81044/12-24-25 (101951-000) - Tyco Electronics

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Wire and Cable

501 Oakside Avenue, Redwood City, CA 94063-3800

WIRE AND CABLE, ELECTRIC, RADIATION-CROSSLINKED,

POLYALKENE-INSULATED COPPER OR COPPER ALLOY

1. SCOPE

1.1 SCOPE

This specification covers wire, insulated with radiation-crosslinked polyalkene in combination

with radiation-crosslinked modified polyvinylidene fluoride. It also covers single and multiple

conductor cables which may be shielded and jacketed. Cable jackets shall be radiation-

crosslinked modified polyvinylidene fluoride. The wire and cable covered by this specification

is suitable for installation in aerospace electrical systems and for general purpose use within

the limitations of applicable performance requirements.

1.2 CLASSIFICATION

Products in accordance with this specification shall be of the following types, as specified in

the applicable specification sheet.

Finished Wire: A single conductor, insulated as specified in the applicable specification

sheet.

Finished Cable: Any construction other than finished wire, utilizing a wire or wires with

or without shielding, and with or without an outer jacket.

1.2.1 Temperature Rating

The maximum conductor temperature of the finished wire and cable, for continuous use in any

combination of conductor and insulation, shall be as specified in the applicable specification

sheet.

2. APPLICABLE DOCUMENTS

2.1 GOVERNMENT-FURNISHED DOCUMENTS

The following documents, of the issue in effect on date of invitation for bids or request for

proposal, form a part of this specification to the extent specified herein.

SPECIFICATION: 44

THIS ISSUE: Issue 5

DATE: 20 April 2005

REPLACES: Issue 4

PAGE: 1 of 12

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Page 2 of 12 SPECIFICATION 44, ISSUE 5

2.1.1 Department of Defense

SPECIFICATIONS

Military

MIL-W-81044 Wire, Electric, Crosslinked Polyalkene, Crosslinked Alkane-Imide

Polymer, or Polyarylene Insulated, Copper or Copper Alloy

STANDARDS

Military

MIL-STD-104 Limits for Electrical Insulation Color

MIL-STD-681 Identification Coding and Application of Hook Up and Lead Wire

MIL-STD-1916 DOD Preferred Methods for Acceptance of Product

(Copies of Department of Defense documents may be obtained from the Naval Publications

and Forms Center, Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Ave.,

Philadelphia, PA 19111-5094)

2.2 OTHER PUBLICATIONS

The following documents, of the issue in effect on date of invitation for bids or request for

proposal, form a part of this specification to the extent specified herein.

2.2.1 American Society for Testing and Materials (ASTM)

E 595 Standard Test Method for Total Mass Loss and Collected Volatile

Condensable Materials from Outgassing in a Vacuum Environment

(Copies of ASTM publications may be obtained from the American Society for Testing and

Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103.)

2.2.2 National Electrical Manufacturers Association (NEMA)

WC 27500 Standard for Aerospace and Industrial Electrical Cable

(Copies of NEMA publications may be obtained from the National Electrical Manufacturers

Association, 1300 N. 17th Street, Rosslyn, Virginia 22209.)

3. REQUIREMENTS

3.1 SPECIFICATION SHEETS

The requirements for the individual wires and cables furnished under this specification shall be

as specified herein and in accordance with the applicable specification sheet. In the event of a

conflict, the requirements of the specification sheet shall govern.

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SPECIFICATION 44, ISSUE 5 Page 3 of 12

3.2 QUALIFICATION

The finished wire and cable furnished under this specification shall be a product which has

been tested and has passed the qualification tests specified herein (see 4.2). Testing for

requalification shall be performed at any time changes in materials or processes occur that are

deemed to have the potential for significantly altering the performance of the product.

3.3 MATERIALS

Materials not specifically designated herein shall be of the quality and form best suited for the

purpose intended. Unless otherwise specified, the materials shall meet the following

requirements.

3.3.1 Conductor Materials

Conductor materials shall be in accordance with MIL-W-81044 and the applicable

specification sheet.

3.3.2 Shield Materials

Shield materials shall conform to the requirements of WC 27500 and the applicable

specification sheet.

3.3.3 Insulating Materials

3.3.3.1 Finished Wire

Finished wire materials shall be in accordance with MIL-W-81044 and the applicable

specification sheet.

3.3.3.2 Cable Jackets

Cable jackets shall be radiation-crosslinked modified polyvinylidene fluoride.

