested. If a bead-chain type of electrode is used, the
beads shall have a diameter of 3/16 inch. The longitudinal spacing of the chains shall be not more than ½ inch. The
transverse spacing of the chains shall be not more than 3/8 inch, except that the spacing may be ½ inch if the transverse
rows of chain are staggered. The electrode shall be provided with a grounded metallic screen or the equivalent as a
guard against contact by personnel. The length of electrode shall be sufficient to meet the requirements in 4.5.5.4.2.

Fault Signaling Device: A fault signing device or system shall include a visible signal, a defect recording device, and/or
an automatic stop device. The arrangement shall be such that when the fault signal is given, it will be maintained until
manually reset.

4.5.5.4 Test Procedure

4.5.5.4.1 Method 1: See Section 13.11 of ASTM D 3032.

Copyright SAE International

4.5.5.4.2 Method 2:

The spark test shall be conducted as near the end of the manufacturing process as is practicable, preferably as the wire
or cable is being cut into shipping lengths. The test voltage shall be as specified in the detail specification. The
conductor or shield of shielded and jacketed cable shall be earth grounded during the spark test. An earth-ground
connection shall be made at both the pay-off and take-up reels except that, if the wire is tested for continuity and the
conductor is of one integral length, the earth-ground connection need be made at only one point; ie, either the take-up or
pay-off reel. In any case, the conductor on a reel at with an earth-ground connection is made shall be bonded directly to
the earth ground on the transformer in the spark tester. The length of the electrode is not specified, but the rate of speed
at which the wire travels through the electrode shall result in any point on the wire being in contact with the electrode for
not less than a total of 18 positive and negative crests of the supply voltage (the equivalent of 9 full cycles of the supply
voltage). A fault detection current trip level of 1.5 milliamps (minimum) is recommended to limit false trips.

The maximum acceptable speed of the wire shall be determined by the following:

Feet per minute = 5/9 x frequency (in hertz) x electrode length (in inches)

4.5.5.5 Results

Report frequency and amplitude of test signal.

4.5.5.6 Information Required in Detail Specification

Test signal frequency and amplitude.

4.5.5.7 Precision Bias

A minimum test voltage of 1500 Volts (rms) is recommended.

4.5.6 Method 506, Surface Resistance

4.5.6.1 Scope

This test is to be used to determine the surface resistance of a finished wire specimen. This test was initially developed
for wires with outer braid as part of the insulation system.

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4.5.6.2 Specimen

See Section 7.3 of ASTM D 3032.

4.5.6.3 Test Equipment

See Section 7.2 of ASTM D 3032.

4.5.6.4 Test Procedure

Section 7.5 of ASTM D 3032 shall be followed. The specimen shall be positioned in the test chamber so that the ends are
at least 1 in (25.4 mm) from any wall of the chamber.

4.5.6.5 Results

Report the DC potential and surface resistance values.

4.5.6.6 Information Required in Detail Specification

Number and wire size of specimens to be tested.

Copyright SAE International

4.5.6.7 Precision Bias

A minimum surface resistance value of 5 M: - inch is usually desirable.

4.5.7 Method 507, Time/Current to Smoke

4.5.7.1 Scope

This test is to be used to determine the time and current at which a finished wire specimen produces smoke.

4.5.7.2 Specimen

A 12 in (304.8 mm) length of size 16 or smaller wire specimen shall be tested.

4.5.7.3 Test Equipment

4.5.7.3.1 Isopropyl alcohol

4.5.7.3.2 DC constant current source

4.5.7.3.3 Black background

4.5.7.3.4 Timer

4.5.7.3.5 Current meter

4.5.7.4 Test Procedure

The wire specimen shall be pre-cleaned using a cloth dampened with isopropyl alcohol and then stripped of 0.5 in
(13 mm) insulation at each end. A DC constant current source shall be used to supply the required current and a suitable
measuring device shall be used to verify current application. The wire specimen shall be suspended horizontally in air
against a black background adequately illuminated to see the smoke. Apply 10 A for 30 s, then 15 A for 30 s and continue
to increase current in 5 A steps every 30 s until there is evidence of smoke.

4.5.7.5 Results

Report current and time when smoke first appears and any pertinent unusual observation of the insulation condition at the
end of the test.

4.5.7.6 Information Required in Detail Specification

Number and wire size of specimens.

4.5.7.7 Precision Bias

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This is a new method which has not had the benefit of any round-robin testing to determine precision.

4.5.8 Method 508, Dry Arc Propagation Resistance

4.5.8.1 Scope

The dry arc propagation resistance test for wire provides an assessment of the ability of an insulation to prevent damage
in an electrical arc environment. In service, electrical arcs may originate from a variety of factors, including insulation
deterioration, faulty installation and chafing. It has been documented that results of an arc-propagation test may vary due
to the method of arc initiation; therefore, this test method was selected as the standard test method to evaluate the
general arc-propagation resistance characteristics of an insulation.

Copyright SAE International

This test method initiates an arc with an oscillating blade. The arc-propagation resistance is defined as the length of arc-
propagation damage along the wires in contact with the blade and by the extent of damage to all adjacent wires
undamaged by the blade. This test also evaluates the ability of the insulation to prevent further arc-propagation when the
electrical arc is re-energized. The power supply, test current, circuit resistances and other variables are optimized for
testing 20 AWG wires. The use of other AWG wires may require modification to the test variables.

4.5.8.2 Specimen

A test specimen shall be a bundle of seven wires and shall be of sufficient length, 14 in (35.6 cm) minimum, to allow the
bundle to be installed in the test fixture. Fifteen bundles shall be required for a full test. A minimum of 122.5 ft (37.3 m) of
wire is required. It is recommended that 20 AWG wire be used for this test.

4.5.8.3 Test Equipment

4.5.8.3.1 An abrader blade made from 6061-T6 aluminum material. Use a grit size 60 grinding wheel or 60 grit sanding
belt to sharpen the blade. A typical abrader blade is shown in Figure 7. Use the blade-sharpening fixture
shown in Figure 9.

4.5.8.3.2 A transparent screen to protect laboratory personnel from molten metal, UV radiation, and other debris that
may be ejected from the test specimen.

4.5.8.3.3 An oscillating mechanism to which the abrader blade is connected. The oscillating mechanism shall provide
a stroke of 1.5 in ± 0.12 in (3.81 cm ± 0.3 cm) at a frequency of 0.5 cps ± 0.05 cps.

4.5.8.3.4 A test fixture that includes a test block to hold the wire at right angles to the abrading blade. The block shall
be made from 6061-T6 aluminum (see Figure 12).

4.5.8.3.5 A three phase wye connect power supply, grounded at wye, derived from a rotary machine rated at least
20 KVA and meets the voltage and frequency requirements of MIL-STD-704 Table I (108 to 118 volts rms
phase-to-neutral at 400 Hz ± 7 Hz).

4.5.8.3.6 A mechanical stop constructed of stainless steel.

4.5.8.3.7 AS3320 - 7.5 (7.5 Amp) and appropriate protective circuit breakers (30 Amp typical).

4.5.8.3.8 Variable load and fixed load resistors.

4.5.8.3.9 Commercial Item Description (CID) from A-A-52080 through A-A-52084 (Type I, IV, or V) lacing tape or
equivalent.

4.5.8.3.10 AS25281 plastic clamps, or equivalent.

4.5.8.4 Test Procedure

4.5.8.4.1 Preparation of a Bundle

Conduct a 2500 V Wet Dielectric test (or pass the wire through an impulse spark test set at 8KV) on 100% of the wire in
accordance with the Wet Dielectric test procedure described in Test Method 510 before the arc propagation resistance
test is performed. Discard any failed sections of wire. Cut seven wire segments at least 14 in (35.6 cm) in length for each
of the 15 bundles. Clean the cut wires using a cloth saturated with isopropyl alcohol. Strip both ends of five of the seven
wire segments. Use these stripped ends for making electrical connections. These five wire segments are the “Active
Wires.” The two unstripped wire segments are the “Passive Wires.” Form the bundle by laying the seven segments
straight and geometrically parallel. Assemble the wires to form the six-around-one configuration shown in Figure 10, with
D1 and D2 being the passive wires. Use lacing tapes defined in 4.5.8.3.9 to hold the test bundle together as shown in
Figure11. Clean the assembled bundle using a cloth saturated with isopropyl alcohol.

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Copyright SAE International

4.5.8.4.2 Bundle Installation

A test fixture shall be used to hold the wire bundle in place perpendicular to the abrader blade. Details of a suggested
test fixture are shown in Figure 12. The wire bundle is clamped with SAE AS25281 plastic clamps, or equivalent, at two
points on the fixture at a minimum distance of 6 in (15.24 cm). The clamp points are equidistant from the point of
application of the abrader. The slide bolt allows the adjusting screw to move the holding plates snugly against the bundle.
Ensure that the active wires A1 and B1 are parallel with the top plane of the test fixture, and that the passive wires D1 and
D2 are in complete contact with the base of the test fixture. The bundle must be restricted from moving while the abrader
blade is cutting wires A1 and B1. The test fixture shall contain an adjustable mechanical stop, which may be set to allow
for various penetration depths of the oscillating blade.

4.5.8.4.3 Electrical Connection

Connect the bundle to the power supply and circuit resistance using the schematic circuit shown in Figure 13. Connect
one end of each active wire to the appropriate phase of the power supply as shown in Table 11. Use an SAE AS3320 -
7.5 (7.5 Amp) circuit breaker and a circuit resistance (Rf) in series with each of the active wires. Use the circuit resistance
(Rf) values (±10%) shown in Table 12. Connect the other end of the five active wires under test to variable resistive (Ri)
loads. Adjust the resistance (Ri) to limit the current flowing through each wire to 1.0 Amp ± 0.2 Amp. Protect the test
circuits with appropriate circuit breakers connected on the supply side of the test set up. Connect the abrader blade to
the neutral of the generator. Connect the generator neutral to ground. The generator load resistors (Rg) shall be set so
that the generator is delivering 10 to 15% of its rated load at a voltage of 108 to 118 Volts rms phase to neutral.

TABLE 11 - ELECTRICAL CONNECTION

Wire Identification Power Supply Layer

A1 Phase A Top
B1 Phase B Top
C1 Phase C Middle
A2 Phase A Middle
B2 Phase B Middle
D1 None Lowest
D2 None Lowest

TABLE 12 - CIRCUIT RESISTANCE

Test Number Circuit Resistance (ohm) ±10%

1 0.0
2 0.5
3 1.0
4 1.5
5 2.0

4.5.8.4.4 Initiation of Test

[Test three bundles for each of the five circuit resistances]. Install the oscillating mechanism, which may use a
reciprocating arm, or vertical and horizontal precision linear ball slides (a suggested ball slide apparatus is shown in
Figure 14). When installing the blade, make sure that the angled side of the blade faces the power side of the circuit.
Adjust the mechanical stop to ensure that the abrader blade penetrates into the A1 and B1 wires a distance of 0.87 ± 0.08
times the radius of the wire. Close all circuit breakers. Apply a load of 0.55 lb ± 0.055 lb (250 g ± 25 g) to the abrader at
the point of contact with one wire. Adjust the blade to ensure that the major plane of the blade lies perpendicular to the
longitudinal axis of the bundle. Apply the abrader blade on the test bundle. Position the protective screen to shield the
operator from ejecting objects and UV radiation. Apply three phase 400 Hz power. Actuate the abrader. Allow the
abrader blade movement to continue.

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Copyright SAE International

4.5.8.4.5 Use one of the following conditions to conduct and complete the test.

4.5.8.4.5.1 If the abrader cuts through A1 and B1 wires without tripping phase A1 or phase B1 circuit breakers, stop
the abrader movement. Disconnect the power.

4.5.8.4.5.2 Conduct the 1000 V Wet Dielectric test on wires A2, B2, C1, D1, and D2 in accordance with the Wet
Dielectric procedure of Test Method 510. Record the number of wires that fail. Measure and record the
total length of physical damage to each wire (including phase A1 and B1 wires) in inches.

4.5.8.4.5.3 If a circuit breaker in any of the phases A2, B2, or C1 trips at any time during the test, stop the abrader and
disconnect the power. Perform tests as listed in 4.5.8.4.5.2.

4.5.8.4.5.4 If either phase A1 or phase B1 circuit breaker trips at any time during the test, stop the abrader.
Disconnect the power and determine if the conductor of wires A1 or B1 are open. If both wires are open,
conclude the test by performing tests as listed in 4.5.8.4.5.2. If wire A1 or B1 is not open, wait 3 to 4 min,
reset the circuit breaker and restart the abrader and then immediately re-apply the power. Continue the
test until either phase A1 or phase B1 circuit breaker has tripped a second time, phase A1 and B1 are
open, or the blade movement is stopped by the mechanical stop. CAUTION: DO NOT RESET A CIRCUIT
BREAKER THAT TRIPS TWICE. Perform the tests as listed in 4.5.8.4.5.2. Use a new abrader blade edge
for each test bundle.

4.5.8.4.5.5 Circuit breakers should be periodically tested to assure they still meet the overload requirements of the
applicable military specification (MS) sheet. Circuit breakers outside their overload trip requirements
should be replaced.

4.5.8.5 Results

Report the number of wires that pass the dielectric test and the length of physical damage to each individual wire in the
bundle.

4.5.8.6 Information Required in the Detailed Specification

Wire type and number of bundles tested.

4.5.8.7 Precision Bias

While this is a new test, numerous round-robin tests have been run to confirm the validity of this procedure. However,
industry wide minimum requirements have not as yet been established.
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FIGURE 8 - BLADE

FIGURE 9 - ALUMINUM BLADE SHARPENING FIXTURE

Copyright SAE International

FIGURE10 - BUNDLE CONFIGURATION

FIGURE11 - BUNDLE TYING

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Copyright SAE International

FIGURE 12 - TEST FIXTURE

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FIGURE 13 - ELECTRICAL CONNECTION

Copyright SAE International

FIGURE 14 - BALL SLIDE BLADE FIXTURE

4.5.9 Method 509, Wet Arc Propagation Resistance

4.5.9.1 Scope
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The wet arc propagation resistance test for wire insulation provides an assessment of the ability of an insulation to
prevent damage in an electrical arc environment. In service, electrical arcs may originate from a variety of factors,
including insulation deterioration, faulty installation and chafing, and may be further induced by water and other fluids
which create conductive paths. It has been documented that results of an arc-propagation test may vary due to the
method of arc initiation; therefore, this test method was selected as the standard test method to evaluate the general arc-
propagation resistance characteristics of an insulation.

This test method initiates an arc by dripping salt water over pre-damaged wires which creates a conductive path between
the wires. The arc-propagation resistance is defined as the length of arc-propagation damage along the wires after the
wet arc test is completed and by the extent of damage to all adjacent wires undamaged by the wet arc test. This test also
evaluates the ability of the insulation to prevent further arc-propagation when the electrical arc is re-energized. The
power supply, test current, circuit resistances and other variables are optimized for testing 20 AWG wires. The use of
other AWG wires may require modification to the test variables.

4.5.9.2 Specimen

A specimen shall be a bundle of seven wires approximately 8 to 16 in (20.3 to 40.6 cm) in length. Fifteen bundles are
required for a full test. A minimum of 70 ft (21.3 m) of wire is required. It is recommended that 20 AWG wire be used.

4.5.9.3 Test Equipment

4.5.9.3.1 A transparent screen to protect laboratory personnel from molten metals, UV radiation, and other debris that
may be ejected from the test specimen.

Copyright SAE International

4.5.9.3.2 A variable speed, peristaltic pump or suitable other device and hypodermic needle or burette. The apparatus
should be able to deliver the electrolyte solution at a rate of 100 mg ± 10 mg (0.0035 oz ± 0.00035 oz) per
minute (8 to 10 drops of 3% sodium chloride solution) to the test specimen. An alternative means of delivery
is acceptable.

4.5.9.3.3 A mechanical device for supporting the test bundle in free air in a horizontal position.

4.5.9.3.4 An electrolyte solution made by dissolving 3% ± 0.5% by weight of sodium chloride in distilled water.

4.5.9.3.5 A three phase wye connector power supply, grounded at wye, derived from a rotary machine of at least
20 KVA and that meets the voltage and frequency requirements of MIL-STD-704.

