AEROSPACE AS22759™ REV.

STANDARD Issued 2001 -07

Revised 201 8-05
Superseding AS22759C

(R) Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy

RATIONALE

Revision is required to update references, add a new Quality Conformance requirement for Fluoride Off-gassing test, add
UV laser marking, and make minor technical changes as needed.

1 . SCOPE

AS22759 specification covers fluoropolymer-insulated single conductor electrical wires made with tin-coated, silver-
coated, or nickel-coated conductors of copper or copper alloy as specified in the applicable detail specification. The
fluoropolymer insulation may be polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), polyvinylidene
fluoride (PVF 2), ethylene-tetrafluoroethylene copolymer (ETFE), or other Fluoropolymer resin. The fluoropolymer may be
used alone or in combination with other insulation materials. These abbreviations shall be used herein. When a wire is
referenced herein, it means an insulated conductor (see 7.7).

1 .1 Part Numbers

Unless otherwise specified (see 3.1 ), part numbers are coded as in the following example (see 3.8 for details):

M22759/1 -22 -9 0 1 2
I I I I I I
I I I I I I______ Third Stripe (Red, etc.)
I I I I I___________ Second Stripe (Brown, etc.)
I I I I________________ First Stripe (Black, etc.)
I I I_____________________ Insulation Color Designator (White, etc.)
I I________________________ Wire Size (see 3.1 )
I_______________________________ Applicable Detail Specification Designator (see 3.1 )

1 .2 Temperature Rating of Wire

The maximum conductor temperature of the wire for continuous use is specified in the detail specification (see 7.1 1 ).

1 .3 Voltage Rating of Wire

The voltage rating of a wire for continuous use is specified in the detail specification (see 7.1 2).

__________________________________________________________________________________________________________________________________________
SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is
entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.”
SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and
suggestions.
Copyright © 201 8 SAE International
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of SAE.
TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) SAE values your input. To provide feedback
Tel: +1 724-776-4970 (outside USA) on this Technical Report, please visit
Fax: 724-776-0790 http://standards.sae.org/AS22759D
Email: [email protected]
SAE WEB ADDRESS: http://www.sae.org
SAE INTERNATIONAL AS22759™D Page 2 of 45

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.
2.1 SAE Publications
Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 1 5096-0001 , Tel: 877-606-7323 (inside USA
and Canada) or +1 724-776-4970 (outside USA), www.sae.org.
AMS1 424 Deicing/Anti-Icing Fluid, Aircraft, SAE Type I
AIR571 7 Mitigating Wire Insulation Damage During Processing and Handling
ARP5607 Legibility of Print on Aerospace Wires and Cables
ARP6400 Recommended Practice for Processing and Handling Wire and Cable with Silver Plated
Conductors and Shields
ARP901 3 Statistical Product Acceptance Requirements
AS1 241 Fire Resistant Phosphate Ester Hydraulic Fluid for Aircraft
AS4373 Test Methods for Insulated Electric Wire
AS4461 Assembly and Soldering Criteria for High Quality/High Reliability Soldered Wire and Cable
Termination in Aerospace Vehicles
AS5768 Tool, Stripper, Electrical Insulation, General Specification For
AS5768/1 Tool, Stripper, Manually Actuated, Electrical Insulation, Round Wire, Size 1 0 to 30
AS5768/2 Tool, Stripper, Manually Actuated, Small Grip, Electrical Insulation, Round Wire, Size 1 6 to 30
AS22759/1 * Wire, Electrical, Fluoropolymer-Insulated, PTFE and PTFE-Coated Glass, Silver-Coated Copper
Conductor, 600-Volt
AS22759/2* Wire, Electrical, Fluoropolymer-Insulated, PTFE, and PTFE-Coated-Glass, Nickel-Coated Copper
Conductor, 600-Volt
AS22759/3* Wire, Electrical, Fluoropolymer-Insulated, TFE-Glass-TFE, Medium Weight, Nickel-Coated
Copper Conductor, 600-Volt
AS22759/4* Wire, Electrical, Fluoropolymer-Insulated, TFE-Glass-FEP, Medium Weight, Silver-Coated
Copper Conductor, 600-Volt
AS22759/5* Wire, Electrical, Fluoropolymer-Insulated, Abrasion Resistant Extruded PTFE, Silver-Coated
Copper Conductor, 600-Volt, RoHS
AS22759/6* Wire, Electrical, Fluoropolymer-Insulated, Abrasion Resistant Extruded PTFE, Nickel-Coated
Copper Conductor, 600-Volt, RoHS
AS22759/7* Wire, Electrical, Fluoropolymer-Insulated, Abrasion Resistant Extruded PTFE, Medium Weight,
Silver-Coated Copper Conductor, 600-Volt, RoHS
SAE INTERNATIONAL AS22759™D Page 3 of 45