3.3.4 Wraps

Wrap tapes, where specified in the applicable specification sheet, shall be applied with an

overlap of 25 percent, minimum, and shall meet the material and construction requirements of

the applicable specification sheet. Overlap is defined as the percentage of tape width covered

by successive turns of tape.

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3.4 FINISHED WIRE AND CABLE

3.4.1 Finished Wire

Finished wire shall conform to the requirements of Table 1 and to those of the applicable

specification sheet.

3.4.2 Finished Cable

Finished cable shall conform to the requirements of Table 2 and to those of the applicable

specification sheet. Component wires used in the cable shall conform to the appropriate

requirements of 3.4.1, prior to cabling.

3.4.3 Accelerated Aging and Life Cycle

When finished cable is tested in accordance with 4.4.1, there shall be no cracking of the jacket

and, when applicable, no dielectric breakdown of the jacket.

3.4.4 Conductor and Shield Continuity

When finished cable is tested in accordance with WC 27500, there shall be no indication of

discontinuity in the conductors or shield.

3.4.5 Identification of Product

When specified by the procuring activity, finished wire or cable shall be identified by a

marking applied to the outer surface. The identification shall consist of the appropriate mark

as specified by contract or the applicable specification sheet. The mark color shall be in

accordance with MIL-STD-104, Class 1, and shall be contrasting to that of the marking

surface. Identification shall be applied with the vertical axis of the printed characters parallel

to the longitudinal axis of the wire or cable when the nominal diameter of the marking surface

is 0.050 inch (1.27 mm) or smaller. The vertical axis of the printed characters may be either

perpendicular or parallel to the longitudinal axis of the wire or cable when the nominal

diameter of the marking surface exceeds 0.050 inch (1.27 mm).

3.4.6 Immersion

When finished cable is tested in accordance with 4.4.4, the diameter change shall be not more

than 5 percent, there shall be no cracking of the jacket and, when applicable, there shall be no

dielectric breakdown of the jacket.

3.4.7 Insulation Flaws

One hundred percent of finished wire and unshielded, unjacketed cable shall pass the impulse

dielectric test or the spark test of MIL-W-81044 using the voltage specified in the applicable

specification sheet. The test shall be performed during the final winding of the wire or cable

on shipment spools or reels.

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SPECIFICATION 44, ISSUE 5 Page 5 of 12

TABLE 1. FINISHED WIRE PROPERTIES

Examination or Test Requirement Test Method Inspection

Class

(see 4.3.1)

Accelerated Aging Specification Sheet and MIL-W-81044 MIL-W-81044 P

Blocking Specification Sheet and MIL-W-81044 MIL-W-81044 Q

Color Specification Sheet and MIL-W-81044 4.4.3 P

Concentricity MIL-W-81044 MIL-W-81044 P

Conductor Diameter Specification Sheet and MIL-W-81044 4.4.3 V

Conductor Elongation and Breaking Strength Specification Sheet and MIL-W-81044 MIL-W-81044 P

Conductor Material Specification Sheet and MIL-W-81044 4.4.3 V

Conductor Resistance Specification Sheet and MIL-W-81044 MIL-W-81044 P

Conductor Stranding Specification Sheet and MIL-W-81044 4.4.3 V

Finished Wire Diameter Specification Sheet and MIL-W-81044 4.4.3 P

Flammability Specification Sheet and MIL-W-81044 MIL-W-81044 P

Humidity Resistance Specification Sheet and MIL-W-81044 MIL-W-81044 Q

Identification and Color Striping Durability Specification Sheet and MIL-W-81044 MIL-W-81044 P

Identification of Product Specification Sheet and 3.4.5 4.4.3 P

Immersion Specification Sheet and MIL-W-81044 MIL-W-81044 Q

Insulation Elongation and Tensile Strength Specification Sheet and MIL-W-81044 MIL-W-81044 P

Insulation Flaws Specification Sheet and 3.4.7 MIL-W-81044 100%

Insulation Construction Specification Sheet and MIL-W-81044 4.4.3 P

Insulation Material Specification Sheet and MIL-W-81044 4.4.3 V

Insulation Resistance Specification Sheet and MIL-W-81044 MIL-W-81044 P

Insulation Thickness Specification Sheet and MIL-W-81044 MIL-W-81044 P

Life Cycle Specification Sheet and MIL-W-81044 MIL-W-81044 Q

Low Temperature-Cold Bend Specification Sheet and MIL-W-81044 MIL-W-81044 P

Radiation Resistance Specification Sheet and 3.4.12 4.4.9 Q

Removability of Insulation MIL-W-81044 MIL-W-81044 P

Shrinkage Specification Sheet and MIL-W-81044 MIL-W-81044 Q

Smoke Test Specification Sheet and MIL-W-81044 MIL-W-81044 Q

Solderability:

Tin coated conductors only

Silver coated conductors only

Specification Sheet

MIL-W-81044

Surface Resistance Specification Sheet and MIL-W-81044 MIL-W-81044 Q

Thermal Shock Resistance Specification Sheet and MIL-W-81044 MIL-W-81044 Q

Vacuum Stability Specification Sheet ASTM E 595 Q

Weight Specification Sheet and MIL-W-81044 MIL-W-81044 P

Wicking Specification Sheet and MIL-W-81044 MIL-W-81044 Q

Workmanship MIL-W-81044 MIL-W-81044 P

Wrap Test Specification Sheet and MIL-W-81044 MIL-W-81044 Q

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TABLE 2. FINISHED CABLE PROPERTIES

Examination or Test Requirement Test Method Inspection

Class

(see 4.3.1)

Accelerated Aging Specification Sheet and 3.4.3 4.4.1 P

Blocking Specification Sheet WC 27500 Q

Cabling Specification Sheet and WC 27500 WC 27500 P

Conductor and Shield Continuity 3.4.4 WC 27500 100%

Dielectric Withstand Specification Sheet WC 27500 100%

Dimensions Specification Sheet 4.4.3 P

Flammability Specification Sheet WC 27500 Q

Identification of Product Specification Sheet and 3.4.5 4.4.3 P

Immersion 3.4.6 4.4.4 Q

Insulation Flaws Specification Sheet and 3.4.7 MIL-W-81044 100%

Jacket Color Specification Sheet and 3.4.8 4.4.3 P

Jacket Concentricity 3.4.9 4.4.5 P

Jacket Elongation and Tensile Strength Specification Sheet 4.4.6 P

Jacket Flaws Specification Sheet and 3.4.10 4.4.7 100%

Jacket Material and Construction Specification Sheet and 3.3.3.2 4.4.3 P

Jacket Removability WC 27500 WC 27500 P

Jacket Thickness Specification Sheet 4.4.3 P

Life Cycle Specification Sheet and 3.4.3 4.4.1 Q

Low Temperature-Cold Bend Specification Sheet and 3.4.11 4.4.8 Q

Radiation Resistance Specification Sheet and 3.4.12 4.4.9 Q

Shield Coverage Specification Sheet WC 27500 P

Shield Material and Construction Specification Sheet and 3.3.2 WC 27500 P

Thermal Shock Specification Sheet WC 27500 Q

Vacuum Stability Specification Sheet ASTM E 595 Q

Weight Specification Sheet MIL-W-81044 P

Workmanship WC 27500 WC 27500 P

Wraps Specification Sheet and 3.3.4 4.4.3 P

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SPECIFICATION 44, ISSUE 5 Page 7 of 12

3.4.8 Jacket Color

Jacket color shall be in accordance with MIL-STD-104, Class 1. The preferred jacket color is

white. Colors specified other than white shall be selected in accordance with MIL-STD-681.

3.4.9 Jacket Concentricity

When finished cable is tested in accordance with 4.4.5, the jacket concentricity shall be 70

percent, minimum.

3.4.10 Jacket Flaws

One hundred percent of finished shielded and jacketed cable shall pass the jacket flaws test in

accordance with 4.4.7 using the voltage specified in the applicable specification sheet.

3.4.11 Low Temperature-Cold Bend

When finished cable is tested in accordance with 4.4.8, there shall be no cracking of the jacket

and, when applicable, no dielectric breakdown of the jacket.

3.4.12 Radiation Resistance

When finished wire is tested in accordance with 4.4.9, there shall be no cracking of the

insulation and no dielectric breakdown. When finished cable is tested in accordance with

4.4.9, there shall be no cracking of the jacket and, when applicable, no dielectric breakdown of

the jacket.

4. QUALITY ASSURANCE PROVISIONS

4.1 RESPONSIBILITY FOR INSPECTION

The supplier is responsible for the performance of all the inspection tests specified herein. The

supplier may utilize his own or any other inspection facility and services acceptable to the

buyer. Inspection records of the examination and tests shall be kept complete and available to

the buyer as required.

4.2 QUALIFICATION INSPECTION

Qualification inspection tests shall consist of all tests listed in Table 1 for wire and in Table 2

for cable.

4.2.1 Sampling for Qualification Inspection

Samples of wire or cable for qualification inspection shall be taken from product which has

been manufactured under the most current Quality Control Plan.