4.5.9.3.6 SAE AS3320 - 7.5 (7.5 Amp) and appropriate protective circuit breakers (30 Amp typical).

4.5.9.3.7 Variable load and fixed load resistors.

4.5.9.3.8 Commercial Item Description (CID) from A-A-52080 through A-A-52084 (Type I, IV, or V) lacing tape or
equivalent.

4.5.9.4 Test Procedure

4.5.9.4.1 Preparation of a Bundle

Conduct a 2500 V Wet Dielectric test (or pass the wire through an impulse spark tester set at 8KV) on 100% of the wire in
accordance with the Wet Dielectric test procedure described in Test Method 510 before the arc-propagation resistance
test is performed. Discard any failed sections of wire. Cut seven wire segments 8 to 16 in (20.3 to 40.6 cm) in length for
each of the 15 bundles. Clean the cut wires using a cloth saturated with isopropyl alcohol. Strip both ends of five of the
seven wire segments. Use these stripped ends for making electrical connections. These five wire segments will be
called “Active Wires.” The two non-stripped wire segments will be called “Passive Wires.” Using a sharp blade, cut a
square groove completely around (360 degrees) the insulation of two of the active wires at their midpoints to expose the
conductor taking care to not cut into the conductor strands. The width of the exposed conductor should be between
0.5 mm and 1.0 mm (0.0197 in and 0.03941 in). Form the bundle by laying the seven wire segments straight and
geometrically parallel. Assemble the wires to form the six-around-one configuration shown in Figure 15, with D1 and D2
being the passive wires. The two pre-damaged wires should be placed in the A1 and B1 positions and care should be
taken to ensure that there is a longitudinal distance of 6.0 to 6.5 mm (0.2362 to 0.2560 in) as measured between the
stripped window and the two exposed conductors. Use lacing tapes defined in 4.5.9.3.8 to hold the test bundle together
as shown in Figure 16. Clean the assembled bundle using a cloth saturated with isopropyl alcohol.

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FIGURE 15 - BUNDLE CONFIGURATION

FIGURE 16 - BUNDLE TYING

4.5.9.4.2 Electrical Connection

Connect the test bundle to the power supply and circuit resistance using the schematic circuit shown in Figure 17.
Connect one end of each active wire to the appropriate phase of the power supply as shown in Table 13. Use an SAE
AS3320 - 7.5 (7.5 Amp) circuit breaker and a circuit resistance (Rf) in series with each of the active wires. Use the circuit
resistance (Rf) values (±10%) shown in Table 14. Connect the other end of the five active wires under test to variable
resistive (Ri) loads. Adjust the resistance (Ri) to limit the current flowing through each wire to 1 Amp ± 0.2 Amp. Protect
the test circuits with appropriate circuit breakers connected on the supply side of the test set up. The generator load
resistors (Rg) shall be set so that the generator is delivering 10 to15% of its rated load at a voltage of 108 to 118 Volts
rms phase to neutral.

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TABLE 13 - ELECTRICAL CONNECTION

Wire Identification Power Supply Layer

A1 Phase A Top
B1 Phase B Top
C1 Phase C Middle
A2 Phase A Middle
B2 Phase B Middle
D1 None Lowest
D2 None Lowest

TABLE 14 - CIRCUIT RESISTANCE

Test Number Circuit Resistance (ohm) ±10%

1 0.0
2 0.5
3 1.0
4 1.5
5 2.0
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FIGURE 17 - ELECTRICAL CONNECTION

4.5.9.4.3 Initiation of Test

[Test three bundles for each of the five circuit resistances.] Using the mechanical supports, mount the test bundle in a
draft-free location so that the wires with the exposed conductors are facing up. Adjust the flow of the electrolyte to 8 to 10
drops per minute. Position the hypodermic needle to drop the electrolyte into the groove between the wires with the
exposed conductor. Position the tip of the needle so that the vertical distance of the tip is between 2.0 and 3.0 in (51 and
76 mm) above the specimen. Position the protective screen to shield the operator from ejecting objects or UV radiation.
Close all circuit breakers. Allow the electrolyte to flow. Apply the three phase 400 Hz power.

4.5.9.4.4 Use one of the following conditions to conduct and complete the test:

4.5.9.4.4.1 If circuit breakers in any of the phases A2, B2, or C1 trip at any time during the test, wait 3 min and
disconnect power. Conduct a 1000 V Wet Dielectric test on wires A2, B2, C1, D1, and D2 in accordance
with the Wet Dielectric procedure of Test Method 510. Record the number of wires that fail. Measure and
record the total length of physical damage to each wire (including phase A1 and B1 wires) in inches.

Copyright SAE International

4.5.9.4.4.2 If either phase A1 or phase B1 circuit breaker trips at any time during the test, disconnect the power and
identify the phase of the tripped circuit breaker. Wait 3 min. Reset the circuit breaker, apply power and
continue the test. Continue the test for 8 h or until either phase A1 or phase B1 circuit breaker has tripped
twice. CAUTION: DO NOT RESET CIRCUIT BREAKER THAT TRIPS TWICE. Conduct a 1000 V Wet
Dielectric test of Test Method 510. Record the number of wires that fail. Measure and record the total
length of physical damage to each wire (including phase A1 and B1 wires) in inches.

4.5.9.4.4.3 If the conductor(s) of phases A1 and B1 wires erode without tripping phase A1 or phase B1 circuit breakers
(as may be indicated by an open circuit indicator), continue the test for a total of 8 h or until the conditions
noted in 4.5.9.4.4.1 or 4.5.9.4.4.2 occur. Conduct a 1000 V Wet Dielectric test on wires A2, B2, C1, D1,
and D2 in accordance with the Wet Dielectric procedure of Test Method 510. Record the number of wires
that fail. Measure and record the total length of physical damage to each wire (including phase A1 and B1
wires) in inches.

4.5.9.4.4.4 Circuit breakers should be periodically tested to assure they still meet the overload trip requirements of the
applicable military specification (MS) sheet. Circuit breakers outside their overload trip limits should be
replaced.

4.5.9.5 Results

Report the number of wires that pass the dielectric test and the length of physical damage to each wire in the bundle.

4.5.9.6 Information Required in Detail Specification

Wire type and number of specimen bundles.

4.5.9.7 Precision Bias

This is a new method and round-robin testing to determine precision is in progress.

4.5.10 Method 510, Voltage Withstand (Wet Dielectric)

4.5.10.1 Scope

This test provides a method to determine insulation integrity following any type of performance test.

4.5.10.2 Specimen

See Section 8.3 of ASTM D 3032.

4.5.10.3 Test Equipment

See Section 8.2 of ASTM D 3032.

4.5.10.4 Test Procedure

See Section 8.4 of ASTM D 3032.

4.5.10.5 Results

Report electrification time, voltage, and time of failure if failure occurs.

4.5.10.6 Information Required in Detail Specification

Performance testing preceding Voltage Withstand and maximum voltage applied.

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4.5.10.7 Precision Bias

A test voltage of at least 2.5 kV is recommended for 600 V or higher rated wire.

4.5.11 Method 511, Wire Fusing Time

4.5.11.1 Scope

This test is to be used to determine the time for an insulated wire to interrupt current in overcurrent conditions.

4.5.11.2 Specimen

Each specimen shall be a 12 in (305 mm) length of wire with the insulation stripped 0.5 in (13 mm) at both ends.

4.5.11.3 Test Equipment

4.5.11.3.1 DC constant current supply.

4.5.11.3.2 Timer.

4.5.11.4 Test Procedure

The specimen shall be mounted so that its length is horizontally suspended in free air and not resting on any surface.
Using a DC constant current supply, apply 2.5 times the free air rated current. See Figure 3 of AS50881 for the free air
rated current. Measure the time to interrupt current (open circuit). The test shall be terminated after 5 min if no current
interruption occurs.

4.5.11.5 Results

Report test current and time to interrupt current.

4.5.11.6 Information Required in Detail Specification

Number and wire size of specimens.

4.5.11.7 Precision Bias

This method has not had the benefit of any round-robin testing to determine precision.

4.5.12 Method 512, Voltage Rating: TO BE DETERMINED

There is not currently an approved test under ASTM D 3032 that covers this requirement, but drafts are being worked on
and the Task Group has decided to await the issuance of the ASTM test.
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4.5.13 Method 513, Smoke Resistance

4.5.13.1 Scope

This test determines if the insulation of a wire will produce smoke when the conductor is subjected to an overload current
which raises the conductor temperature to the rated temperature of the insulation.

4.5.13.2 Specimen

Test sample shall consist of a wire specimen approximately 15 feet in length.

Copyright SAE International

4.5.13.3 Test Equipment

4.5.13.3.1 A flat black viewing background at least 10 feet in length

4.5.13.3.2 Voltmeter.

4.5.13.3.3 Ammeter.

4.5.13.3.4 Thermometer.

4.5.13.3.5 Constant Current Power Supply.

4.5.13.4 Test Procedure

4.5.13.4.1 This test shall be conducted at room ambient temperature in still air. The specimen shall be suspended so
that at least the central 10 foot section is horizontal and unsupported. One end of the wire shall be suitably
weighted so that no sagging will occur. The resistance of the central 10 foot section shall be measured in
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accordance with Method 403 (Conductor Resistance). During the test, while passing direct current through
the wire to raise its temperature, the voltage drop shall be measured over the 10 foot section, The voltage to
current ratio (resistance) needed to provide the required smoke test temperature specified in the individual
specification (based on conductor resistance change) shall then be determined by use of the following
formula.

ET = Ra
IT
( 1+ TT - Ta
K + Ta
)
FIGURE 18 – FORMULA FOR VOLTAGE TO CURRENT RATIO

Where:
ET = Voltage drop over the central 10 foot section at smoke test temperature.
IT= Test current (amps) to provide the required smoke test temperature.
Ra = Measured conductor resistance at room ambient (ohms)
TT = Smoke test temperature (°C) specified in the individual specification
Ta = Ambient temperature (°C)
K = Temperature coefficient of resistance (from NBS HDBK 100) as follows:
K = 234.5 for standard annealed copper conductors
K = 279.0 for high strength copper alloy conductors

4.5.13.4.2 The current shall be increased slowly until the resistance of the conductor is stabilized at the value calculated
above. The conductor temperature shall be maintained for 15 minutes during which time the finished wire
under current load will be observed for any evidence of smoke against the flat black background.

4.5.13.5 Results

Report any evidence of smoke from the wire insulation.

4.5.13.6 Information Required in Detail Specification

The detailed specification shall list the test temperature and tolerance.

4.5.13.7 Precision Bias

The recommended test temperature is the rated temperature of the wire insulation.
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SAE AS4373E Page 48 of 103

4.6 Test Methods Group 600 - Environmental Tests

4.6.1 Method 601, Fluid Immersion

4.6.1.1 Scope

This test is to be used to determine the effects of various fluids to the insulation on the wire specimen.

4.6.1.2 Specimen

Three 24 in (610 mm) wire specimens shall be used for each test fluid.

4.6.1.3 Test Equipment

4.6.1.3.1 Containers large enough to immerse to within 6 in (152 mm) of each end of the wire specimen, for each fluid
in the fluid table below.

4.6.1.3.2 Quantities of each of the fluids selected from Table 14.

4.6.1.3.3 A micrometer or other device capable of measurement to 0.001 in (0.025 mm).

4.6.1.3.4 A device to remove the insulation off each end of the wire specimen.

4.6.1.3.5 A thermometer.
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4.6.1.4 Test Procedure

4.6.1.4.1 Each 24 in (610 mm) specimen, for each test fluid in Table 15, shall have its diameter measured and shall
then be immersed to within 6 in (152 mm) of each end for the time and temperature specified. During
immersion, the radius of bend of the wire shall be not less than 14 nor more than 35 times the specified
maximum diameter of the wire under test. Upon removal from the test fluid, the specimen shall be wiped dry
and then remain for 1 h in free air at room temperature. The diameter shall be measured and compared to
the initial diameter. The insulation shall be removed for a distance of 0.5 in (13 mm) from each end of the
specimen. The specimen shall then be subjected to the Bend Test Method 713 and Voltage Withstand (Wet
Dielectric) Method 510.

4.6.1.5 Results

Report the initial diameter and the diameter after immersion; the time and temperature of immersion and the results of the
Bend Test Method 712 and of the Voltage Withstand (Wet Dielectric) Test Method 510.

4.6.1.6 Information Required in Detail Specification

The wire size and the fluids to be used for immersion.

4.6.1.7 Precision Bias

This is a fluid and material dependent test.

Copyright SAE International

TABLE 15 - FLUID TABLE

Test Temp Test Temp Immersion

Test Fluid °C °F Time (h)
a MIL-L-23699, Lubricating Oil, Aircraft Turbine Engine, 48-50 118-122 20
Synthetic Base
b MIL-H-5606 (Inactive for New Design), Hydraulic Fluid, 48-50 118-122 20
Petroleum Base, Aircraft Missile, and Ordnance
c TT-I-735, Isopropyl Alcohol 20-25 68-77 168
d MIL-DTL-5624, Turbine Fuel, Aviation, Grade JP-4 either or 20-25 68-77 168
MIL-T-83133, JP-8
e SAE AMS1424, Anti-Icing and Deicing-Defrosting Fluid, 48-50 118-122 20
undiluted
f SAE AMS1424, Anti-Icing and Deicing-Defrosting Fluid, diluted 48-50 118-122 20
60/40 (fluid/water) ratio
g MIL-C-43616, Cleaning Compound, Aircraft Surface 48-50 118-122 20
h ASTM D 1153, Methyl Isobutyl Ketone (For use in organic 20-25 68-77 168
coatings)
i SAE AS1241, Fire Resistant Hydraulic Fluid for Aircraft 48-50 118-122 20
j MIL-L-7808, Lubricating Oil, Aircraft Turbine Engine, Synthetic 118-121 244-250 30
Base
k MIL-C-87937, Cleaning Compound, Aircraft Surface, Alkaline 63-68 145-154 20
Waterbase, undiluted
l MIL-C-87937, Cleaning Compound, Aircraft Surface, Alkaline 63-68 145-154 20
Waterbase, diluted 25/75 (fluid/water) ratio
m TT-S-735, Standard Test Fluids; Hydrocarbon, Type I 20-25 68-77 168
n TT-S-735, Standard Test Fluids; Hydrocarbon, Type II 20-25 68-77 168
o TT-S-735, Standard Test Fluids; Hydrocarbon, Type III 20-25 68-77 168
p TT-S-735, Standard Test Fluids; Hydrocarbon, Type VII 20-25 68-77 168
q Dielectric-coolant fluid, synthetic silicate ester base, Monsanto 20-25 68-77 168
Coolanol 25 or equivalent
r ASTM-D4814, Gasoline, Automotive, Combat 20-25 68-77 168
s MIL-PRF-87252, Coolant Fluid, Hydrolytically Stable, Dielectric 20-25 68-77 168

4.6.2 Method 602, Forced Hydrolysis

4.6.2.1 Scope

This test was developed for tape wrapped polyimide insulated wires and results may not indicate the hydrolytic stability of
other constructions.

4.6.2.2 Specimen

A 30 in (762 mm) specimen shall be used to run this test.

4.6.2.3 Test Equipment

4.6.2.3.1 PTFE or PTFE coated mandrels that are 6 times the diameter of the wire.

4.6.2.3.2 0.5 lb (0.227 kg) weights capable of being attached to the wire insulation.
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4.6.2.3.3 An air oven capable of maintaining the rated temperature of the finished wire specimens.

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4.6.2.4 Test Procedure

4.6.2.4.1 Heat Conditioned Wire

4.6.2.4.1.1 Specimen Preparation

Specimens shall be wrapped 10 times around a 6X mandrel and secured so that the specimen maintains continuous
contact with the mandrel. After wrapping tightly, hang a 0.5 lb (0.227 kg) weight to keep the wire against the mandrel
during oven aging.

4.6.2.4.1.2 Procedure

Place the prepared specimens and mandrels into an oven pre-heated to the finished wire's rated temperature. The
specimens shall remain in the oven for 8 h. Upon completion of the thermal conditioning, remove the specimens and
allow to cool to room temperature. Immerse the specimens and mandrels into a 5% Saline solution at 70 °C (158 °F) with
at least 2 in (5 cm) of each end out of the solution, for 672 h. Upon conclusion of the soak, remove the specimens and
allow to cool to room temperature. Perform a final Voltage Withstand (Wet Dielectric) test, Method 510, at 2500 V AC.