AS22759/8* Wire, Electrical, Fluoropolymer-Insulated, Abrasion Resistant Extruded PTFE, Medium Weight,
Nickel-Coated Copper Conductor, 600-Volt, RoHS
AS22759/9* Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Silver-Coated Copper Conductor,
1 ,000-Volt, RoHS
AS22759/1 0* Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Nickel-Coated Copper Conductor,
1 ,000-Volt, RoHS
AS22759/1 1 * Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Silver-Coated Copper Conductor,
600-Volt, RoHS
AS22759/1 2* Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Nickel-Coated Copper Conductor,
600-Volt, RoHS
AS22759/1 3* Wire, Electrical, Fluoropolymer-Insulated, FEP-PVF2, Medium Weight, Tin-Coated Copper
Conductor, 600-Volt, RoHS
AS22759/1 4* Wire, Electrical, Fluoropolymer-Insulated, FEP-PVF2, Light Weight, Tin-Coated Copper
Conductor, 600-Volt, RoHS
AS22759/1 5* Wire, Electrical, Fluoropolymer-Insulated, FEP-PVF2, Light Weight, Silver-Coated High Strength
Copper Alloy Conductor, 600-Volt, RoHS
AS22759/1 6* Wire, Electrical, Fluoropolymer-Insulated, Extruded ETFE, Medium Weight, Tin-Coated Copper
Conductor, 600-Volt, 1 50°C, RoHS
AS22759/1 7* Wire, Electrical, Fluoropolymer-Insulated, Extruded ETFE, Medium Weight, Silver-Coated High
Strength Copper Alloy Conductor, 600-Volt, 1 50°C, RoHS
AS22759/1 8* Wire, Electrical, Fluoropolymer-Insulated, Extruded ETFE, Light Weight, Tin-Coated Copper
Conductor, 600-Volt, 1 50°C, RoHS
AS22759/1 9* Wire, Electrical, Fluoropolymer-Insulated, Extruded ETFE, Light Weight, Silver-Coated High
Strength Copper Alloy Conductor, 600-Volt, 1 50°C, RoHS
AS22759/20* Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Silver-Coated High Strength Copper
Alloy Conductor, 1 000-Volt, RoHS
AS22759/21 * Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Nickel-Coated High Strength Copper
Alloy Conductor, 1 000-Volt, RoHS
AS22759/22* Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Silver-Coated High Strength Copper
Alloy Conductor, 600-Volt, RoHS
AS22759/23* Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Nickel-Coated High Strength Copper
Alloy Conductor, 600-Volt, RoHS
AS22759/24-/27* MIL-W-22759 detail versions (/24-/27) were canceled without supersession. To maintain harmony
between AS22759 and MIL-DTL-22759 the AS22759/24-/27 numbers will not be used
AS22759/28* Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Polyimide Coated, Silver-Coated
Copper Conductor, 600-Volt, RoHS
AS22759/29* Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Polyimide Coated, Nickel-Coated
Copper Conductor, 600-Volt, RoHS
SAE INTERNATIONAL AS22759™D Page 4 of 45