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4.2.2 Qualification Test Reports

When requested by the procuring activity, qualification test reports shall be plainly identified

with the following information:

Qualification test report for

WIRE AND CABLE, ELECTRIC, RADIATION-CROSSLINKED,

POLYALKENE-INSULATED, COPPER OR COPPER ALLOY

Manufacturer's Name

Part number of qualification sample

Specification 44

4.3 QUALITY CONFORMANCE INSPECTION

Quality conformance inspection consists of a series of tests and inspections that assure that

raw materials and manufacturing processes are consistent and result in products that conform

to specification requirements. In cases where customer requirements for sampling and testing

exceed the requirements of this specification, the customer requirements shall apply.

4.3.1 Inspection Classification

a. Vendor Control (V) - Requirements for raw materials such as conductor, insulation and

jacketing material over which the vendor has control and responsibility.

b. Process Control (P) - Inspections performed on samples taken from lots of wire or cable.

Inspections may be performed on finished wire and cable or after the process which

establishes the specified characteristic. The Quality Control Plan establishes the frequency

of inspection based on process control data.

c. One hundred Percent (100%) - Tests performed on the total length of each wire or cable.

Tests may be performed on the finished product or "in process", as applicable.

d. Qualification (Q) - Test performed only at the time of initial qualification or

requalification.

4.3.2 Nonconforming Inspection Lots

Disposition of material found unacceptable during quality-conformance inspection shall be in

accordance with MIL-STD-1916.

4.4 TEST METHODS

4.4.1 Accelerated Aging and Life Cycle

Finished cable shall be tested in accordance with the procedures specified in MIL-W-81044,

using the bend test of 4.4.2 herein. The voltage withstand test of 4.4.10 herein shall then be

conducted on shielded and jacketed specimens only. Finished cable specimens shall be

prepared by removing 2 inches (51 mm) of the jacket from each end of the specimen. When

applicable, the shield then shall be pushed back and formed into a pigtail at each end of the

specimen and 1 inch (25 mm) of insulation from each conductor shall be removed from each

end of the specimen. The conductors then shall be tied together at each end and loaded with

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SPECIFICATION 44, ISSUE 5 Page 9 of 12

the weight specified in the applicable specification sheet. The test mandrel shall be as

specified in the applicable specification sheet.

4.4.2 Bend Test

At a temperature maintained between 20 and 25°C, one end of the cable specimen shall be

secured to the mandrel and the other end to the load weight specified in the applicable

specification sheet. The mandrel shall be rotated until the full length of the specimen is

wrapped around the mandrel and is under the specified tension with adjoining turns in contact.

The mandrel then shall be rotated in the reverse direction until the full length of the specimen

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

specimen. The specimen then shall be examined visually for cracks.

4.4.3 Examination of Product

All samples of wire and cable shall be examined to determine conformance with this

specification and the applicable specification sheet with regard to requirements not covered by

specific test methods.

4.4.4 Immersion

Finished cable shall be tested in accordance with the procedure specified in MIL-W-81044,

using the bend test of 4.4.2 herein. The voltage withstand test of 4.4.10 herein shall then be

conducted on shielded and jacketed specimens only. Cable specimens shall be prepared by

removing 2 inches (51 mm) of the jacket from each end of a 24-inch (610-mm) length of each

specimen. When applicable, the shield then shall be pushed back and formed into a pigtail at

each end of the specimen and 1 inch (25 mm) of insulation from each conductor shall be

removed from each end of the specimen.

4.4.5 Jacket Concentricity

The concentricity of the cable jacket shall be determined by first locating and recording the

minimum wall thickness measured on a cross section of the jacket. The maximum wall

thickness of this same cross section of the jacket shall be measured and recorded. The wall

thickness shall be the radial distance between the inner and outer rim of the jacket as measured

under suitable magnification. The ratio of the minimum wall thickness to the maximum wall

thickness, times 100, shall define the percent concentricity.

4.4.6 Jacket Elongation and Tensile Strength

The elongation and tensile strength of the jacket shall be determined in accordance with the

procedure specified for insulation elongation and tensile strength in MIL-W-81044.

4.4.7 Jacket Flaws

Finished shielded and jacketed cable shall be tested in accordance with the jacket flaws test of

WC 27500, or the procedure of the impulse dielectric test of MIL-W-81044 with the shield

grounded at one or both ends.

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4.4.8 Low Temperature-Cold Bend

Jacketed cable shall be tested using the procedure of WC 27500. Temperature, mandrel

diameter and test weight shall be as specified in the applicable specification sheet. After

examination for cracks, shielded and jacketed specimens shall be subjected to the voltage

withstand test of 4.4.10 herein.