4.6.2.4.2 Unconditioned Wire

4.6.2.4.2.1 Specimen Preparation

Specimens shall be wrapped 10 times around a 6X mandrel and secured so that the specimen maintains continuous
contact with the mandrel.

4.6.2.4.2.2 Procedure

Immerse the specimens and mandrels into a 5% Saline solution at 70 °C (158 °C) with at least 2 in (5 cm) of each end out
of the solution for 672 h. Upon conclusion of the soak, remove the specimens and allow to cool to room temperature.
Perform a final Voltage Withstand (Wet Dielectric) test, Method 510, at 2500 VAC.

4.6.2.5 Results

For the heat conditioned wire, report the time and temperature for heat conditioning. For both heat conditioned and
unconditioned wire report dielectric failure of the wire if any failure occurs.

4.6.2.6 Information Required in Detail Specification

Number of specimens and wire size to be tested.

4.6.2.7 Precision Bias

This test method has not had the benefit of any round-robin testing to determine precision.

4.6.3 Method 603, Humidity Resistance

4.6.3.1 Scope

This test is to be used to determine the effects of humidity and temperature cycling on the wire specimen's insulation.

4.6.3.2 Specimen

A 52 ft (16 m) length of size 12 or smaller specimen of wire shall be tested.

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4.6.3.3 Test Equipment

4.6.3.3.1 A test chamber capable of maintaining an internal temperature of 70 °C ± 3 °C (158 °F ± 5 °F) and an internal
relative humidity of 95% ± 5%. The test chamber shall be capable of being sealed to retain the total moisture
content in the test space. The heat loss from the chamber shall be sufficient to reduce the internal
temperature from the above specified operating temperature to 38 °C (100 °F) or lower within a period of 16 h
from the time of removal of the source of heat.

4.6.3.3.2 Distilled or demineralized water shall be used to obtain the required humidity.

4.6.3.4 Test Procedure

The specimen shall be placed in the test chamber and the temperature and relative humidity raised over a 2 h period to
the values specified in 4.6.3.3.1 and maintained at such for a period of 6 h. At the end of the 6 h period the heat shall be
shut off. During the following 16 h period, the temperature shall drop to 38 °C ± 3 °C (100 °F ± 5 °F) or lower. At the end
of the 16 h period, heat shall be again supplied for a 2 h period to stabilize to 70 °C ± 3 °C (158 °F ± 5 °F). This cycle (2 h
heating, 6 h at high temperature, 16 h cooling) shall be repeated 15 times to extend the total time of the test to 360 h. At
the end of the fifteenth cycle, the 50 ft (16.4 m) center section of the specimen shall be removed from the chamber and
tested within 2 h for insulation resistance in accordance with Method 504.

4.6.3.5 Results

Report the insulation resistance in M - 1000 ft.

4.6.3.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested.

4.6.3.7 Precision Bias

Lengths of less than 50 ft (16.4 m) will not produce reliable results.

4.6.4 Method 604, Weight Loss Under Temperature and Vacuum

4.6.4.1 Scope

This test is used to determine the weight loss from a wire specimen when subjected to vacuum and temperature. Some
preconditioning may be required.

4.6.4.2 Specimen

A 24 in (610 mm) wire specimen shall be used for this test.

4.6.4.3 Test Equipment

4.6.4.3.1 A chamber capable of 33 mm Hg and the temperature rating of the wire specimen for 384 h operation.

4.6.4.3.2 A device to measure the weight of the specimens.

4.6.4.4 Test Procedure

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4.6.4.4.1 Each specimen shall be weighed.

4.6.4.4.2 If preconditioning is specified in the detail specification, then such preconditioning shall be performed.

Copyright SAE International

4.6.4.4.3 When preconditioning is required, the specimens shall be weighed again after completion of the
preconditioning. The specimens shall be transferred to the chamber preset at the wire's rated temperature.
As soon as practical, the chamber pressure shall be reduced to 33 mm Hg. The specimens shall remain in
this pressure and temperature condition in the chamber for 384 h.

4.6.4.4.4 At the completion of this 384 h test, the specimens shall be removed from the chamber and weighed again
within 30 min.

4.6.4.5 Results

The initial weight, the weight after preconditioning (if applicable), and the final weight shall be reported. The applicable
weight loss value may be calculated. The preconditioning conditions (if applicable) and the temperature and pressure of
the chamber shall be reported.

4.6.4.6 Information Required in the Detail Specification

The number and wire size of the specimens, the preconditioning parameters, and the chamber temperature and pressure.

4.6.4.7 Precision Bias

This test method has not had the benefit of any round-robin testing to determine precision.

4.6.5 Method 605, Propellant Resistance

With ever-increasing local and federal regulations for handling corrosive, toxic, and/or explosive materials such as
propellants, it is impractical for non- government laboratories to perform this type of test. The manufacturers of missile
systems who use these propellants have their own propellant tests, and they report that they also routinely route wires
and cables away from areas in their missiles where even accidental spillage may have had come in contact with installed
wires and cables. As a result, a test method for propellant resistance is not included in AS4373.

4.6.6 Method 606, Weathering Resistance

4.6.6.1 Scope

This test is to be used to determine the effects of UV light and condensation exposure to the insulation on the wire
specimens.

4.6.6.2 Specimen

A 36 in (914 mm) wire specimen shall be used for this test.

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4.6.6.3 Test Equipment

4.6.6.3.1 A UV light chamber per ASTM G 53 requirements.

4.6.6.3.2 Chamber capable of condensation exposure per ASTM G 53 requirements.

4.6.6.4 Test Procedures

This test shall be conducted by following ASTM G 53 for operating ultra violet (UV) light and water exposure apparatus.
Use the following parameters for UV and condensation cycling:

a. 8 h UV at 70 °C ± 3 °C (158 °F ± 5 °F) = 1 cycle

b. 4 h Condensation at 40 °C ± 3 °C (104 °F ± 5 °F)

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Perform 120 cycles of UV and condensation exposure. Remove the specimens after 120 cycles and subject them to the
Bend Test Method 712 and the Voltage Withstand (Wet Dielectric) Test Method 510. Insure wire portion exposed to UV
is in flex area.

4.6.6.5 Results

Report any cracking or splitting and any visible changes to the insulation or markings and the results of the Bend and
Voltage Withstand Tests.

4.6.6.6 Information Required in the Detail Specification

Number and wire size of the specimens to be tested.

4.6.6.7 Precision Bias

This test method has not had the benefit of any round-robin testing to determine precision.

4.6.7 Method 607, Wicking

4.6.7.1 Scope

This test is applicable only for multi-layered or overbraided wires. This test is to be used to determine the length of dye
travel within or between layers of insulation and to determine dye travel in overbraided wire. It is not applicable for
determining wicking of fluids in the conductor.

4.6.7.2 Specimen

The specimens to be tested shall be 4 in ± 1/16 in (102 mm ± 1.6 mm) in length with square-cut ends.

4.6.7.3 Test Equipment

4.6.7.3.1 A container to hang the specimens into a depth of 2 in (51 mm).

4.6.7.3.2 A quantity of standard dye solution sufficient to meet the requirements of 4.6.7.4. The dye solution shall be
prepared as follows:

a. Ethyl Alcohol: 30 ml

b. Rhodamine B dye: 0.02 g

c. Aerosol OT: 3 ml

d. Distilled water to make 2 L

The dye shall be dissolved in the ethyl alcohol before adding to the water. The solution shall be kept stoppered and a
fresh solution shall be prepared every 30 days. A new portion of the solution shall be used for each test conducted.

4.6.7.3.3 A sharp blade to remove the wire insulation.

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4.6.7.3.4 A clean dry lint free cloth.

4.6.7.3.5 A UV light source.

4.6.7.3.6 A scale capable of measurement to 1/16 in.

4.6.7.4 Test Procedures

Wicking of the dye shall be determined as follows:

4.6.7.4.1 Multi-layer Wire

The specimen shall be placed upright with the lower 2 in (51 mm) of its length immersed in the dye solution (4.6.7.3.2) in
an open container and shall be left for 24 h at room temperature in a draft free area. It shall then be removed from the
dye solution and the surface of the insulation shall be wiped with a clean, dry, lint free cloth. Within 5 min after removal
from the solution, the specimen shall be observed under ultraviolet light to determine, to the nearest 1/16 of an inch, the
distance the dye solution has traveled in any part of the insulation by wicking action. The layers of insulation may be
dissected away with a sharp blade, working from the upper end of the specimen to facilitate observation.

4.6.7.4.2 Overbraided Wire

Repeat immersion and UV observation but determine the wicking action, if any, to the nearest 1/16 of an inch in the
overbraid only.

4.6.7.5 Results

Report the distance traveled by the dye solution by either 4.6.7.4.1 or 4.6.7.4.2 depending upon the type of wire being
tested.

4.6.7.6 Information Required in the Detail Specification

Number and wire size of the specimens to be tested and which procedure to use.

4.6.7.7 Precision Bias

This test can be used for design evaluation or process control.

4.6.8 Method 608, Fluoride Offgassing

4.6.8.1 Scope

This test and method provides an assessment of a fluorinated materials propensity to release fluoride based compounds
which may cause corrosion in confined areas. The results generated by this test may be used to establish minimum
performance standards for fluorine offgassing.

4.6.8.2 Specimen

The specimen shall be a sufficient length of wire to meet the requirements noted in 4.6.8.4.2, cut flush on both ends.

4.6.8.3 Test Equipment

4.6.8.3.1 60 ml straight-sided polypropylene bottles with caps. (Nalgene 2118-0002 or equivalent).

4.6.8.3.2 Analytical balance to five significant figures.

4.6.8.3.3 Temperature controlled water bath (Fisher Scientific Isotemp 210 or equivalent).

4.6.8.3.4 Fluoride ion selective electrode (Thermo-Orion 9609BNWP or equivalent).

4.6.8.3.5 pH / ISE meter compatible with fluoride electrode (Thermo-Orion 4-Star Benchtop or equivalent).

4.6.8.3.6 Total Ionic Strength Adjustment Buffer 2 (TISAB 2).

4.6.8.3.7 Mixer, Magnetic stirrer (stir plate), with Teflon covered stir bars, or motorized stirrer.

4.6.8.3.8 Type I water.

4.6.8.3.9 Sodium Fluoride Solution, Calibration Standard.

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4.6.8.4 Sample Preparation

4.6.8.4.1 Pre-clean sample containers: soak new 60 ml polypropylene bottles overnight in Type I water room temp,
triple rinse with Type I water and air-dry under cover. Used bottles should be triple rinsed with Type I water
and air dried under cover.

4.6.8.4.2 Prepare three wire insulation samples for testing. Ensure no oils or contaminants touch the surface of the
insulation during sample preparation. For each sample, remove 0.5 grams (± 0.05 grams) of insulation from
the sample wire. Use a clean razor blade to slice a lengthwise sliver of insulation so it can be removed
lengthwise from the conductor. Cut removed insulation into 2.5 cm sections. Ensure no wire strand
fragments remain inside the insulation. Place each sample into a pre-cleaned polypropylene bottle.

4.6.8.4.3 Add 20.0 ml (± 0.5 ml) of Type I water to each sample bottle. In addition, prepare a blank bottle by adding
20.0 ml of Type I water. Tightly cap the bottles.

4.6.8.4.4 Mark outside of the bottle indicating the water level so evaporation losses can be documented.

4.6.8.4.5 Place tightly capped bottles (samples and blank) into a preheated temperature controlled water bath or oven
at 70ºC (+/-2ºC). Condition bottles for 168 hours, periodically inspecting the set-up to ensure wire specimens
are still submerged and the caps remain tightly secured.

4.6.8.4.6 Remove bottles from the bath after the extraction time and cool to room temperature 23ºC (±2ºC)
(approximately 45 minutes) prior to performing 4.6.8.5.1.

4.6.8.4.7 Document if any evaporation occurred. If so, add Type I water to bring the level back to the mark.

4.6.8.5 Test Procedures

4.6.8.5.1 Analyze extract in the polypropylene bottles using a fluoride Ion Selective Electrode (ISE). The ISE apparatus
should be operated and calibrated using manufacturer’s instructions and known standards which bracket the
sample concentrations. The following steps should be followed for the most accurate results.
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4.6.8.5.2 Add 20 ml (± 0.5 ml) of Total Ionic Strength Adjustment Buffer 2 (TISAB 2) to each sample, and blank for a
final volume of 40 ml (± 0.5 ml) each.

4.6.8.5.3 Prepare standards of 1 ppm (ȝg/ml), 10 ppm (ȝg/ml),100 ppm (ȝg/ml) of F¯ to calibrate ISE per
manufacturer’s recommended procedures.

4.6.8.5.4 Calibrate the ISE probe/meter using prepared standards and manufacturer’s recommended procedures for
direct calibration using a meter with ISE mode.

4.6.8.5.5 Immerse electrode in the standard for five minutes. Stir at a low to moderate speed using a Teflon covered
stir bar and a stir plate. Record the meter value and repeat for each standard.

4.6.8.5.6 After calibrating with standards. Immerse electrode in first unknown sample for five minutes. Stir at a low to
moderate speed using a Teflon covered stir bar and a stir plate or motorized stirrer. If the reading falls within
the standard range determined in 4.6.8.5.4, then record value. Otherwise, repeat 4.6.8.5.4 with appropriate
standards to bracket the sample. For multiple measurements, remove electrode, rinse with Type 1 water,
and then wipe dry with a chemwipe before continuing to the next reading. Repeat cleaning process between
readings and between samples.

4.6.8.5.7 Repeat 4.6.8.5.6 for two additional measurements and record the mean. Ensure probe is cleaned between
readings.

4.6.8.5.8 Repeat 4.6.8.5.6 and 4.6.8.5.7 for the two other unknown samples and blank.

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4.6.8.6 Results

4.6.8.6.1 Report the mean value in micrograms/milliliters of fluoride for each of the three samples and blank as parts
per million (ppm) of F¯ in solution.

4.6.8.6.2 Report the mean value in ppm of F¯ as the concentration of extractable fluoride in the wire insulation in
micrograms of F¯/gram of sample, unless otherwise specified by the Detailed Specification.

4.6.8.6.3 Calculation: (to report ppm of F¯ as the concentration of extractable fluoride in the wire insulation in
micrograms of F¯/gram of sample).

F¯ = ((Fs – Fb) / W) x S

Where:
F¯ = the concentration of extractable fluoride in the wire insulation in micrograms/gram,
ppm F¯ = the concentration of extractable fluoride in the wire insulation in micrograms/gram.
Fs = the amount of fluoride reported by ISE in μg.
Fb = the amount of fluoride in the blank in μg.
W = the weight of the original wire (or insulation) sample in grams.
S i= solution amount that includes TISAB and soak solution which should be 40 milliliters.

4.6.8.7 Information Required in the Detail Specification

Number of specimens and wire size to be tested. Also maximum acceptable level of extractable fluoride in ppm or
micrograms of F¯ per gram of sample.

4.6.8.8 Precision Bias

Proper calibration with standards is critical to the outcome of this test. Use of methods other than ISE to measure fluoride
concentration is not recommended.

4.6.9 Method 609, Nitric Acid Immersion

4.6.9.1 Scope

This test determines the ability of a wire to resist degradation when exposed to a strong acid. This test utilizes red fuming
nitric acid for this test. Failures are defined as dielectric breakdowns of the insulation.

4.6.9.2 Specimen

Test samples shall be a minimum of three specimens at least 24 inches in length.

4.6.9.3 Test Equipment

4.6.9.3.1 One Pyrex, stainless steel, or similar inert vessel to contain the acid in a sufficient quantity to completely
immerse the wire within six inches of each end.

4.6.9.3.2 Sufficient quantity of red fuming nitric acid with a specific gravity of 1.52.

4.6.9.4 Test Procedures

4.6.9.4.1 The test specimens shall be immersed to within 1.50 inches of each end in red fuming nitric acid (specific
gravity 1.52) at room temperature for 8 hours. Adequate ventilation shall be provided for all fumes.

4.6.9.4.2 Following the acid immersion, the specimens shall be removed and immersed, except for 1.50 inches at each
end, for 1 hour in water at room temperature containing 0.5 percent of Aerosol OT or equivalent wetting
agent.
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4.6.9.4.3 The specimens in the water solution shall then be subjected to the wet dielectric test method 510.

4.6.9.5 Results

Report the results of the wet dielectric test.

4.6.9.6 Information Required in the Detail Specification

List if this test is applicable for the wire type specified.

4.6.9.7 Precision Bias

None.