AS22759/30* Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Polyimide Coated, Silver-Coated High
Strength Copper Alloy Conductor, 600-Volt, RoHS
AS22759/31 * Wire, Electrical, Fluoropolymer-Insulated, Extruded TFE, Polyimide Coated, Nickel-Coated High
Strength Copper Alloy Conductor, 600-Volt, RoHS
AS22759/32* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Light Weight, Tin-Coated
Copper, 1 50°C, 600-Volt, RoHS
AS22759/33* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Light Weight, Silver-
Coated High Strength Copper Alloy, 200°C, 600-Volt, RoHS
AS22759/34* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Normal Weight, Tin-
Coated Copper, 1 50°C, 600-Volt
AS22759/35* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Normal Weight, Silver-
Coated High Strength Copper Alloy, 200°C, 600-Volt
AS22759/36-/40* MIL-W-22759 detail versions (/36-/40) were canceled without supersession. To maintain harmony
between AS22759 and MIL-DTL-22759 the AS22759/36-/40 numbers will not be used
AS22759/41 * Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Normal Weight, Nickel-
Coated Copper, 200°C, 600-Volt
AS22759/42* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Normal Weight, Nickel-
Coated High Strength Copper Alloy, 200°C, 600-Volt
AS22759/43* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Normal Weight, Silver-
Coated Copper, 200°C, 600-Volt
AS22759/44* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Light Weight, Silver-
Coated Copper, 200°C, 600-Volt, RoHS
AS22759/45* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Light Weight, Nickel-
Coated Copper, 200°C, 600-Volt, RoHS
AS22759/46* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Light Weight, Nickel-
Coated High Strength Copper Alloy, 200°C, 600-Volt, RoHS
AS22759/47* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Low Fluoride, Light
Weight, 80 Microinch, Silver-Coated High Strength Copper Alloy, 200°C, 600-Volt, RoHS
AS22759/48* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Low Fluoride, Light
Weight, 80 Microinch, Silver-Coated Copper, 200°C, 600-Volt, RoHS
AS22759/49* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Low Fluoride, Normal
Weight, 80 Microinch, Silver-Coated High Strength Copper Alloy, 200°C, 600-Volt, RoHS
AS22759/50* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Low Fluoride, Normal
Weight, 80 Microinch, Silver-Coated Copper, 200°C, 600-Volt, RoHS
AS22759/51 * Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Low Fluoride, Light
Weight, Silver-Coated High Strength Copper Alloy, 200°C, 600-Volt, RoHS
AS22759/52* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Low Fluoride, Light
Weight, Silver-Coated Copper, 200°C, 600-Volt, RoHS
SAE INTERNATIONAL AS22759™D Page 5 of 45

AS22759/53* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Low Fluoride, Normal
Weight, Silver-Coated High Strength Copper Alloy, 200°C, 600-Volt, RoHS
AS22759/54* Wire, Electrical, Fluoropolymer-Insulated, Cross-linked Modified ETFE, Low Fluoride, Normal
Weight, Silver-Coated Copper, 200°C, 600-Volt, RoHS
AS22759/55* Wire, Electrical, Fluoropolymer-Insulated, Cross Linked Modified ETFE, Lightweight, Silver
Coated, Extra High Strength Copper Alloy, 200 °C, 600 Volt, ROHS
AS22759/56* Wire, Electrical, Fluoropolymer-Insulated, Cross Linked Modified ETFE, Normal Weight, Silver
Coated, Extra High Strength Copper Alloy, 200 °C, 600 Volt, ROHS
AS22759/57* Wire, Electrical, Fluoropolymer-Insulated, Cross Linked Modified ETFE, Normal Weight, Nickel
Coated, Extra High Strength Copper Alloy, 200 °C, 600 Volt, ROHS
AS22759/58* Wire, Electrical, Fluoropolymer-Insulated, Cross Linked Modified ETFE, Lightweight, Nickel
Coated, Extra High Strength Copper Alloy, 200 °C, 600 Volt, ROHS
AS22759/59-/79* For future detail specifications
AS22759/80* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Light Weight, Tin Coated, Copper
Conductor, 1 50°C, 600 Volts, RoHS
AS22759/81 * Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Light Weight, Silver Coated, High
Strength or Ultra High Strength Copper Alloy, 200°C, 600 Volts, RoHS
AS22759/82* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Light Weight, Nickel Coated, High
Strength or Ultra High Strength Copper Alloy, 260°C, 600 Volts, RoHS
AS22759/83* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Over Braid, Normal Weight, Silver
Coated, Copper Conductor, 200°C, 600 Volts, RoHS
AS22759/84* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated Over Braid, Normal Weight, Nickel
Coated, Copper Conductor, 260°C, 600 Volts, RoHS
AS22759/85* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated Over Braid, Normal Weight, Tin
Coated, Copper Conductor, 1 50°C, 600 Volts, RoHS
AS22759/86* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Silver Coated,
Copper Conductor, 200°C, 600 Volts, RoHS
AS22759/87* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Nickel Coated,
Copper Conductor, 260°C, 600 Volts, RoHS
AS22759/88* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Tin Coated, Copper
Conductor, 1 50°C, 600 Volts, RoHS
AS22759/89* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Silver Coated, High
Strength or Ultra High Strength Copper Alloy, 200°C, 600 Volts, RoHS
AS22759/90* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Nickel Coated, High
Strength or Ultra High Strength Copper Alloy, 260°C, 600 Volts, RoHS
AS22759/91 * Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Light Weight, Silver Coated, Copper
Conductor, 200°C, 600 Volts, RoHS
AS22759/92* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Light Weight, Nickel Coated, Copper
Conductor, 260°C, 600 Volts, RoHS
SAE INTERNATIONAL AS22759™D Page 6 of 45