4.4.9 Radiation Resistance

A 10-foot (3-m) specimen of the finished wire or cable shall be subjected to the electron

radiation dosage specified in the applicable specification sheet at an average rate of between 5

and 10 megarads (50 and 100 kGy) per minute. Following exposure, the center portion of the

specimen shall be wound around the mandrel as specified in the applicable sheet. The ends of

the specimen shall extend at least 6 inches (152 mm) beyond the wound portion. For finished

wire and shielded and jacketed specimens, the specimen shall then be removed from the

mandrel without unwinding and shall be subjected to the voltage withstand test of 4.4.10. For

jacketed only specimens, the specimen shall be examined for cracks while still on the mandrel.

4.4.10 Voltage Withstand Test (Post Environmental)

The uninsulated ends of the specimen shall be attached to an electric lead. The specimen shall

be immersed in a 5-percent, by weight, solution of sodium chloride in water at 20 to 25°C,

except that the uninsulated ends and 1.5 in. (38 mm) of insulated wire or cable at each end of

the specimen shall protrude above the surface of the solution. After immersion for 5 hours, the

voltage specified in the applicable specification sheet at 60 Hz shall be applied between the

conductor or the shield, as applicable, and an electrode in contact with the liquid. The voltage

shall be gradually increased at a uniform rate from zero to the specified voltage in 0.5 minute,

maintained at that voltage for a period of 5 minutes for finished wire specimens and 1 minute

for finished cable specimens, and gradually reduced to zero in 0.5 minute.

4.4.10.1 Inner Jacket

For accelerated aging and life cycle cable specimens only, containing a jacket between two

shields, the voltage withstand test of 4.4.10 shall additionally be conducted on the inner jacket

with the voltage as specified in the applicable specification sheet being applied between the

two shields.

5. STANDARD PACKAGING

Unless otherwise specified (see 6.1), the following shall define the standard spooling and

labeling requirements for wire and cable furnished under this specification. Standard shipping

tolerance on ordered quantity for both wire and cable shall be ± 10 percent.

5.1 SPOOLING REQUIREMENTS

All layers of wire or cable shall be wound on spools or reels (see 5.1.3) with sufficient tension

to prevent shifting of layers and creation of crossovers within layers.

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SPECIFICATION 44, ISSUE 5 Page 11 of 12

5.1.1 Finished Wire

Finished wire lengths shall be wound on spools or reels with the ends spliced together to

provide one mechanically and electrically continuous length. Unless otherwise specified, the

minimum continuous length between splices shall be in accordance with Table 3.

TABLE 3. FINISHED WIRE LENGTHS

Wire Size Range

(AWG) Minimum Length

30 through 10

8 and larger

100 feet (30 m)

50 feet (15 m)

(NOTE: Metric lengths specified above apply only to those orders placed in metric.)

5.1.2 Finished Cable

Finished cable lengths shall be wound on spools or reels with all ends exposed. There shall be

no more than 5 lengths per spool or reel and no length shall be less than 50 feet (15 m).

5.1.3 Spools and reels

Spools and reels shall be of a nonreturnable type. Each spool and reel shall have an

appropriate diameter for the respective wire or cable size. In no case shall the barrel of the

spool or reel have a diameter less than 3.5 in. (89 mm). Spools and reels shall be suitably

finished to prevent corrosion under typical storage and handling conditions. Loaded plastic

spools shall not exceed 50 pounds (23 kg). Loaded wooden reels shall have no weight

restriction.

5.1.4 Containers

Unless otherwise specified (see 6.1), wire and cable shall be delivered in standard commercial

containers so constructed as to ensure acceptance by common or other carrier for safe

transportation at the lowest rate to the point of delivery.

5.2 LABELING REQUIREMENTS

All spools and reels shall be identified with the following information:

Manufacturer's Part Number

Lot Number

Quantity in Feet (or Meters)

Name of Manufacturer

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6. NOTES

6.1 ORDERING DATA

Procurement documents should specify the following:

a. Title, number, and date of this specification

b. Applicable specification sheet part number

c. Quantity

d. Special preparation for delivery requirements, if applicable (see Section 5.)

6.2 METRIC UNITS

Unless otherwise specified, the metric units noted herein are for information only.

6.3 MIL-W-81044

Wherever MIL-W-81044 refers to "applicable specification sheet", use the applicable Tyco

Electronics specification sheet (3.1).