4.7 Test Methods Group 700 - Mechanical Tests

4.7.1 Method 701, Abrasion

A test method for the abrasion resistance of wire has not been included in this standard. It has been shown that no one
test can reproduce the various conditions of abrasion that can occur in an aerospace vehicle. The various tests that have
been tried over many years have shown poor reproducibility.

4.7.2 Method 702, Cold Bend

4.7.2.1 Scope

This test is to be used to evaluate a wire specimen's resistance to cracking at low temperatures while being wrapped
around a mandrel.

4.7.2.2 Specimen

A 36 in ± 1/2 in (914 mm ± 13 mm) specimen shall be used in this test.

4.7.2.3 Test Equipment

4.7.2.3.1 A chamber capable of maintaining -65 °C ± 3 °C (-85 °F ± 5 °F) and allows mechanical access for wrapping
the specimen around a mandrel.

4.7.2.3.2 A rotatable mandrel for installation into the above chamber.

4.7.2.3.3 A sharp blade to remove the specimen insulation.

4.7.2.3.4 A test weight sufficient to hold the specimen taut on the mandrel.

4.7.2.4 Test Procedure

One end of the specimen shall be secured to the rotatable mandrel in the cold chamber and the other end to the test
weight sufficient to hold the specimen taut on the mandrel. Provisions shall be made for rotating the mandrel by means of
a handle or control located outside the chamber. The specimen of wire and the mandrel shall be conditioned at -65 °C ±
3 °C (-85 °F ± 5 °F) for 4 h. At the end of this period and while both mandrel and specimen are still at this low
temperature, the specimen shall be wrapped helically, for its entire length or for 20 turns, whichever is the lesser number
of turns, around the mandrel without opening the chamber. The bending shall be accomplished at a uniform rate of 2 rpm
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± 1 rpm. At the completion of this test the specimen shall be removed from the cold box and from the mandrel without
straightening. Allow the specimen to return to room temperature. The specimen shall be examined for cracks in the
insulation. Allow specimen to return to room temperature and then remove the insulation for a distance of 1 in ± 1/8 in
(25.4 mm ± 3.2 mm) from each end of the specimen and subject the specimen to Method 510 - Voltage Withstand Test
with the bent portion submerged.

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4.7.2.5 Results

Report any cracking or the results of Method 510 - Voltage Withstand as required.

4.7.2.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested and mandrel size and weight required for each wire size and type.

4.7.2.7 Precision Bias

This test can be used for design evaluation or for process control. Mandrel sizes and weights will differ for each.

4.7.3 Method 703, Dynamic Cut-Through

4.7.3.1 Scope

This test is to be used to evaluate the resistance of the insulation of a wire specimen to the penetration of a cutting
surface.

4.7.3.2 Specimen

The specimen shall be 18 in (450 mm) in length for this test.

4.7.3.3 Test Equipment

See Section 22.2 of ASTM D 3032 for the necessary equipment to perform this test. For the elevated temperature test,
the cut through apparatus must be fixed inside the test chamber so that the test can be performed without disturbing the
thermal environment. The standard cutting edge shall be a 20 ml diameter sewing needle.

4.7.3.4 Test Procedure

See Sections 22.4 through 22.5 of ASTM D 3032 for the test procedure.
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4.7.3.5 Results

Report the force to cut-through each specimen and the temperature of the test.

4.7.3.6 Information Required in the Detail Specification

Number and wire size of the specimens to be tested and test temperature.

4.7.3.7 Precision Bias

This method has not had the benefit of any round-robin testing to determine precision.

NOTE: ASTM D 3032 states that precision for this test is not yet known and that optional cutting edges may be
considered for different sizes of wires. If other cutting edges are used they should be covered in the detail
specification sheet.

4.7.4 Method 704, Flex Life

4.7.4.1 Scope

This test is used to determine the ability of insulated wire to withstand repeated mechanical flexing. Step 1 procedure is to
determine the number of flex cycles to catastrophic failure, which will be used for the baseline value for step 2. Step 2 is
to more accurately predict the number of cycles when conductor strand breakage can begin.

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4.7.4.2 Specimen

The specimens shall be size 22 wires prepared in accordance with 4.7.4.2.1 and 4.7.4.2.2.

NOTE: Prior to testing, check the dielectric strength of the insulation on each specimen. Use test method 510 of AS4373,
eliminating the 4 h soak. Discard and replace all specimens that fail.

4.7.4.2.1 Step 1, Flex to Failure

Six 18 in specimens are required. Attach a Number 10 ring tongue terminal to one end of each specimen, be sure the
terminal is attached to the conductor only. The terminal is used to attach weights to the specimens under test.

4.7.4.2.2 Step 2, Predetermined Number of Cycles

Twelve 18 in specimens are required. Specimens are to be prepared as described in 4.7.4.2.1.

4.7.4.3 Test Equipment

Construct the test fixture as shown in Figure 19. The PTFE coated mandrels shall have a diameter approximately six
times the outer diameter of the wire specimen. The flex arm shall rotate +90 degrees from vertical; a total of 360 degrees
of motion constitutes 1 cycle. Flex rate shall be 25 to 30 cpm. Weights having a total minimum value of 4.0 lb shall be
attached to the conductor of the specimen and placed between the guide rods which are used to eliminate weight swing.

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FIGURE 19 - FLEX LIFE TEST SETUP

4.7.4.4 Test Procedure

4.7.4.4.1 Step 1, Flex to Failure

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Install the specimen in the fixture, attach the weight and flex at 25 to 30 cpm. Flex until complete separation of insulated
wire occurs and the weight drops (catastrophic failure).

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4.7.4.4.2 Step 2, Predetermined Number of Cycles

Using the baseline established from Step 1, Step 2 specimens shall be tested in sets of two with increasing number of flex
cycles. Perform the cycle testing on the twelve specimens by installing the specimens in the fixture, attach the weights
and flex at 25 to 30 cpm. Flex for the specified number of cycles unless catastrophic failure occurs first.

The first 2 specimens shall be cycled to 50% of the baseline established by Step 1. Stop the test, remove the specimens
from the fixture and examine each specimen by removing the insulation in the area of flexure, count and record the
number of broken strands

Continue this process increasing the cycles by 10% on two each of the remaining specimens (e.g., 60% 70% 80% 90%)
of the baseline value. More than two specimens may be tested at one time provided the cycling can be halted periodically
to remove the next specimens for examination.

4.7.4.5 Results

4.7.4.5.1 Step 1, Flex Until Failure

Record the number of cycles to failure for each specimen. Establish the baseline for Step 2 testing by determining the
average number of cycles to failure of the specimens tested.

4.7.4.5.2 Step 2, Predetermined Number of Cycles

Describe and/or photograph the condition of each specimen at the point of flexure. Note the condition of the insulation
and record the number of broken strands of the conductor for each specimen. Note any catastrophic failures and the
number of cycles when occurred.

4.7.4.6 Information Required in the Detailed Specification

The value of the weight (recommend 20% of the breaking strength) to be used for each gauge size tested, shall be
provided, if other than wire size 22 is to be tested.

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4.7.4.7 Precision Bias

This procedure does not have the benefit of round-robin testing.

NOTE: This test method was developed to better define when flexing causes strand breakage in the conductor as
catastrophic failure alone can be misleading.

4.7.5 Method 705, Insulation Tensile Strength and Elongation

4.7.5.1 Scope

This test is to be used to produce tensile property data for process control purposes of extruded electrical insulation.

4.7.5.2 Specimen

See Section 17.3 of ASTM D 3032 for specimen preparation.

As a suggestion for insulated wire constructions whose conductor is smaller than 12 mm2 (6 AWG), the test specimen
shall consist of a length of the entire section of the insulation with the conductor removed. A method for removing the
conductor from the finished wire specimen is to circumferentially sever a 4 in segment of insulation from the center of a
24 in specimen. Then slowly elongate the conductor beyond its point of elasticity. Cut the conductor and remove the
unstressed segment of insulation.

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4.7.5.3 Test Equipment

See Section 17.2 of ASTM D 3032 for test apparatus.

4.7.5.4 Test Procedure

See Sections 17.4 through 17.5 of ASTM D 3032 for the test procedure. The jaw separation shall be 1 in ± 0.1 in and the
jaw separation speed shall be 2 in ± 0.2 in per minute. If the jaw separation must be adjusted to allow for extensometers,
the jaw separation speed shall be adjusted to maintain the same strain rate.

4.7.5.5 Results

Report rate of jaw separation, tensile strength, and elongation.

4.7.5.6 Information Required in the Detail Specification

Rate of jaw separation, minimum allowable tensile strength and elongation, temperature of the test, any special
conditioning requirements, number and wire size of specimens to be tested.

4.7.5.7 Precision Bias

Reference ASTM D 412 for the precision of this test. It should be noted that a variance of ±10 to 20% from the average
value is typical for this test, and that different materials will typically have higher or lower variances that cannot be
predicted in advance of the test.

4.7.6 Method 706, Notch Propagation

4.7.6.1 Scope

This test is to be used to determine the susceptibility of finished wire to withstand notching or nicking without propagating
the notch completely through the insulation to the conductor.

4.7.6.2 Specimen

A 6 in (150 mm) specimen shall be used for this test.

4.7.6.3 Test Equipment

4.7.6.3.1 A notching tool as described in Figure 20.

4.7.6.3.2 A 6X mandrel for wrapping of the specimen.

4.7.6.4 Test Procedure

A notching tool shall be built for each of the notch depths required. Use the tool to notch a 6 in (150 mm) specimen.
Wrap and reverse wrap the entire specimen around a 6X mandrel. Visually examine the specimen at the end of each 10
cycles to detect when the notch penetrates to the conductor. The wrap and unwrap cycle shall continue until the
conductor has been exposed (failure) or until 100 cycles have been completed. The number of cycles to failure shall be
recorded.

4.7.6.5 Results

Report the number of cycles to failure and the notch depth for each failure.

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FIGURE 20 - NOTCHING TOOL

4.7.6.6 Information Required in the Detail Specification

Number and wire size of the specimens to be tested and notch depth(s).

4.7.6.7 Precision Bias

This test method has not had the benefit of any round-robin testing to determine precision.

NOTE: With some constructions it may be difficult to visually detect the conductor, 10X visual magnification may be used.

4.7.7 Method 707, Stiffness and Springback

4.7.7.1 Scope

This test is used to generate data for comparison between specimens using the same stiffness and springback apparatus.
Stiffness and springback affect harness manufacturing, harness and cable installation, and maintenance operations.

4.7.7.2 Specimen

An 8 in (203 mm) finished wire specimen shall be used for this test. The specimen shall be straightened prior to testing to
remove the majority of curvature from storage on the supply reels.

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4.7.7.3 Test Equipment

4.7.7.3.1 An apparatus consisting of a pivoting arm mounted in the center of a scaled plate shall be fabricated
according to Figures 21 and 22.

FIGURE 21 - TEST FIXTURE FOR STIFFNESS AND SPRINGBACK TEST

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FIGURE 22 - STIFFNESS AND SPRINGBACK TEST FIXTURE BASE PLATE

4.7.7.3.2 A torque meter/wrench.

4.7.7.3.3 Alligator clip and string or equivalent.

4.7.7.4 Test Procedure

The test fixture shall be placed on a flat surface with the edge of the plate on the side of the wire specimen exit point from
the hub located next to a clear vertical drop. The span selector shall be adjusted for the desired length of bend. The
pivot arm shall be rotated to the 90 degree position (at rest location). One end of the wire specimen shall be terminated
with a spade lug. The non-terminated end of the wire specimen shall be routed through the hole in the test fixture hub.
The spade lug shall be attached at the base of the span selector. A weight as listed in Table 16 shall be attached to the
non-terminated end of the wire specimen using an alligator clip and string. The weight shall be hung over the edge of the
plate such that the wire specimen and string are directed along the same radial line as the hole in the hub.

TABLE 16 – STIFFNESS AND SPRINGBACK LOADS

Wire Size Weight (lb) Weight (kg)

22 1.0 0.45
26 0.5 0.23

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Using the torque meter, slowly rotate the pivot arm to the 0 degree position. The maximum torque value observed during
the bending is the stiffness. The pivot arm shall be held at the 0 degree position for about 10 s. While holding the arm,
the torque meter shall be removed. While maintaining finger contact with the arm, the arm shall be allowed to slowly
rotate back toward the 90 degree position due to any tension in the wire specimen. Allow 10 s after springback action
stops. The indicated angle is the springback.

4.7.7.5 Results

Report the torque needed to pull the specimen through the 90 degree bend and the degrees of springback.

4.7.7.6 Information Required in the Detail Specification

Number and wire size of the specimens to test and span selector length.

4.7.7.7 Precision Bias

This is a new method that has not had the benefit of any round-robin testing to determine precision. Limited testing
indicates the following will bias comparison test results:

a. Different conductor constructions (unilay, concentric), materials (copper, aluminum, alloy, plating), sizes (i.e., 22 AWG
versus 24 AWG), and different conductor stranding.

b. Different wall thickness of insulating material.

c. Different span selector settings (the shorter the span the more pronounced the performance difference between
constructions).

4.7.8 Method 708, Mandrel and Wrapback Test

4.7.8.1 Scope

This test is to be used to determine whether a specimen will crack when wrapped upon itself or around a mandrel. The
wrapback test has been used for process control purposes with wires insulated with PTFE to determine the degree of
sintering of the insulation.

4.7.8.2 Specimen

Use a 12 in (305 mm) finished wire specimen for the wrapback test and a 12 in (305 mm) plus the additional length
required for winding on the mandrel for the mandrel test.

4.7.8.3 Test Equipment

4.7.8.3.1 An air oven capable of maintaining the specified temperatures and tolerances.

4.7.8.3.2 Test mandrels as called out in the Detail Specification.

4.7.8.4 Test Procedure

4.7.8.4.1 Wrap Back Test

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This test applies to wire sizes 10 through 30. The 12 in (305 mm) specimen shall be bent back on itself at the mid-portion
on a radius not less than the radius of the wire. One end of the specimen shall be wound tightly around the other end as
a mandrel for a total of four close turns and placed in an elevated temperature oven for a time period as specified in the
Detail Specification (see Figure 23). After removal from the oven, the specimen shall be examined visually, without the
aid of magnification, for cracks.

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FIGURE 23 - WRAP BACK TEST

4.7.8.4.2 Mandrel Test

This test applies to wire sizes 0000 through 8. The specimen, with a length of 12 in (305 mm), plus the additional length
required for winding on the mandrel, shall be wound tightly for two close turns around a mandrel diameter and
temperature as specified in the Detail Specification. The winding shall be accomplished manually and shall be in the
middle portion of the specimen so that 6 in (152 mm) of each end shall remain straight. The specimen shall then be
removed from the mandrel without unwinding, examined visually for cracks, and subjected to the Voltage Withstand Test
Method No. 510.

4.7.8.5 Results

Report any cracking of the insulation. Report the Voltage Withstand Test results for the Mandrel test of Procedure
4.7.8.4.2.

4.7.8.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested, temperature and time at temperature for the Wrapback Test, and
mandrel diameter and test temperature for the Mandrel Test.

4.7.8.7 Precision Bias

The wrapback test has not had the benefit of round-robin testing to determine its suitability for insulating materials other
than PTFE.

4.7.9 Method 709, Wrinkle Test

4.7.9.1 Scope

This test is to be used to evaluate the quality of insulation application and the ability of the insulation to resist wrinkling. It
is applicable only to wire sizes 10 and smaller.

4.7.9.2 Specimen

The test specimen shall be a 12 in (305 mm) length of finished wire.

4.7.9.3 Test Equipment

4.7.9.3.1 A device to provide 3X magnification.

4.7.9.3.2 Steel mandrels sized appropriately for the specimens tested.

4.7.9.4 Test Procedure

Bend the wire specimen one full turn around the mandrel as specified in Table 17.

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TABLE 17 – WRINKLE TEST MANDREL SIZE

Mandrel Mandrel
Wire Size Size
Size inch Mm
24-30 1/8 3.2
22 3/16 4.76
20 1/4 6.4
18 5/16 7.9
16 3/8 9.5
14 1/2 12.7
12 3/4 19.0
10 1.0 25.4

The wire specimen shall then be examined at 3X magnification for wrinkles. It may be examined on the mandrel or after
removal from the mandrel leaving the coil intact.

4.7.9.5 Results

Report wrinkling for each specimen tested.