AS22759/93* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Light Weight, Silver Coated, Extra
High Strength Copper Alloy, 200°C, 600 Volts, RoHS
AS22759/94* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Light Weight, Nickel Coated, Extra
High Strength Copper Alloy, 260°C, 600 Volts, RoHS
AS22759/95* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Silver Coated, Extra
High Strength Copper Alloy, 200°C, 600 Volts, RoHS
AS22759/96* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Nickel Coated,
Extra High Strength Copper Alloy, 260°C, 600 Volts, RoHS
AS22759/97-/1 79* For future detail specifications
AS22759/1 80* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Light Weight, Tin
Coated, Copper Conductor, 1 50°C, 600 Volts, RoHS
AS22759/1 81 * Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Light Weight,
Silver Coated, High Strength or Ultra High Strength Copper Alloy, 200°C, 600 Volts, RoHS
AS22759/1 82* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Light Weight,
Nickel Coated, High Strength or Ultra High Strength Copper Alloy, 260°C, 600 Volts, RoHS
AS22759/1 83* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Over Braid, Smooth Surface,
Normal Weight, Silver Coated, Copper Conductor, 200°C, 600 Volts, RoHS
AS22759/1 84* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Over Braid, Smooth Surface,
Normal Weight, Nickel Coated, Copper Conductor, 260°C, 600 Volts, RoHS
AS22759/1 85* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Over Braid, Smooth Surface,
Normal Weight, Tin Coated, Copper Conductor, 1 50°C, 600 Volts, RoHS
AS22759/1 86* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Normal Weight,
Silver Coated, Copper Conductor, 200°C, 600 Volts, RoHS
AS22759/1 87* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Normal Weight,
Nickel Coated, Copper Conductor, 260°C, 600 Volts, RoHS
AS22759/1 88* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Normal Weight,
Tin Coated, Copper Conductor, 1 50°C, 600 Volts, RoHS
AS22759/1 89* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Normal Weight,
Silver Coated, High Strength or Ultra High Strength Copper Alloy, 200°C, 600 Volts, RoHS
AS22759/1 90* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Normal Weight,
Nickel Coated, High Strength or Ultra High Strength Copper Alloy, 260°C, 600 Volts, RoHS
AS22759/1 91 * Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Light Weight,
Silver Coated, Copper Conductor, 200°C, 600 Volts, RoHS
AS22759/1 92* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Light Weight,
Nickel Coated, Copper Conductor, 260°C, 600 Volts, RoHS
AS22759/1 93* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Light Weight,
Silver Coated, Extra High Strength Copper Alloy, 200°C, 600 Volts, RoHS
AS22759/1 94* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Light Weight,
Nickel Coated, Extra High Strength Copper Alloy, 260°C, 600 Volts, RoHS
SAE INTERNATIONAL AS22759™D Page 7 of 45

AS22759/1 95* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Normal Weight,
Silver Coated, Extra High Strength Copper Alloy, 200°C, 600 Volts, RoHS
AS22759/1 96* Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Smooth Surface, Normal Weight,
Nickel Coated, Extra High Strength Copper Alloy, 260°C, 600 Volts, RoHS
AS29606 Wire, Electrical, Stranded, Uninsulated Copper, Copper Alloy, or Aluminum, or Thermocouple
Extension, General Specification For
AS9003 Inspection and Test Quality System
AS50881 Wiring, Aerospace Vehicle
* AS22759 detail specifications
2.2 European Committee for Standardization
Available from European Parliament, Bât. Altiero Spinelli, 60 rue Wiertz / Wiertzstraat 60, B-1 047 - Bruxelles/Brussels
Belgium
RoHS Restriction of Hazardous Substances Directive (RoHS) 2002/95/EC by January 1 , 201 5
2.3 ASQ Publications
Available from American Society for Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203, Tel: 800-248-1 946
(United States or Canada)), 001 -800-51 4-1 564 (Mexico) or +1 -41 4-272-8575 (all other locations), www.asq.org
ANSI/ASQC-Z1 .4 Sampling Procedures and Tables for Inspection by Attributes
2.4 ASTM Publications
Available from ASTM International, 1 00 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 1 9428-2959, Tel:
61 0-832-9585, www.astm.org.
ASTM B286 Copper Conductors for Use in Hookup Wire for Electronic Equipment
ASTM D1 49 Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical
Insulating Materials at Commercial Power Frequencies
ASTM D471 Standard Test Method for Rubber Property
ASTM D770 Standard Specification for Isopropyl Alcohol
ASTM D792 Standard Methods of Test for Specific Gravity and Density of Plastics by Displacement
ASTM D882 Standard Test Methods for Tensile Properties of Thin Plastic Sheeting
ASTM D1 1 53 Methyl Isobutyl Ketone (for Use in Organic Coatings)
ASTM D1 655 Standard Specification for Aviation Turbine Fuels
ASTM D21 1 6 Standard Specification for FEP-Fluorocarbon Molding and Extrusion Materials
ASTM D3032 Hook Up Wire Insulation Standard Test Method For
ASTM D31 59 Standard Specification for Modified ETFE-Fluoropolymer Molding and Extrusion Materials
SAE INTERNATIONAL AS22759™D Page 8 of 45

ASTM D3222 Standard Specification for Unmodified Poly (Vinylidene Fluoride) (PVDF) Molding Extrusion and
Coating Materials
ASTM D4591 Temperature and Heats Determining of Transition of Fluoropolymers by Differential Scanning
Calorimetry
ASTM D481 4 Standard Specification for Automotive Spark-Ignition Engine Fuel
ASTM D4895 Standard Specification for Polytetrafluoroethylene (PTFE) Resin Produced From Dispersion
2.5 IPC-Association Connecting Electronics Industries Publications
Available from IPC, 3000 Lakeside Drive, 309 S, Bannockburn, IL 6001 5, Tel: 847-61 5-71 00, www.ipc.org.
J-STD-002 Component Leads, Terminations, Lugs, wires, Solderability Tests For
2.6 National Conference of Standards Laboratories (NCSL)
Available from NCSL International, 2995 Wilderness Place, Suite 1 07, Boulder, CO 80301 , Tel: 303-440-3339,
www.ncsli.org.
NCSL Z540.3 Calibration of Measuring and Test Equipment, Requirements for
2.7 U.S. Government Publications
Copies of these documents are available online at http://quicksearch.dla.mil.
A-A-59921 Cleaning Compound, Aircraft Surface
MIL-STD-1 04 Limits for Electrical Insulation Color
MIL-STD-1 29 Marking for Shipment and Storage
MIL-STD-202 Electronic and Electrical Components Parts
MIL-STD-681 Identification Coding and Application of Hookup and Lead Wire
MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5
MIL-DTL-1 2000 Cable, Cord, and Wire, Electric; Packaging of
MIL-DTL-831 33 Turbine Fuel, Aviation, Kerosene Types, NATO F-34 (JP-8) and NATO F-35
MIL-PRF-5606 Hydraulic Fluid, Petroleum Base; Aircraft, Missile and Ordnance
MIL-PRF-7808 Lubricating Oil, Aircraft, Turbine Engine, Synthetic Base
MIL-PRF-23699 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base
MIL-PRF-87252 Coolant Fluid, Hydrolytically Stable, Dielectric
MIL-PRF-87937 Cleaning Compound, Aerospace Equipment
SD6 Provisions Governing Qualification
SAM System for Award Management*
*Available from https://www.sam.gov/portal/public/SAM/.
SAE INTERNATIONAL AS22759™D Page 9 of 45

3. REQUIREMENTS
3.1 Detail Specification (see 2.1 )
The product requirements shall be as specified herein and in accordance with the applicable detail specification. In the
event of any conflict between the requirements of this specification and the detail specification, the latter shall govern. The
detail specification shall be formatted as shown in Appendix A.
3.2 Qualification (see 4.2)
The wire furnished herein shall be a product that has been tested and has passed the qualification tests specified herein
and has been listed on or approved for listing on the applicable Qualified Products List (see 9.2).
3.2.1 Conformity to Qualified Sample
Except for changes approved by the purchase order, it is understood that wire supplied under the purchase order shall be
the same material formulations, material sources, and manufacturing processes as approved by the Qualifying Activity.
Any unapproved changes made after the qualification approval date, unless accepted by the Qualifying Activity, may
constitute cause for rejection. All identified unapproved changes must be reported to the Qualifying Activity. Failure of a
manufacturer to notify the Qualifying Activity of a change in design, material, manufacturing process (including quality
conformance) or plant location shall be reason for adverse action or removal from the Qualified Products List.
3.3 Materials (see 5.1 )
Unless otherwise specified in the detail specification, the wire materials shall be as specified herein. The wire insulation
shall contain no additives except those required as wetting agents in suspensoids, pigmentation for colors, and lubricants
used in extrusion. Fillers shall be added only when required. The use of reclaimed or recycled insulation material is not
prohibited, but if used, the recycled materials shall not have been degraded, shall be free of contaminants, and shall be
identical with the original materials in performance. When required in the detail specification, the wire shall comply with
Restriction of Hazardous Substances Directive (RoHS).
3.3.1 Conductor Material (see 5.1 .1 )
All conductors shall meet the material requirements of AS29606. The wire supplier is responsible for all quality assurance
and compliance requirements imposed on the conductor per AS29606. Conductor material data shall be maintained for a
minimum of 6 years (see 4.3.2 and 4.4.3).
3.3.2 PTFE Coated Fibrous Glass Yarns Material (see 5.1 .2)
All fibrous glass yarns used in braiding shall be coated with PTFE resin to the extent of not less than 1 5% by weight of the
coated yarn. In addition, after each braid application, the braid shall be coated with PTFE. This coating shall be a PTFE
finisher, PTFE extrusion, or PTFE unsupported tape.
3.3.3 PTFE Coated Fibrous Glass Tapes Material (see 5.1 .3)
All fibrous glass tapes used in insulation shall contain not less than 50% of PTFE by weight of the coated tape.
3.3.4 Fluoropolymer (FP)/Polyimide/Fluoropolymer (FP) Tapes Material (see 5.1 .4)
FP/Polyimide/FP tapes used as a wrap on a conductor shall be as specified in Table 1 .
SAE INTERNATIONAL AS22759™D Page 1 0 of 45