4.7.9.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested.

4.7.9.7 Precision Bias

This is a process control test.

4.7.10 Method 710, Durability of Wire Manufacturer's Color and/or Identification

4.7.10.1 Scope

This test shall be used to evaluate the durability of color/markings applied to the wire for coding. This test is not
applicable for braided wire constructions.

4.7.10.2 Specimen

A 6 in (152 mm) finished wire specimen shall be used.

4.7.10.3 Test Requirement

4.7.10.3.1 The marking durability test fixture shall be designed to hold a 6 in (152 mm) specimen of finished wire firmly
clamped in a horizontal position with the upper longitudinal surface of the specimen fully exposed. The
durability apparatus, such as the GE Scrape Abrader Apparatus or equivalent, shall be capable of rubbing a
small cylindrical sewing needle, 0.025 in ± 0.002 in (0.63 mm ± 0.05 mm) in diameter, repeatedly over the
upper surface of the wire. The longitudinal axis of the needle and the specimen must be at right angles to
each other. A weight affixed to a jig above the sewing needle shall control the weight normal to the surface of
the insulation. A motor-driven, reciprocating cam mechanism and counter shall be used to deliver an
accurate number of abrading strokes in a direction parallel to the axis of the specimen. The length of the
stroke shall be 3/8 in (9.5 mm) and the frequency of the stroke shall be 120 strokes (60 stroking cycles) per
minute.

4.7.10.3.2 After each test the sewing needle should be examined for wear and replaced if worn.

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4.7.10.4 Test Procedure

NOTE: The 0.5 lb (0.227 kg) weight and the 250 strokes (125 cycles) stated in this procedure are default values if none
are provided in the Detail Specification.

In performing the test, the specimen shall be mounted in the specimen clamp and a 0.5 lb (0.227 kg) weight shall be
applied through the abrading sewing needle to the colored or marked surface. The counter shall be set at zero and the
drive motor started. The specimen shall be subjected to 250 strokes (125 cycles) and shall then be examined. If a
continuous line of solid color insulation coating or of the stripe, band, or printed marking, as applicable, has been removed
or obliterated by the needle, the specimen shall be considered failed. Three specimens shall be tested from each
specimen unit and failure of any specimen shall constitute failure of the specimens unit.

4.7.10.5 Results

Report any specimen that fails.

4.7.10.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested.

4.7.10.7 Precision Bias

This is a process control test. The surface finish on the sewing needle may affect the results of this test.

4.7.11 Method 711, Durability and Legibility of Wire Installer's Identification

4.7.11.1 Scope

This test is used to determine the capability of finished insulated wire to be legibly and permanently marked by the
installer. The test will also determine if the marking process can chemically or physically degrade the insulation. The
Aerospace Vehicle Wiring Specification, AS50881, imposes the following requirements upon identification marking on
wires: “the characters shall be legible and permanent and the method of identification shall not impair the characteristics
of the wire.”

4.7.11.2 Specimen

Specimens shall be long enough to be properly processed by the marking machines of choice. Allow, as a minimum, 3 ft
(92 cm) of specimen per fluid in the immersion test (1 set). Four specimen sets are required.

4.7.11.3 Test Equipment

4.7.11.3.1 Wire Marking Machines designed for marking wire insulation

4.7.11.3.2 Test Fluids

4.7.11.3.3 Test-Fluid Heating Apparatus

4.7.11.3.4 Ultraviolet/Condensation Chamber

4.7.11.3.5 Heat Aging Oven

4.7.11.3.6 Abrasion Tester (General Electric #51204061, Wellman #31581238G1 or Equivalent)

4.7.11.3.7 Wet Dielectric Test Apparatus

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4.7.11.4 Test Procedure

4.7.11.4.1 Wire Marking

Mark all specimens with repeated groupings of an alphanumeric character string using the marking system according to
the governing process standard, or according to the equipment manufacturer’s operating instructions if there is not a
process standard. The print string must include a minimum of six different alphanumeric characters. Special marks such
as bar codes may also be made. Gaps between groups of marks shall be no longer than 3 in (7.6 cm). Any necessary
curing shall be performed as part of the marking process.

4.7.11.4.2 Visual Examination of Marking

A marked test specimen shall be wiped with a soft, lint-free cloth, placed flat on a work surface and visually examined
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from a distance of 15 in ± 2 in (38 cm ± 5 cm) without additional magnification (other than what is normally used for the
aided eye). A light source shall be used which can provide an ambient nominal illumination of 30 ft candles. For initial
examination only, a magnification of between 6 and 10 times shall be used to inspect for any mechanical damage to the
insulation or conductor.

4.7.11.4.3 Abrasion Durability

All specimens shall be mounted in the specimen clamp of the scrape abrasion tester so that the abrading needle of the
fixture (Figure 24) will make contact with the mark. A weight of 500 g, including the weight of the fixture shall be applied
through the needle to the identification marking. The abrading needle shall be 0.025 in ± 0.002 in (0.064 cm ± 0.005 cm).
The specimen shall be subjected to 125 cycles (250 strokes). Perform a visual examination in accordance with 4.7.11.4.2.
The specimens shall then be divided into three groups or four groups if the weathering resistance test is specified. Each
test specified in 4.7.11.4.4 through 4.7.11.4.7 requires one group of specimens.

4.7.11.4.4 Thermal Aging

Specimens shall be thermally aged for 166 h at rated temperature. Perform a visual examination test in accordance with
4.7.11.4.2 and, if required in the detail specification, a marking contrast examination in accordance with 4.7.11.4.8.

4.7.11.4.5 Fluid Immersion

One 3-ft (1 m) specimen of each type of mark shall be immersed in the first fluid. A second 3-ft specimen of each type of
mark shall be immersed in the second fluid, and so on. Perform a visual examination in accordance with 4.7.11.4.2 and,
if required in the detail specification, a marking contrast examination in accordance with AS4373 Method 1001 and an
abrasion durability test in accordance with 4.7.11.4.3.

4.7.11.4.6 Weathering Resistance

When required by the detail specification, specimens shall be subjected to weathering resistance tests per ASTM G 53.
Specimens shall be subjected to 14 cycles of exposure to ultraviolet light and condensation. Each cycle consists of 8 h of
UV exposure at 63 °C followed by 4 h of condensation at 400 °C. Perform a visual examination in accordance with
4.7.11.4.2 and, if required in the detail specification, a marking contrast examination in accordance with AS4373 Method
1001.

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FIGURE 24 - CLAMP DEVICE FOR PRINT DURABILITY TEST

4.7.11.4.7 Wet Dielectric

Perform the wet dielectric test per ASTM D 3032 Section 5, except that a minimum voltage of 2.5 KV, 60 Hz, shall be
applied for 1 min. Voltage shall be ramped up and down at a 500 V/s rate.

4.7.11.5 Results

Determine if the characters remain legible after the abrasion durability test. There shall be no continuous line of erasure
or obliteration through the marking. Record results. Note if any visible degradation has occurred, if the mark is still
readable, if the mark is totally obliterated, etc.; if the bar code is used, report whether the bar code remains machine
readable. Note that on small gauge wire, even fresh alphanumeric characters may be difficult to read. Report the results
of each specimen on the wet dielectric test (pass or fail).

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4.7.11.6 Information Required in the Detail Specification

4.7.11.6.1 Wire type and size to be marked.

4.7.11.6.2 Marking process to be tested. If special marks such as bar codes are to be tested, this must also be
specified.

4.7.11.6.3 Fluids to be used in immersion test. Fluid temperature and duration of immersion must also be specified for
each fluid.

4.7.11.6.4 Weathering Resistance test is optional. Its inclusion must be specified in the detail specification.

4.7.11.6.5 Specify weight and number of cycles used for the abrasion durability test on tape construction wire and cable.

4.7.11.6.6 Test to be performed and sequence of testing, if different then as specified herein.

4.7.11.7 Precision Bias

This is a process control test, but may be used as a component performance test. The surface finish on the sewing
needle may affect the results of this test. The number of cycles and weight used for the abrasion durability test should,
where applicable, comply with the requirement for durability of wire manufacturer's identification for that insulation
construction.

4.7.12 Method 712, Bend Test

4.7.12.1 Scope

This test provides a method to determine the sensitivity of the insulation to cracking.

4.7.12.2 Specimen

A 24 in (610 mm) wire specimen shall be used. (Longer lengths may have to be used on some of the large size
specimens.)

4.7.12.3 Test Equipment

Mandrels and weights as specified in Table 18.

4.7.12.4 Test Procedure

In a 20 to 25 °C (68 to 77 °F) environment, one end of the specimen shall be secured to the mandrel and the other end to
the load weight given above. The mandrel shall be rotated until the full length of the specimen is wrapped around the
mandrel and is under tension with adjoining coils in contact. The mandrel shall then be rotated in reverse direction until
the full length of the wire, which was outside during the first wrapping, is now next to the mandrel. This procedure shall
be repeated until two bends in each direction have been formed in the same section of the wire. The outer surface of the
wire shall then be observed for cracking of the insulation.

4.7.12.5 Results

Report the mandrel size and weight used and any observation on insulation cracking.

4.7.12.6 Information Required in the Detail Specification

None.

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TABLE 18 – BEND TEST MANDRELS AND LOADS

Wire Nominal Diameter Load Weight Load Weight

Size of Mandrel lb +3% kg +3%
30 50X 0.50 0.227
28 50X 0.50 0.227
26 50X 0.50 0.227
24 50X 0.50 0.227
22 50X 1.00 0.454
20 50X 1.00 0.454
18 50X 1.00 0.454
16 50X 1.00 0.454
14 50X 3.00 1.36
12 40X 3.00 1.36
10 40X 3.00 1.36
8 30X 4.00 1.81
6 30X 4.00 1.81
4 30X 4.00 1.81
2 30X 6.00 2.72
1 30X 6.00 2.72
0 20X 6.00 2.72
00 20X 8.00 3.63
000 20X 8.00 3.63
0000 20X 12.00 5.44

4.7.12.7 Precision Bias

This is an established test.

4.7.13 Method 713, Circumferential Insulation Elongation

4.7.13.1 Scope

This test determines the elongation of insulation of a wire in a circumferential (radial) direction. This test was developed
to measure the resistance of polytetrafluoroethylene (PTFE) and mineral filled PTFE to rupture when under a radial
stress.

4.7.13.2 Specimen

Three 1.0 to 1.5 inch slugs of insulation are needed for this test.

4.7.13.3 Test Equipment

4.7.13.3.1 Wire strippers to remove an undamaged insulation slug.

4.7.13.3.2 A sharp razor blade or cutting tool.

4.7.13.3.3 Power driven apparatus capable of driving test cone at 20 ± 2 inches/minute.

4.7.13.3.4 Circumferential Elongation Apparatus (see Figure 25).

4.7.13.3.5 Specimen holding block (see Figure 27).

4.7.13.3.6 Scale, strip chart, or other means to measure the length the cone travels at specimen).

4.7.13.4 Sample Preparation

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4.7.13.4.1 A 1.0 to 1.5 inch slug or insulation shall be removed from the conductor. Care shall be taken to prevent
scratching, crimping, stretching or otherwise damaging the insulation. The diameter of the exposed
conductor should be measured to the nearest 0.001 inch. Cut five cylindrical test specimens 0.125 inch + .02
inch in length from the insulation slug using a sharp razor blade or an appropriate sample preparation fixture.
Both ends of the cylindrical test specimens shall be cut square.

4.7.13.5 Test Procedure

4.7.13.5.1 Slide a specimen onto the cone until it just touches the edges of the cone. The cone should be attached to a
movable crosshead as shown in Figure 26. Position the specimen holding block perpendicular to the cone as
shown in Figure 27. The overall test apparatus is shown in Figure 26. Align the cone tip and the appropriate
sized hole of the specimen holding block for the wire size being tested. Move the cone through the stationary
specimen at a uniform speed of 20 + 2 inches/minute until the specimen ruptures. Determine the length of
the cone that has passed through the specimen causing rupture. The percent circumferential elongation is
calculated as follows:

% CE = (2 x L x Tan Į - CD) x l00

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Where:
% CE = Percent circumferential elongation
L = Cone length required to rupture specimen (inches).
CD = Conductor Diameter (inches).
Į = Measured cone angle taper (degrees).
2 x L x Tan Į = Inner diameter of the test specimen at rupture (inches).

4.7.13.5.2 Test five specimens.

4.7.13.6 Results

Report the average value of the 5 specimens tested.

4.7.13.7 Information Required in the Detail Specification

The detailed specification shall list the applicability of this test.

4.7.13.8 Precision Bias

This method has been actively used in aerospace specification sheets for 30 years.

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FIGURE 25 – CIRCUMFERENTIAL ELONGATION APPARATUS

FIGURE 26 – TEST MANDREL FOR CIRCUMFERENTIAL ELONGATION

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FIGURE 27 – SPECIMEN HOLDING BLOCK

4.7.14 Method 714, Wrap (Mandrel Wrap)

4.7.14.1 Scope

This test determines if a wire is susceptible to cracking when wrapped around a mandrel. This test has been applied to
many wire types especially over braided or tape wrapped wires. This test or the wrap back test is usually required in the
individual wire specification.

4.7.14.2 Specimen

Test sample shall consist of a wire specimen approximately 2 feet in length.

4.7.14.3 Test Equipment

4.7.14.3.1 Test mandrels of the size indicated either below or in the specification sheet.

4.7.14.3.2 Means to secure the wires to the test mandrels.

4.7.14.4 Test Procedure

4.7.14.4.1 Each specimen of finished wire, with a length of 12 inches plus the additional length required for winding on
the mandrel, as specified in the table or in the individual specification, shall be wound tightly for two close
turns around a mandrel. Refer to Table 19 for mandrel sizes to be used by wire size. The winding may be
accomplished manually or automatically and shall be in the middle portion of the specimen so that at least six
inches of each end shall remain straight. The specimen shall then be removed from the mandrel, examined
visually for cracks, and subjected to the wet dielectric test method 510.

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TABLE 19 – WRAP TEST MANDRELS

Mandrel Diameter Mandrel Diameter

WIRE SIZE (inches) (±3%) WIRE SIZE (inches) (±3%)
30 0.125 10 0.375
28 0.125 8 0.750
26 0.125 6 1.00
24 0.125 4 1.25

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22 0.125 2 2.00
20 0.125 1 2.50
18 0.250 0 3.00
16 0.250 00 4.00
14 0.375 000 5.00
12 0.375 0000 6.00

4.7.14.5 Results

Report any observed cracks and the results of the wet dielectric test.

4.7.14.6 Information Required in the Detail Specification

Specifications shall list the required mandrel size if different than the preferred sizes listed in the table of this test method.

4.7.14.7 Precision Bias

None.

4.8 Test Methods Group 800 - Thermal Tests

4.8.1 Method 801, Flammability

4.8.1.1 Scope

This test evaluates a finished wire specimen's burning characteristics.

4.8.1.2 Specimen

A 24 in (610 mm) finished wire specimen shall be used for this test.

4.8.1.3 Test Equipment

4.8.1.3.1 A Bunsen-type gas burner with a 1/4 in (6.35 mm) inlet, a needle valve in the base for gas adjustment, a bore
of 3/8 in (9.53 mm) nominal, and a barrel length of approximately 4 in (10.16 cm) above the air inlets.

4.8.1.3.2 A thermocouple pyrometer.

4.8.1.3.3 CP methane or equivalent.

4.8.1.3.4 A specimen holder designed so that the lower end of a 24 in (60.96 cm) wire specimen is held by a clamp,
while the upper end of the specimen passes over a pulley and can be suitably weighted to hold the specimen
taut at an angle of 60 degrees with the horizontal, in a plane parallel to and approximately 6 in (15.24 cm)
from the back of the chamber (see 4.8.1.3.5).

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4.8.1.3.5 A test chamber approximately 1 ft (30.48 cm) square by 2 ft (60.96 cm) in height, open at the top and front to
provide adequate ventilation for combustion but to prevent drafts.