Table 1 - FP/polyimide/FP tapes

0.00045 (FP) / 0.00065 (Polyimide) 0.0005 (FP) / 0.001 0 (Polyimide)
Wire Tape Characteristics / 0.0001 (FP) / 0.0005 (FP)
Tensile Strength
(min average lb/in 2) 20000 1 9000
Longitudinal Elongation
(min average %) 40 40
Dielectric Strength
(min average volts/mil) 4000 4000
Specific Gravity (g/cc) 1 .78 nominal 1 .81 nominal
Thickness 1 / 1 .1 mils min - 1 .3 mils max 1 .85 mils min - 2.1 5 mils max
1 / Description of the film describe the nominal thickness of each layer. Each film has a polyimide substrate
(center) with a modified Fluoropolymer (FP) coating on the outside.

3.3.5 Unsupported PTFE Tape Material (see 5.1 .4)

Unsupported PTFE tapes shall be as specified in Table 2. For extruded unsintered PTFE tapes, requirements are only
applicable to detail specifications which do not contain a wire insulation state of sinter requirement on the PTFE tape
layer.
Table 2 - Unsupported PTFE tapes
Extruded Unsintered
Skived PTFE Tape Cast PTFE Tape PTFE Tape
Tape Thickness (mils)
Wire Tape
Characteristics 0-3.5 3.6-5.5 5.6 min 0-3.5 3.6-5.5 0-5.5
Dielectric
Strength
(min average
volts/mil) 2700 2200 1 500 3200 2700 700
Specific Gravity 2.1 4 min 2.1 4 min
(g/cc) 2.21 max 2.21 max 1 .5 min
Tensile Strength
(min average
lb/in 2) 4000 3000 1 300
Longitudinal
Elongation
(min average %) 300 300 50

3.3.6 Fluoropolymer Insulation Resin Material (see 5.1 .5)

Fluoropolymer insulation material properties used for extrusion of wire primary and jacket insulations as well as insulating
tapes shall conform to the material controls specified in Table 3.
Table 3 - Fluoropolymer insulation resin properties
Fluoropolymer Insulation Material Material Specification
Polytetrafluoroethylene (PTFE) ASTM D4895
Fluorinated Ethylene Propylene (FEP) ASTM D21 1 6
Polyvinylidene Fluoride (PVF2) ASTM D3222
Ethylene-tetrafluoroethylene copolymer (ETFE) ASTM D31 59
SAE INTERNATIONAL AS22759™D Page 1 1 of 45

3.4 Conductor Construction (see 5.2)

3.4.1 Conductor Construction Prior to Insulation Application (see 5.2.1 and 7.4)
The conductor construction prior to the application of the insulation shall be in accordance with AS29606.
3.4.2 Insulated Conductor Splice (see 5.2.2)
Insulated conductor splices shall meet the requirement of AS29606.
3.4.3 Insulated Conductor Tin and Silver Solderability (see 5.2.3)
The insulated conductor with tin coated or silver coated strands shall meet the “Acceptable” solder coverage of the
stranded conductor in accordance with J-STD-002. The test is not applicable to wires with nickel coated strands (see 7.2).
3.4.4 Insulated Conductor Geometric Characteristics (see 5.2.4)
The insulated conductor diameter, strand count, and strand diameter shall be in accordance with AS29606 and listed in
the detail specification.
3.4.5 Insulated Conductor Strand Blocking - Adhesion (see 5.2.5)
For 1 9-strand conductor (wire sizes 26 through 1 2), the total number of unbonded single strands plus the number of
metallic bonded pairs and metallic bonded groups of strands in the specimen shall be not less than 1 3. For all other
conductors (7 strands, etc.), the total count of unbonded single strands, metallic bonded pairs of strands, and metallic
bonded groups of strands shall not be less than 0.70 times the number of strands in the conductor.
3.4.6 Insulated Conductor Elongation and Tensile Break Strength (see 5.2.6)
The wire conductor elongation and tensile break strength shall be in accordance with AS29606.
3.5 Wire Insulation Properties (see 5.3)
3.5.1 Insulation Construction and Mechanical Properties (see 5.3.1 )
The wire insulation/jacket construction (see 5.3.1 .1 ) and mechanical properties (see 5.3.1 .2 and 5.3.1 .3) shall be as
specified in the detail specification and Tables 4 through 6.
Table 4 - PTFE extruded insulation and jacket
Wire Size
Wire Insulation Properties 28-20 1 8-1 2 1 0-8 6-4/0 28-1 4 1 2-8 6-4/0 28-1 6 1 4-1 2 1 0-8 6-4/0
Tensile Strength
(min average lb/in 2) 4500 4000 3500 n/a
Longitudinal Elongation
(min average %) 250 200 n/a
Circumferential Elongation
(min average) 200 1 50 1 00 n/a
SAE INTERNATIONAL AS22759™D Page 1 2 of 45
Table 5 - Abrasion resistant (mineral filled) PTFE extruded insulation and jacket
Wire Size
Wire Insulation Properties 24-20 1 8-4 2-4/0 28-8 6-4 2-4/0 24-1 6 1 4-1 2 1 0-4 2-4/0
Tensile Strength
(min average lb/in 2 ) 4000 3500 n/a
Longitudinal Elongation
(min average %) 200 1 50 n/a
Circumferential Elongation
(min average) 1 00 75 50 n/a

Table 6 - FEP, ETFE, PVF2, and XLETFE (cross linked) extruded insulation and jacket
Wire Insulation Properties FEP ETFE PVF 2 XLETFE 1 /
Tensile Strength 2000 5000 5000 5000
(min average lb/in 2)
Longitudinal Elongation 1 50 1 50 250 75 1 /
(min average %)
1 / Longitudinal Elongation of the inner layer of dual-wall insulations is 1 25% minimum for
size 1 0 and smaller only.

3.5.2 Primary and Jacket Insulation Tape Splices (see 5.3.2)

Wire splices shall be permitted in the insulation tapes provided the performance characteristics of the wire are not
affected. No splice in one layer of insulation tape shall be so positioned on the wire as to overlap any part of a splice in
another layer of insulation tape. The measured maximum diameter of the wire at a splice in the insulation tape shall not
exceed the measured diameter of the wire where no tape splice is present by more than five times the nominal thickness
of the tape in which the splice occurs (seven times for single-tape insulations). Splices of the outer insulation tape shall
not be longer than 1 inch and not more than one splice of the outer insulation tape shall occur in any 1 50 feet of the wire.
3.5.3 Wire Primary Insulation Flaws (see 5.3.3)
The primary insulation shall be subjected to the spark test, impulse dielectric test, or the high frequency spark test. This
evaluation shall be performed before the application of any additional layers to the wire. Any portion showing insulation
breakdown shall be cut out of the primary insulation at least two inches on each side of the failure. Unless otherwise
specified in the detail specification, the test voltage shall be as specified in Table 7.
Table 7 - Primary insulation flaw voltages
Test Type Voltage Requirement
Spark (see 5.3.3.1 ) 1 .5 KV (rms)
Impulse Dielectric (see 5.3.3.2) 6.0 KV (peak)
High Frequency Spark (see 5.3.3.3) 4.2 KV (rms)

3.5.4 Wire Final Insulation Flaws (see 5.3.3)

One hundred percent of the wire shall pass either the impulse dielectric test or the preferred high frequency spark test.
The test shall be performed during the final winding of the wire on shipment spools or reels. Unless otherwise specified,
the test voltage shall be as specified in Table 8.
Table 8 - Wire final insulation flaw voltages
Test Type Voltage Requirement
Impulse Dielectric (see 5.3.3.2) 8.0 KV (peak)
High Frequency Spark (see 5.3.3.3) 5.7 KV (rms)
SAE INTERNATIONAL AS22759™D Page 1 3 of 45