4.8.1.3.6 Facial tissue conforming to A-A-1 505 or equivalent.

4.8.1.4 Test Procedure

The specimen shall be marked at a distance of 8 in (20.32 cm) from its lower end to indicate the point for flame
application and shall be placed in the specified 60 degree position in the test chamber. The lower end of the specimen
shall be clamped in position in the specimen holder and the upper end shall be passed over the pulley of the holder and
weighted with the weight sufficient to keep the wire taut. If specified in the detailed specification, a sheet of the facial
tissue shall be suspended taut and horizontal 9.50 in below the point of application of the flame to the wire specimen, so
that any material dripping from the wire specimen shall fall upon the tissue. The flame shall be 3 in with a 1 in inner cone.
The flame temperature shall be at least 954 °C at its hottest point. With the burner held perpendicular to the specimen
and at an angle of 30 degrees from the vertical plane of the specimen, the hottest portion of the flame shall be applied to
the lower side of the wire at the test mark. The period of test flame application shall be 30 s for all sizes of wire and the
test flame shall be withdrawn immediately at the end of that period.

4.8.1.5 Results

Report the distance of flame travel, the time of burning after removal from the test flame and the presence of any
incendiary drips from the wire during testing. Breaking of the wire specimen for size 24 and smaller shall not be
considered as failure provided the requirements for flame travel limits, duration of flame, and absence of incendiary
dripping are met.

4.8.1.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested.

4.8.1.7 Precision Bias

This is an established test.

4.8.2 Method 802, High Pressure/High Temperature Air Impingement (Burst Duct)

4.8.2.1 Scope

This test is to be used to evaluate the effects of a burst hot air duct on the insulation of a finished wire specimen.

4.8.2.2 Specimen

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A seven-wire harness shall be used in this test.

4.8.2.3 Test Equipment

4.8.2.3.1 A cylindrical tube of 1 in (25 mm) inner diameter, capable of carrying 315 °C ± 3 °C (600 °F ± 5 °F) air at 70 to
80 psi shall be used. A 0.015 in ± 0.0015 in (0.38 mm ± 0.038 mm) wide slit should be cut along the length of
the tube for 1.00 in ± 0.010 in (25 mm ± 0.25 mm) to enable the air to impinge upon a wire harness.

4.8.2.3.2 A SAE AS3320 - 7.5 Amp circuit breaker.

4.8.2.3.3 A power supply.

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4.8.2.4 Test Procedure

The seven-wire harness shall be constructed as shown in Figure 28. The wire harness shall be firmly mounted above and
perpendicular to the slot in the tube with a distance of 1.0 in ± 0.125 in (25 mm ± 3.2 mm) between them. Apply power to
the harness and then initiate air flow through the tube. Air temperatures shall be maintained at 315 °C ± 3 °C (600 °F ±
5 °F) and air pressure shall be maintained at 70 to 80 psi. After 2 h, remove power, interrupt air flow, and determine if any
of the following conditions exist or existed during the test.
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FIGURE 28 - ELECTRICAL CONNECTIONS FOR TEST METHOD 802

a. Circuit breaker open (interrupted)

b. Bare conductor visible

c. Conductor broken

d. Continuous flaming for more than 3 s

Existence of one or more of these conditions constitutes failure of the test and shall be recorded.
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4.8.2.5 Results

Report any of the aforementioned conditions in 4.8.2.4.

4.8.2.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested.

4.8.2.7 Precision Bias

4.8.2.7.1 Due to differences in vehicle performance, changes in pressure and temperatures for different vehicles
should be considered for this test, and the test adjusted to reflect these conditions.

4.8.2.7.2 This method has not had the benefit of any round-robin testing to determine precision.

4.8.3 Method 803, Smoke Quantity

4.8.3.1 Scope

This method provides a test for determining the smoke generated from an insulated wire when exposed to radiant heat
and to flame for 20 min.

4.8.3.2 Specimen

See Section 7.3.2.5 of ASTM F 814.

4.8.3.3 Test Equipment

See Section 6 of ASTM F 814.

4.8.3.4 Test Procedure

See Section 10 of ASTM F 814.

4.8.3.5 Results

See Section 12 of ASTM F 814.

4.8.3.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested.

4.8.3.7 Precision Bias

See Section 13 of ASTM F 814 and the X3 Commentary (pages 890-894) of ASTM F 814.

4.8.4 Method 804, Relative Thermal Life and Temperature Index

4.8.4.1 Scope

This method provides a means for developing time versus temperature curves and temperature indices for flexible
electrical insulating material systems used as primary insulation or jackets on wire. The procedure of AS4851 shall be
used in conjunction with ASTM D 3032 as described in AS4851 and below.

NOTE: This test requires at least 10 months to complete.

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4.8.4.2 Specimen

The specimens shall be 16 in (406 mm) in length for this test. (See Section 14.6 of ASTM D 3032.)

4.8.4.3 Test Equipment

See Section 14.4 of ASTM D 3032 for the equipment necessary to perform this test.

4.8.4.4 Test Procedure

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See Section 14.7 of ASTM D 3032 for the procedures necessary to perform this test.

4.8.4.5 Results

The results shall be reported in accordance with Section 14.10 of ASTM D 3032.

4.8.4.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested as given in Section 14.5 of ASTM D 3032.

4.8.4.7 Precision Bias

The Precision Bias shall be as stated in Section 14.11 of ASTM D 3032.

4.8.5 Method 805, Thermal Shock Resistance

4.8.5.1 Scope

This test is to be used to evaluate short-term shrinkage or expansion of the finished wire insulation after thermal shock.

4.8.5.2 Specimen

A 5 ft (1.52 m) length of finished wire shall be used for this test, with a minimum coil diameter of 1 ft (0.305 m). See
Section 21.4 of ASTM D 3032.

4.8.5.3 Test Equipment

See Section 21.3 of ASTM D 3032 for the equipment necessary to perform this test.

4.8.5.4 Test Procedures

This test shall be performed in accordance with Section 21.5 of ASTM D 3032 except that the oven temperature shall be
the rated temperature of the insulated wire specimen and the low temperature shall be -55 °C ± 3 °C (-67 °F ± 5 °F).
Also, the exposure time at each temperature shall be 30 min.

4.8.5.5 Results

See Section 21.6 of ASTM D 3032 for the data to be reported. Also, the specimens shall have no flaring of the insulation
layers.

4.8.5.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested and temperature rating of the insulated wire.

4.8.5.7 Precision Bias

See Section 21.7 of ASTM D 3032. Also see the recommended values in Table 20.
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TABLE 20 - MAXIMUM RECOMMENDED VALUES

Wire Size Inches mm

30 - 12 0.0625 1.6
10 - 8 0.1 2.5
6 - 0000 0.125 3.2

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4.8.6 Method 806, Property Retention After Thermal Aging

4.8.6.1 Scope

This test evaluates the mechanical properties of the same specimens of insulated, finished wire before and after 1000 h
of thermal aging.

4.8.6.2 Specimen

A wire specimen of sufficient length to conduct the tests listed below shall be arranged in a 12 in (305 mm) coil.

4.8.6.3 Test Equipment

4.8.6.3.1 An air oven capable of maintaining the specified temperatures and tolerances.

4.8.6.3.2 See the Test Methods listed below for the necessary equipment required to perform this test.

4.8.6.4 Aged Test Procedure

The coiled wire specimen shall be placed on a flat surface in a temperature chamber and conditioned at the rated
temperature for 1000 h. The specimen shall then be removed from the chamber, placed on a flat surface, and allowed to
cool to ambient temperature. Once cooled, the coil shall be cut to appropriate lengths to conduct the tests listed in Table
21. Use separate specimens for each test.

TABLE 21 – AGING TEST SPECIMEN LENGTH REQUIREMENTS

Test Method Length Required

Dynamic cut-thru 703 18 ft (5.49 m)
Flex life 704 18 in (45.7 cm)
Notch propagation 706 6.0 ft (1.83 m)

4.8.6.5 Results

Report the unaged and aged data required in the Test Methods listed above.

4.8.6.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested, temperature rating of the insulated wire and specific cutting edge to be
used in Test Method 703.

4.8.6.7 Precision Bias

This is a new method that has not had the benefit of any round-robin testing to determine precision.

4.8.7 Method 807, Multi-day Heat Aging Test (Life Cycle)

4.8.7.1 Scope

This test is to be used to assess the ability of an insulated wire to maintain integrity after 5 days of heat aging.

Copyright SAE International

4.8.7.2 Specimen

The specimen shall be a 24 in (610 mm) specimen of finished wire.

4.8.7.3 Test Equipment

4.8.7.3.1 An air oven capable of maintaining the specified temperatures and tolerances.

4.8.7.3.2 PTFE coated steel mandrels sized appropriately for the specimens tested.

4.8.7.4 Test Procedure

Remove 1 in (25.4 mm) of insulation from each end of the finished wire specimen. The central portion of the specimen
shall then be bent over a horizontal mandrel of the diameter specified in the detailed specification. Each end of the
conductor shall be loaded separately with a weight specified in the detail specification so that the portion of the insulation
between the conductor and mandrel is under compression and the conductor is under tension (see Figure 29). The
mandrel and specimen shall then be placed in the oven for 120 h at 30 °C (86 °F) above proposed rated insulation
temperature. The specimen shall then be cooled to 20 to 25 °C (68 to 77 °F) within 1 h. When cooled, the wire specimen
shall then be subjected to the Bend Test Method 712 and Voltage Withstand (Wet Dielectric) Method 510.

FIGURE 29 - TYPICAL SAMPLE ARRANGEMENT

4.8.7.5 Results

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Report the oven temperature, mandrels, and weights used in the Heat Aging Test. Report any cracks in the insulation as
a result of straightening the specimen and the results of the Bend Test and Voltage Withstand Test.

4.8.7.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested, temperature rating of the insulated wire, mandrel size and weights.

4.8.7.7 Precision Bias

This is a process control test and as such is material dependent. The temperature, mandrels, and weights may have to
be different from material to material.

Copyright SAE International

4.8.8 Method 808, Blocking

4.8.8.1 Scope

This test evaluates a finished wire specimen for adhesion (blocking) of adjacent turns of the specimen when subjected to
the rated temperature of the specimen.

4.8.8.2 Specimen

A piece of finished wire of sufficient length to perform the test.

4.8.8.3 Test Equipment

4.8.8.3.1 Metal spools or mandrels as specified below.

4.8.8.3.2 An air oven capable of maintaining the specified temperatures and tolerances.

4.8.8.4 Test Procedure

One end of a piece of finished wire of sufficient length to perform the test shall be helically wound onto a metal spool or
mandrel of the specified diameter at the tension shown in Table 22. Each succeeding turn shall be in close contact with
each other. The winding shall be continuous until there are at least three evenly wound layers of such helical turns on the
spool or mandrel. The free end of the wire shall then be affixed to the spool to prevent unwinding or loosening of the
turns. The spool (or mandrel) and wire shall be placed for 24 h in an air oven at the rated temperature of the wire ±3 °C
(5 °F). At the end of 24 h, cool the spooled wire to room temperature, unwind wire from spool manually, and examine for
adhesion (blocking) of adjacent turns.

TABLE 22 – BLOCKING MANDRELS AND TENSIONS

Wire Min Barrel Dia of Winding Tension Winding Tension

Size Spool or Mandrel lb +3% kg +3%
30 50X 0.50 0.227
28 50X 0.50 0.227
26 50X 0.50 0.227
24 50X 0.50 0.227
22 50X 1.00 0.454
20 50X 1.00 0.454
18 50X 1.00 0.454
16 50X 1.00 0.454
14 50X 3.00 1.36
12 40X 3.00 1.36
10 40X 3.00 1.36
8 30X 4.00 1.81
6 30X 4.00 1.81
4 30X 4.00 1.81
2 30X 6.00 2.72
1 30X 6.00 2.72
0 20X 6.00 2.72
00 20X 8.00 3.63
000 20X 8.00 3.63
0000 20X 12.00 5.44
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Copyright SAE International

4.8.8.5 Results

Report the temperature of the test and any blocking that is observed during unwinding of the wire from the spool.

4.8.8.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested and temperature rating of the specimen.

4.8.8.7 Precision Bias

This is a process control test.

4.8.9 Method 809, Lamination Sealing

4.8.9.1 Scope

This test evaluates tape wrapped insulation for sealing between wraps after thermal stress.

4.8.9.2 Specimen

A 12 in (305 mm) specimen of the finished wire shall be cut so that the insulation and conductor are flush at both ends.

4.8.9.3 Test Equipment

4.8.9.3.1 An air oven capable of maintaining the specified temperatures and tolerances.

4.8.9.4 Test Procedure

The specimen shall be maintained in an air oven at a temperature and for the duration described in the procurement
specification. At the end of this period, the specimen shall be removed from the oven and allowed to return to room
temperature. The specimen shall then be visually examined for delamination. Any separation of layers, either along the
insulation or at the ends, shall constitute failure.

4.8.9.5 Results

Report any delamination or separation observed either at the ends or along the insulation length.

4.8.9.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested and test temperature and duration.

4.8.9.7 Precision Bias

This is a process control test.

4.8.10 Method 810, Topcoat Cure

4.8.10.1 Scope

This test is to be used to evaluate a polyimide or modified polyimide topcoat of a finished wire specimen for cracking after
exposure to boiling water vapor.

4.8.10.2 Specimen

A 12 in (305 mm) length of finished wire shall be used for this test.

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Copyright SAE International

4.8.10.3 Test Equipment

4.8.10.3.1 200 ml of distilled water.

4.8.10.3.2 A 2 L Erlenmeyer flask with a rubber stopper fitted with a water-cooled reflex condenser.

4.8.10.3.3 A mandrel in the sizes as follows:

a. For wire sizes 18 and smaller - the specified maximum diameter of the wire

b. For wire sizes 16 and larger - 3X the specified maximum diameter of the wire

4.8.10.4 Test Procedure

Place 200 ml of distilled water together with a few boiling chips or beads in a 2 L Erlenmeyer flask. Close the flask using a
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rubber stopper fitted with a water-cooled reflux condenser. The flask shall be heated by hot plate or heating mantle until
the water is boiling and condensate is returning from the reflux condenser. One end of the specimen shall be inserted into
the flask by passing it between the rubber stopper and the side of the flask or through a snugly fitting hole in the stopper,
so that 5 in of the wire length extends into the vapor phase inside the flask. The portion of the wire inside the flask shall be
essentially straight and shall not be in contact with the sides of the flask or condenser, the layer of liquid water in the
bottom of the flask, or the liquid condensate returning from the condenser. Heating of the flask shall be resumed, with
stopper and reflux condenser again in place, for exactly 1 h. The specimen shall then be removed from the flask. A 4 in
(102 mm) section cut from the vapor-exposed portion of the wire, avoiding the 1 in which was nearest the rubber stopper.
The 4 in (102 mm) specimen shall be allowed to cool at room temperature for a minimum of 15 min. It then shall be
wrapped in a tight spiral for six turns (or the full length of the specimen, whichever is lesser) around a mandrel specified in
4.8.10.3.3. The specimen shall be inspected visually for cracks without the aid of magnification.

4.8.10.5 Results

Report any cracks observed without the aid of magnification.

4.8.10.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested.

4.8.10.7 Precision Bias

This is a process control test.

4.8.11 Method 811, Cross-link Proof Test

4.8.11.1 Scope

This test is to be used to assess the adequacy of the cross-linking (conversion to a thermoset material) of an insulated
wire specimen. The test is performed for a short period of time at a temperature much greater than the temperature
rating of the insulation. To pass this test, the wire must withstand the bend and wet dielectric tests after the thermal
exposure. This process control test was derived from the test in AS22759/32-/35, /41-/46. These documents may be
used in selecting mandrel sizes if the specified mandrel diameter in the detailed specification sheet is not appropriate.

4.8.11.2 Specimen

A 24 in (610 mm) specimen of finished wire shall be used.

Copyright SAE International

4.8.11.3 Test Equipment

4.8.11.3.1 Air circulating test oven capable of maintaining the chamber at the temperature limits specified. The oven
shall have a means to secure the test mandrel horizontally to assure that the weighted specimen does not
touch any part of the chamber.

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4.8.11.3.2 PTFE coated steel mandrels to prevent sticking of the wire specimens.

4.8.11.3.3 A suitable temperature recorder to accurately and continuously monitor the chamber temperature.

4.8.11.3.4 Test weights as required.

4.8.11.4 Test Procedure

Approximately 1 in (25.4 mm) of insulation shall be removed from each end of the finished wire specimen. The test oven
shall be set and thermally stabilized at the specified temperature. The test oven shall be shut off before inserting the test
specimens. Each end of the conductor shall be loaded separately with the test weight required in the individual
specification. The central portion of each weighted specimen shall then be bent into a “U” shape over a horizontally
placed mandrel of the diameter required (see Figure 30). The portion of the insulation between the conductor and
mandrel will be under compression and the conductor is under tension. The mandrel with the weighted specimens shall
then be placed in the oven and the oven turned back on. The specimens shall be maintained for 7 h at the temperature
required. The start of the time period shall be determined at the point in time when the oven re-stabilizes at the specified
test temperature.

NOTE: Placing both weights together on the combined ends of the wire specimen constitutes a significant change in the
parameters of this test method.

NOTE: Test validity may be compromised if the weights are subjected to movement during the oven aging. Minimization
of weight movement during the test is recommended if it can be accomplished without changing the test
conditions or parameters.

After completion of the oven thermal exposure, the oven shall be shut off, the door opened and the specimens allowed to
cool down to room temperature in the oven for at least 1 h. When cooled, the wire shall immediately be freed from
tension, removed from the mandrel and straightened. The specimen shall then be subjected to the Bend Test Method
712 and Voltage Withstand (Wet Dielectric) Method 510.

FIGURE 30 - TYPICAL SAMPLE ARRANGEMENT

Copyright SAE International

4.8.11.5 Results

Report the mandrels and weights used. Report any cracks in the insulation as a result of straightening the specimen and
the results of the Bend Test and Voltage Withstand (Wet Dielectric) Test.

4.8.11.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested, mandrel size and weight.

4.8.11.7 Precision Bias

This test is a process control test and, as such, is material dependent. The temperature, mandrels and weights may have
to be different from material to material.

4.8.12 Method 812, Flame Resistance

4.8.12.1 Scope

This test shall be used to determine the resistance (ohms) while the finished insulated wire is subjected to direct flame
and vibration.

4.8.12.2 Specimen

Three 24 in (61 cm) specimens shall be used in this test.

4.8.12.3 Test Equipment

4.8.12.3.1 A quantity of ASTM D 910 grade 100/130LL aviation gasoline.

4.8.12.3.2 A solution of 50% turbine fuel conforming to MIL-DTL-5624, grade JP-4 and 50% aircraft lubricating oil
conforming to SAE-J1966, grade 1100.

4.8.12.3.3 A quantity of vapors from aircraft lubricating oil conforming to SAE-J1966, grade 1100 which shall be
maintained at a temperature of 120 °C ± 3 °C (248 °F ± 5 °F).

4.8.12.3.4 A mounting rack as shown in Figure 31.

4.8.12.3.5 A test circuit as shown in Figure 31 including ohmmeter and thermocouple.

4.8.12.3.6 A shorting bar for use in the test circuit.

4.8.12.3.7 Two nickel-chrome ribbons as described in the following procedure.

4.8.12.3.8 A burner as described in the following procedure.

4.8.12.3.9 A vibration apparatus as described in the following procedure.

4.8.12.4 Test Procedures

4.8.12.4.1 Preconditioning of Specimens

A 24 in (610 mm) specimen shall have its center 18 in (457 mm) section immersed for 24 h at room temperature in
aviation gasoline conforming to ASTM D 910 grade 100/130LL. A second specimen shall be immersed in like manner for
24 h at room temperature in a solution of 50% turbine fuel conforming to MIL-DTL-5624, grade JP-4, and 50% aircraft
lubricating oil conforming to SAE-J1966, grade 1100. A third specimen shall be suspended for 4 h in the vapors of aircraft
lubricating oil conforming to SAE-J1966, grade 1100, which shall be maintained at a temperature of 120 °C ± 3 °C (248 °F
± 5 °F). Upon removal from the liquid the specimens shall be wiped with a clean cloth.
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Copyright SAE International

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FIGURE 31 - FLAME RESISTANCE TEST FIXTURE

Copyright SAE International

4.8.12.4.2 Specimen Installation

Each specimen shall be mounted in the rack with the center 7 in (178 mm) section centered 1 in (25.4 mm) above the
burner top plate as shown on Figure 31. Each of the two nickel-chrome ribbons shall be wrapped once around the
specimen with the edges butted together. The two ribbons shall be 1 in (25.4 mm) apart at the midsection of the 7 in
(178 mm) section as illustrated on Figure 31. The conductor of the specimen and the nickel-chrome ribbons shall be
connected in the test circuit as shown on Figure 31. A shorting bar shall be inserted between the nickel-chrome ribbons
and the conductor, and the meter adjusted to read approximately 0 :.

4.8.12.4.3 Burner Adjustment

The thermocouple shall be located in a plane 1 in (25.4 mm) above the burner top plate, near the center of the burner.
The burner, Figure 32, shall be ignited and the flow of gas, air, and secondary air shall be adjusted to give a non-
oxidizing, non-reducing (neutral) flame approximately 1 in (25.4 mm) high with a flame temperature, as measured by the
thermocouple, of 1090 °C ± 30 °C (1994 °F ± 86 °F).

CAUTION: The proper flame will be obtained by using a minimum amount of gas and secondary air. The flame shall be
uniform over the top of the top plate area and the tip of the blue cone shall be approximately 1 in (25.4 mm)
above the burner top plate. The burner shall be run until a stable temperature and flame has been achieved
before starting any test. The tip of each flame shall not be yellow; to achieve this, for each gas valve
adjustment, the air valve shall be opened to the point beyond that which gives a yellow-tipped flame.
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FIGURE 32 - BURNER DETAILS

Copyright SAE International

4.8.12.4.4 Vibration

After the flame has stabilized, the specimen shall be vibrated at approximately 30 Hz with the rack having a maximum
total travel of approximately 0.06 in (1.5 mm).

4.8.12.4.5 Test Procedure

After removing the thermocouple, the vibrating specimen shall be positioned in the stabilized flame so that the lower
surface of the specimen is at the same position in the flame as that previously occupied by the hot junction of the
thermocouple. The 7 in (178 mm) midsection shall be centered over the burner top plate. The specimen shall remain in
this position in the flame for a 5 min test period. With the ohmmeter observed continuously during this period, the
minimum reading shall be recorded. At the end of the 5 min period, discontinue vibration and allow the specimen to
remain in the flame for an additional 10 min. The burner shall be repositioned under the thermocouple and the flame
temperature checked at the end of the 15 min test period.

4.8.12.5 Results
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Report the minimum value observed on the ohmmeter, the time observed and the time to break.

4.8.12.6 Information Required in the Detail Specification

Number and wire size of specimens and times for observation.

4.8.12.7 Precision Bias

This is a special test method for fire zone wires and has not had the benefit of round-robin testing to determine precision.

4.8.13 Method 813, Insulation State of Sinter

4.8.13.1 Scope

This test is to be used to evaluate the degree of sinter (or densification) of polytetrafluoroethylene (PTFE) insulation on a
wire specimen using a differential scanning calorimeter as described in ASTM D 4591.

4.8.13.2 Specimen

The specimen shall be 18 in minimum (450 mm) in length for this test.

4.8.13.3 Test Equipment

High precision balance capable of repeatable measurement to 0.005 mg and a Differential Scanning Calorimeter (DSC)
as described in ASTM D 4591.

4.8.13.4 Test Procedure

Follow the procedures detailed in ASTM D 4591 with these added test details:

4.8.13.4.1 The specimen shall be prepared from just the PTFE portion of the structure. Any coating materials that
transfer to the PTFE shall be scraped off with a sharp blade prior to including the specimen into the specimen
holder and prior to weighing. The weight of the PTFE specimen should be between 7.0 mg. to 12.0 mg and
measured to nearest 0.01 mg.

4.8.13.4.2 The heating temperature scan shall be set to start at 270 °C and stop at 380 °C with a ramp rate of 10.00 °C
per minute.

Copyright SAE International

4.8.13.4.3 After completion of the test, the specimen shall be cooled to room temperature. The cooling of the specimen
can either be at a controlled or uncontrolled rate. If a controlled rate is used, it should be at the same rate as
the heating phase. If a second heat measurement is required by the specification sheet, the test shall be
repeated using the same specimen and heat profile and initiated once the temperature of the chamber is
below 270 °C.

4.8.13.4.4 The thermal curve shall be integrated between the points 290 °C and 360 °C using the sigmoidal method (if
available) to draw the connection between the curve points. (The sigmoidal method will reduce the amount of
variation caused when the 270 °C point on the curve is at a lower heat flow value than the 380 °C point. A
method using straight lines between the points will sometimes cut across some areas before the 380 °C point
and the software will artificially subtract this from the total value.)

4.8.13.5 Results

Report the value integrated between 290 °C and 360 °C that is normalized to J/g unless otherwise specified by the Detail
Specification.

4.8.13.6 Information Required in Detail Specification

Number of specimens and wire size to be tested.

4.8.13.7 Precision Bias

This method has not had the benefit of any round-robin testing to determine precision.

NOTE: ASTM D 4591 and ASTM D 3418 only state the precision on materials such as polypropylene.

4.8.14 Method 814, High Temperature Endurance

4.8.14.1 Scope

This test determines the ability of the insulation to resist degradation due to exposure to a high temperature. Degradation
is judged by change in conductor resistance, cracking during bending, insulation dielectric breakdown, or decreased
resistance to fluids.

4.8.14.2 Specimen

Test sample shall consist of one continuous length of at least 24 feet (for inside the oven) and an additional length to
attach to the current source outside the test oven.
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4.8.14.3 Test Equipment

4.8.14.3.1 Air oven capable of maintaining a temperature of 343°C ± 3°C (650°F ± 5°F). The oven shall have test ports
to allow the sample leads to be connected to a power supply.

4.8.14.3.2 An air oven capable of maintaining the specified temperatures and tolerances.

4.8.14.3.3 AC or DC constant current power supply to provide the currents listed in Table 20.

4.8.14.3.4 Voltmeter.

4.8.14.3.5 Ammeter

4.8.14.3.6 Fluids as specified in the individual specification.

4.8.14.3.7 Test mandrels as specified in Table 24.

Copyright SAE International

4.8.14.3.8 Load weights as specified in Table 24.

4.8.14.4 Test Procedure

4.8.14.4.1 The wire sample shall be placed in the oven which shall be maintained at 343°C ± 3°C (650°F ± 5°F). The
ends of the specimen shall be run through the ports of the oven and connected to the current source which

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may be either AC or DC as shown in Figure 33. The current through the conductor shall be adjusted to
stabilize at the value given in Table 23 for the applicable wire size. When the stabilized oven test
temperature and the stabilized conductor current are reached, the initial voltage and current measurements
shall be recorded. The current loaded wire shall remain in the air oven at an oven temperature of 343°C ±
3°C (650°F ± 5°F) for a period of 100 +1, -0 hours. The current through the conductor shall be checked
periodically and maintained at the required test value.

4.8.14.4.2 At the end of the 100 hour period, while still at the stabilized temperature and conductor current, final voltage
and current measurements shall be recorded. Change in resistance during the conditioning period shall be
calculated from the voltage and current measurements. The wire shall then be cooled to room temperature
and examined for visual defects. Change in color of the finished wire or printed identification shall not be
considered a defect. The ends of the wire sample that were outside the oven during conditioning shall be
discarded. From the wire which was inside the oven during conditioning, seven 3 foot specimens shall be cut
for additional testing as noted below.

4.8.14.4.3 Specimen No. 1: Perform bend test (method 712) followed by voltage withstand test (method 510).

4.8.14.4.4 Specimens No. 2 through no. 7: Perform fluid immersion test (method 601) followed by the bend test
(method 712) and voltage withstand test (method 510). The specific fluids to be used shall be specified in the
individual detailed specification sheet. The bend test mandrels and weights are specified in Table 24.

4.8.14.4.5 The change in conductor resistance shall be calculated as follows:

% Change in Resistance =

VF VI
( IF
- II )
VI
( ) II
Where:

VF = Final Voltage
IF = Final Current
VI = Initial Voltage
II = Initial Current

4.8.14.5 Results

Report the percent change in conductor resistance: results of the bend and wet dielectric tests, the results of the fluid
immersion tests, and any visual defects observed.

4.8.14.6 Information Required in the Detail Specification

The detailed specification shall list the wet dielectric test voltage, the maximum percent conductor resistance change
allowed, and the fluids to be used.

Copyright SAE International

4.8.14.7 Precision Bias

This test has been used to evaluate high temperature wire for 30 years.

TABLE 23 – HIGH TEMPERATURE ENDURANCE CURRENT FOR CONDITIONING

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TABLE 24 – HIGH TEMPERATURE ENDURANCE MANDRELS AND LOADS

Copyright SAE International

FIGURE 33 – HIGH TEMPERATURE ENDURANCE TEST SETUP

4.9 Test Methods Group 900 - Wire Diameter and Weight

4.9.1 Method 901, Finished Wire Diameter

4.9.1.1 Scope

This test is to be used to determine the finished wire specimen diameter.

4.9.1.2 Specimen

Test specimens shall be three 24-in wire lengths.

4.9.1.3 Test Equipment

See Section 15.2.1 of ASTM D 3032 - the micrometer method for the equipment necessary to perform this test.

4.9.1.4 Test Procedure

Determine the wire diameter by measuring the outer diameter in at least three locations along the length of the insulated
wire. Each measurement shall consist of two micrometer readings taken 90 degrees from each other. For sizes 8 and
larger, a circumferential measuring tape calibrated for diameter measurements may be used in lieu of the micrometer
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method.

4.9.1.5 Results

Report each measured insulated wire diameter and the average diameter for each specimen measured.

4.9.1.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested.

Copyright SAE International

4.9.1.7 Precision Bias

This is an established test.

4.9.2 Method 902, Finished Wire Weight

4.9.2.1 Scope

This test is to be used to evaluate the weight of a finished wire specimen.

4.9.2.2 Specimen

A 10 ft (3 m) finished wire specimen shall be used for Procedure 1 of 4.9.2.4.1 below. The actual length of the specimen
in Procedure 2 of 4.9.2.4.2 below shall be measured and used for the weight determination.

4.9.2.3 Test Equipment

4.9.2.3.1 A suitable scale with the ability to read to at least three significant figures.

4.9.2.4 Test Procedures

4.9.2.4.1 Procedure 1

The length and weight of a specimen at least 10 ft (3 m) long shall be accurately measured and the resultant
measurements converted to pounds per 1000 ft (kg per km).

4.9.2.4.2 Procedure 2

The net weight of the finished wire on each reel or spool shall be obtained by subtracting the tare weight of the reel or
spool from the gross weight of the reel or spool with wire. The net weight of the wire on each reel or spool shall be
divided by the exactly determined length of wire on that reel or spool and the resultant figure converted to pounds per
1000 ft (kg per km). When wood or other moisture absorbent materials are used for reel or spool construction, weight
determinations shall be made under substantially the same conditions of relative humidity.

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4.9.2.5 Results

The wire weight as determined in Procedure 1 or 2 above shall be the finished wire weight and reported as well as the
procedure used.

4.9.2.6 Information Required in the Detail Specification

Number and wire size of specimens to be tested and which procedure to use.

4.9.2.7 Precision Bias

This is an established test.

4.10 Test Methods Group 1000 - Wire Identification Marking and Evaluation

4.10.1 Method 1001, Wire Marking Contrast

4.10.1.1 Scope

This test and method provides an assessment of the specific level of contrast between the identification marks and the
background wire insulation. It is intended to be used both as a quality assurance tool for wire marking activities and for
determination of the intrinsic laser markability of specific wire insulation types. This method is limited to white and to other
light colored insulation materials.
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SAE AS4373E Page 97 of 103

4.10.1.2 Definitions

The terms used herein shall be interpreted in accordance with AS5649.

4.10.1.3 Specimen Preparation

Before marking, assure that the wire surface is clean and dry and free from foreign materials. If necessary, surface shall
be cleaned with isopropyl alcohol to remove any foreign material deposits.

4.10.1.3.1 Qualification/Certification Specimens

Specimens prepared for wire qualification or process certification require the UV marking system to be certified to the
following characteristics:

4.10.1.3.1.1 Wavelength

Near Ultra violet wavelength range of 240 to 380 nm.

4.10.1.3.1.2 Laser Marking Fluence

Applied marking laser fluence shall be 0.9 J/cm2 ± 0.1 J/cm2. The system used shall ensure that the laser fluence
delivered to the wire remains within the specified range for all markings. Refer to AS5649 for recommended pulse
lengths and general marking conditions.

4.10.1.3.1.2.1 Verification of Laser Fluence

Laser fluence shall be determined by first measuring the laser beam energy at the marking point or point of impact using
a suitable calibrated laser energy calorimeter. The area of the laser beam shall be determined by making a mark on a
suitable piece of flat plastic material held at the focal point of the laser system. After making a mark on the flat plastic
material, the area of the laser beam shall be determined by measuring the mark dimensions using a suitable microscope
and graticule. The laser fluence shall be calculated by dividing the laser beam energy by the mark area.
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4.10.1.3.1.3 Specimen Length

Sufficient wire shall be marked to provide for examination of a minimum of six marks, two marks from three different areas
separated by at least 3 ft (92 cm).

4.10.1.3.1.4 Specimen Mark

The mark shall be made using a laser and optical beam delivery system at the prescribed fluence. Character strings
using alphanumeric and symbols are acceptable. The size of the mark should be greater than 1 mm or utilize 70% of the
exposed surface area in the case of 24 and 26 awg wire. When marking wire specimens, take care to ensure that the top
center of the wires are positioned in the same plane as the flat plastic sample to assure that the marking is carried out at
the same fluence.

4.10.1.3.1.5 Results

Report wavelength, pulse length and fluence level used during preparation of wire markability qualification specimens.

4.10.1.3.2 In-Process Specimens

Specimens marked in an manufacturing environment for the purpose of process control or process validation, do not
require stringent controls on the UV marking system’s capabilities. Sufficient wire shall be marked to provide for three
specimens, each having a marked string of characters of at least 2 in (50 cm) in length. These specimens shall be taken
from areas separated by at least 3 ft (92 cm) along the wire.

Copyright SAE International

4.10.1.4 Specimen Characteristics

Identification markings to be measured shall be uniform in color and characters shall have well defined edges. Marked
specimens shall be cleaned with a soft lint-free cloth to avoid distortion of test results that might otherwise result from
surface deposits or a roughened surface.

4.10.1.5 Test Equipment

The measuring device shall comprise, at a minimum, a photometer, an illumination system and a purpose designed
holding fixture suitable for wire and cable. The device for holding specimens and any accessories and the equipment in
the vicinity of the measurement area shall be matt black in color to absorb scattered light. The system shall be designed
to ensure that test results are not falsified by external influences.

4.10.1.5.1 Photometer

The luminance shall be determined with a calibrated electrical photometer, which shall incorporate a photopic filter to
simulate the response of the human eye. The photometer shall be designed to be stable and free from vibrations and to
exclude the influences of external light and reflections from scattered light. The manufacturer’s instructions concerning
the photometer working range and operation shall be observed.

4.10.1.5.2 Illumination and Viewing System

The illumination system shall consist of two light sources of equal intensity (See Figure 34). The two sources may be two
separate lamps or preferably, two fiber light guides fed from a single lamp. The light from the sources shall overlap to
illuminate a central spot on the sample at an angle of 45 degrees to the surface. The light cones shall illuminate the wire
sample longitudinally along its length in a manner that avoids the formation of shadows. The photometer shall be
installed to view the specimen along the normal to the surface, i.e., at 90 degrees, and above the principal focus at a
distance that depends upon the objective’s focal distance. It shall be adjusted during calibration and after every change
of objective.

FIGURE 34 - LIGHTING EQUIPMENT

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Copyright SAE International

4.10.1.5.2.1 If two separate lamps are used they shall be of identical power consumption and shall always be
exchanged in pairs. The radiating light energy and color temperature of the lamps shall be compatible with
the working range of the photometer, according to the manufacturer’s instructions. Only gas filled lamps
with tungsten filaments shall be used. The color temperature shall be 3000 K ± 500 K.

4.10.1.5.2.2 The voltage supply for the lamps shall be insensitive to line fluctuations. A stabilized D.C. power line unit
shall be used.

4.10.1.5.3 Equipment Design and Methodology

To determine the contrast, measurements shall be taken of the luminance from both marked and unmarked areas of the
insulation. Depending upon the contrast measuring equipment design, the photometer may be used to either take a
series of point measurements sequentially or to determine contrast instantaneously by the simultaneous measurement of
the luminance of all the sample points of an area of the specimen. If a point measurement system is used, sufficient
points shall be sampled on both the marked and unmarked portion of the wire to ensure that a good average value of the
reflectance of each is obtained.

4.10.1.5.3.1 Measurement Spot Size

The maximum admissible diameter of the photometer measurement spot shall not be in excess of 75% of the character
stroke width. This is particularly important if using a measurement system where spot sizes are typically relatively large.

4.10.1.5.3.2 Measurement Area

The contrast shall be measured over a finite area to include a significant portion of the marked and unmarked surface of
the wire. Spot measurements shall not be made immediately adjacent to the edge of a character, either on the mark or
the unmarked insulation, to avoid scattered light from the adjacent area from interfering with the measurement.

4.10.1.5.3.3 Calibration

The photometer shall be calibrated by use of a reference sample, e.g., ceramic tiles of known reflectance, certified and
traceable to National Standards. The frequency of calibration shall be in accordance with the equipment manufacturer’s
guidelines.

4.10.1.5.3.4 Measurement Tolerance

The measuring tolerance of the photometer shall be not more than 2 percentage points.

4.10.1.6 Test Procedure

4.10.1.6.1 Precautionary Measures

There may be a danger from some illumination systems that they may cause the samples to heat up significantly. In this
instance measurements shall be taken without delay and the sample removed from the test area after measurements
have been taken. Contrast measurements shall not be taken in areas of the specimen incorporating the wire
manufacturer’s marking, in areas where tapes overlap on tape wrapped wires or where there are visible inclusions,
deformities or other irregularities, as these can cause errors in determination of the contrast values.

NOTE: If checking for repeatability it is of the utmost importance that the same character of the same mark and the same
position within the character are measured each time. Significant variations in contrast may otherwise occur.

WARNING: The contrast formula in 4.10.1.7 is limited in its application to white and light colored wires. Care must be
taken when interpreting the contrast results of some dark colored wires.

--```,``,,,`,,,,,`,,`,`,``,`,,,-`-`,,`,,`,`,,`---

Copyright SAE International

4.10.1.6.2 Picture Definition

The image markings and the wire or cable surface shall be adjusted to insure that it is sharp and in focus. However, care
should be taken NOT to make such adjustments unnecessarily, as this may then require the equipment to be recalibrated.
Refer to the manufacturer’s instructions.

4.10.1.6.3 Sample Area

When measuring the contrast of the marks, ensure that measurements are made on the marked and unmarked areas
about the central axis of the wire, along its length, and just either side within a band equal to ±20% of the diameter of the
wire or cable (on small sized wires this may not be possible due to the limited size of the wire). This is to ensure that the
most uniform part of the mark is measured so that errors are not introduced that result from changes in the laser fluence
resulting from wire curvature. See Figure 35.

FIGURE 35 - CONTRAST MEASUREMENT ON WIRE SPECIMEN MARKINGS

4.10.1.6.4 Number and Location of Measurements

In order to take into account variations in the measurement process and any that may result from the operator, the wire
and the markings, a sufficient number of measurements must be made. An average value for the overall contrast
measurement of the specimens is obtained to ensure a statistically meaningful result, regardless of the equipment and
the means used.

4.10.1.6.4.1 Contrast measurements shall be made from at least two characters from within each selected specimen
over a minimum length of 2 in (50 mm). Contrast values shall be calculated for a minimum of six separate
characters within the sample marking and these shall be used to produce an average measurement.
Characters shall be sampled from either end and from the middle of the identification code or other wire
marking. See Figure 35.

4.10.1.6.4.2 Either the single point system or the area measurement system is acceptable within the limits described in
this test method. Single point measurement systems require the user to take individual luminance readings
manually from the mark and the background and to manually compute contrast value. When using a single
point system, a minimum of three measurement points shall be taken from each character mark and three
measurement points for the background for the background unmarked insulation at intervals throughout the
sample. A single measurement is required for each character for area measurement systems, which use a
digitized image of the wire surface and automatically calculate the contrast value from many hundreds of
data points obtained from the pixels within the image.

4.10.1.6.4.3 To allow for the large measurement spot size of single point measurement systems, measurement shall be
taken from large “block” marks specially printed for the purpose, as shown in Figure 35 or from
alphanumeric characters where the spot size is substantially smaller than the character stroke width. Note
that block marks may be of various shapes, including rectangular and circular, as long as they provide an
area for measurement that is significantly larger than the photometer measurement spot size.
--```,``,,,`,,,,,`,,`,`,``,`,,,-`-`,,`,,`,`,,`---

Copyright SAE International

4.10.1.7 Determination of Contrast Values

Values shall be determined by measuring the luminance of identification marks and of the unmarked insulation adjacent
to the marks in accordance with the photometer manufacturer’s instructions. For point measurement systems,
measurement of the background shall be accomplished at a minimum distance greater than the diameter of the measured
spot from the side of the nearest mark.

4.10.1.7.1 The contrast shall be calculated as follows:

C (Lb Lm) u 100%

(Eq. 5)
Lb

where:

C = Contrast

Lb = Background luminance of the unmarked insulation

Lm = Luminance of the marked insulation

WARNING: This equation is to be used for markings on white or light colored insulation only.

4.10.1.7.2 Six contrast determinations from a minimum of three specimens shall be averaged to find the arithmetic
mean. The average shall meet the minimum requirement of the detailed specification of the relevant standard
with no single determination more than 2% below the requirement.

4.10.1.8 Results

Record the UV laser wavelength, the laser fluence, and the six contrast determinations. The results shall be averaged to
find the arithmetic mean. The average shall meet the minimum requirement of the detailed specification of the relevant
standard with no single determination more than 2 percentage points below the requirement.

4.10.1.9 Information Required in the Detailed Specification

Minimum contrast level.

4.10.1.10 Precision Bias

While this is a new test, the verification of mark contrast has been performed by end users for more than 10 years.

NOTE: Measurements shall be taken as close as possible to the center line of the wire or cable on at least three
--```,``,,,`,,,,,`,,`,`,``,`,,,-`-`,,`,,`,`,,`---

separate marks within a local area of minimum length of 2 in (50 mm).

5. NOTES

5.1 A change bar (|) located in the left margin is for the convenience of the user in locating areas where technical
revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left
of the document title indicates a complete revision of the document, including technical revisions. Change bars and
(R) are not used in original publications, nor in documents that contain editorial changes only.

PREPARED BY SAE SUBCOMMITTEE AE-8D, WIRE AND CABLE OF

COMMITTEE AE-8, AEROSPACE ELECTRICAL/ELECTRONIC DISTRIBUTION SYSTEMS
Copyright SAE International
Provided by IHS Markit under license with SAE Licensee=US Army Materiel Command/5974512002, User=smith, barry
No reproduction or networking permitted without license from IHS Not for Resale, 06/19/2018 12:05:34 MDT
SAE AS4373E Page 102 of 103

APPENDIX A – UNIQUE OR CRITICAL TEST EQUIPMENT

The following is a listing of unique and/or critical test equipment used in various AS4373 test methods. It is intended to
serve as a reference for those planning to perform the tests covered by this document. It is not intended as an
endorsement of any manufacturer’s equipment. Equivalents may be substituted at the discretion of the test laboratory.

The committee responsible for the writing and maintaining of AS4373 welcomes input on additional sources of supply for
any and all unique equipment listed in this document.
--```,``,,,`,,,,,`,,`,`,``,`,,,-`-`,,`,,`,`,,`---

FIGURE A1 – TEST EQUIPMENT (SOURCE REFERENCE)

Copyright SAE International

FIGURE A1 - TEST EQUIPMENT (SOURCE REFERENCE) - (CONTINUED)

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Copyright SAE International

Common questions

According to AS4373E, the testing methods to evaluate the thermal properties of insulated wires in Group 800 (Thermal Tests) include flammability, thermal shock resistance, property retention after thermal aging, multi-day heat aging test, high temperature endurance, and others. These tests reveal various wire performance aspects like resistance to fire, ability to maintain integrity under sudden temperature changes, longevity under prolonged heat exposure, and resilience to continuous high temperatures. For example, the thermal/mechanical resistance test (Method 106) evaluates the wire's cut-through resistance when exposed to heat, simulating potential damage that could occur during the removal of overbraids . The multi-day heat aging test and high temperature endurance specifically assess the wire's durability and performance longevity under high-temperature conditions .

The Weathering Resistance test, listed as Method 606 in Test Methods Group 600, addresses the challenge of assessing the degradation of materials used in insulated electric wire due to environmental factors like UV radiation and weathering elements. This test measures the ability of the material to maintain its physical and chemical properties under prolonged exposure to weather elements . Outcomes of the test typically include evaluations of the material’s resistance to discoloration, cracking, or other physical damages, ensuring its durability and effectiveness in practical applications .

The Fluid Immersion test in Test Methods Group 600 assesses the environmental resistance of wire insulation by determining the effects of various fluids. It involves immersing wire specimens in different fluids to evaluate how the insulation withstands these conditions. The test simulates environments involving contact with fluids such as cleaning compounds, hydraulic fluids, lubricating oils, and other materials listed in standard fluid tables used in aerospace and similar industries . It provides a measure of the insulation's durability and resistance to potential chemical degradation when exposed to these substances .

The Mechanical Test Group 700 is responsible for evaluating various mechanical aspects to assess the durability of electric wires. Specific tests in this group include Abrasion, Cold Bend, Dynamic Cut Through, Flex Life, Insulation Tensile Strength and Elongation, Notch Propagation, Stiffness and Springback, Mandrel and Wrapback Test, Wrinkle Test, and Durability tests for Wire Manufacturer's and Installer's Identification, among others . These tests help determine the wires' ability to withstand mechanical stresses during installation and operation .

The latest revision of AS4373E introduces several advancements in testing methods, including the development of new tests such as Adhesion of Nickel Coating, Spark Test of Finished Wire Insulation, Smoke Resistance, Fluoride Off-gassing, Nitric Acid Immersion, Circumferential Insulation Elongation, and High-Temperature Endurance . These improvements enhance wire testing protocols by addressing a wider range of material properties and conditions, allowing for better assessment of wire insulation under various environmental stresses . The inclusion of these tests reflects an effort to ensure the durability and reliability of wire insulation in aerospace applications .

The Smoke Resistance test, part of the Electrical Tests Group 500, measures whether wire insulation emits smoke when subjected to specific temperatures under electrical load . The procedure involves raising the wire temperature with a direct current and observing for smoke emission against a dark background . This test provides critical insight into the insulation's ability to resist high temperatures without producing smoke, which is crucial for maintaining safety standards in environments where smoke could indicate or contribute to fire hazards . Ensuring wire insulation does not emit smoke under operational conditions can enhance overall safety compliance and prevent potential fire risks.

The test for Conductor Elongation and Tensile Breaking Strength assesses wire reliability by determining the ability of the conductor, particularly soft (annealed) copper or copper alloy, to withstand elongation and tension. The test uses specific machinery capable of measuring the applied tension to within ±1% and ensures the wire's ability to maintain structural integrity under stress. This helps evaluate the durability and strength of the wire, which are critical factors in its overall performance and reliability in various applications . This test is significant for ensuring the wire does not fail under mechanical stress, thereby confirming its dependability in use without premature failure or breakage .

The Dynamic Cut-Through test in Mechanical Tests Group 700 evaluates the resistance of wire insulation to penetration by a cutting surface, specifically using a sewing needle as the standard cutting edge . It is important because it determines the durability and effectiveness of the wire insulation in preventing damage from cutting forces, which is critical for ensuring the long-term insulation integrity and safety of electrical systems . The test involves assessing the force required to cut through the insulation, providing data on its mechanical resilience .

The Nitric Acid Immersion test within Environmental Tests Group 600 assesses wire suitability by determining the wire's chemical resistance when immersed in red fuming nitric acid. This test involves immersing the wire in the acid at room temperature for 8 hours, followed by a water immersion, and then a wet dielectric strength test is conducted. The test results reveal how well the wire insulation withstands strong acids, indicating its potential suitability for use in corrosive environments .

The Spark Test of Finished Wire Insulation in AS4373E is significant for detecting defects in the wire insulation. It identifies flaws in the exterior insulation and can also verify defects in the interior insulation walls of multi-layered systems. This is critical for maintaining the quality of wire insulation by ensuring there are no breaches that could lead to electrical failures . The method uses high-frequency and standard frequency waveform options to test the insulation integrity, providing a flexible and reliable testing framework . By identifying insulation weaknesses early, manufacturers can address potential risks, ensuring the reliability and safety of the wire in practical applications .

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