3.5.5 Insulation State of Sinter (see 5.3.4)

Layers of insulations shall meet the state of sinter requirement as specified in the detail specification.
3.5.6 Tape Overlap (see 5.3.5)
The minimum (and maximum if applicable) percent overlap in applying each layer of insulation tape shall be as indicated
in the detail specification.
3.5.7 Outer Insulation Tape Layer Surface Smoothness (see 5.3.6)
The difference in the wall thickness of the outer insulation layer at the discernible tape edge shall not exceed the limits in
Table 9.
Table 9 - Smooth surface tape wall thickness percent different
Wire Size Percent Difference (%)
26 thru 1 0 1 0.0
8 thru 6 7.0
4 thru 4/0 5.0

3.5.8 Fluoride Off-Gassing (see 5.3.7)

Unless otherwise specified in the detail specification, the fluoride extraction level, when required, shall not exceed
20 parts per million.
3.5.9 Lamination Sealing (see 5.3.8)
When lamination sealing is required in the detail specification, there shall be no evidence of tape separation or lifting.
3.5.1 0 Polyimide Topcoat Cure (see 5.3.9)
When polyimide topcoat cure is required in the detail specification, the topcoat shall have no visible cracks.
3.5.1 1 Insulation Proof Test (Crosslink Proof / Accelerated Aging / Short-Term Thermal Stability - see 5.3.1 0)
When the insulation proof test is required in the detail specification, the exposure temperature shall be 300 °C ± 3 °C
(572 °F ± 5.4 °F) and the change in marking, color, or conductor pitting (see 7.4.2) shall not be considered. There shall be
no observed cracks or splits when subjected to the bend test and no dielectric breakdown of the insulation.
3.5.1 2 Insulation Blocking (see 5.3.1 1 )
Adjacent turns or layers of the wire shall not stick to one another.
3.5.1 3 Insulation Shrinkage (see 5.3.1 2)
Insulation shrinkage shall not exceed the values specified in the detail specification. Unless otherwise specified in the
detail specification insulation expansion is not required.
3.5.1 4 Insulation Layer Wicking (see 5.3.1 3)
Wicking between the insulation layers shall not travel beyond dye length specified in the detail specification.
SAE INTERNATIONAL AS22759™D Page 1 4 of 45

3.6 Wire Electrical Properties (See 5.4)

3.6.1 Wire Conductor Electrical Resistance (see 5.4.1 )
The wire conductor electrical resistance shall be in accordance with the detail specification.
3.6.2 Wire Electrical Insulation Resistance (see 5.4.2)
Unless otherwise specified in the detail specificati on , th e i n su l ati on resi stan ce sh al l be 500 0 M Ω m i n i m u m for 1 000 feet.
3.6.3 Wire Electrical Surface Resistance (see 5.4.3)
The wire surface resistance shall be in accordance with the detail specification.
3.6.4 Electrical Dielectric Resistance – Wet Dielectric Voltage (see 5.4.4)
The wire electrical dielectric resistance shall be in accordance with the detail specification following the specified test
conditioning.
3.7 Wire Physical Properties (see 5.5)
3.7.1 Wire Diameter (see 5.5.1 )
The wire diameter shall be as specified in the detail specification.
3.7.2 Wire Weight (see 5.5.2)
The wire weight shall be as specified in the detail specification.
3.7.3 Wire Insulation Stripping (see 5.5.3)
All insulation shall be readily removable by conventional wire stripping devices without damage to the conductor. The
insulation of wire size 1 0 or smaller shall be removed in accordance with the required stripping tool specified in AS5768/1
or /2 and the wire shall be found “acceptable” as defined by AS5768.
3.7.4 Wire Insulation Strip Force (see 5.5.4)
When specified in the detail specification, the pull off force (strip) for wire size 26 through 1 4 shall be as specified using
the required AS5768/1 or AS5768/2 stripper blades.
3.7.5 Wire Insulation Concentricity and Wall Thickness (see 5.5.5)
The insulation concentricity shall be 70%. The concentricity requirement shall apply to both the wire primary insulation and
the wire construction. The concentricity requirement shall not apply to tape-wrap primary insulation layer or tape jackets.
When required in the detail specification, the minimum wall thickness shall be as specified.
3.7.6 Workmanship (see 5.5.6)
The insulation shall be free of cracks, splits, irregularities, and embedded foreign material.
3.7.7 Continuous Lengths (see 5.5.7)
The individual continuous lengths of wire in each lot shall be of such footage that when inspected the lot shall conform to
the Schedule A continuous length requirements of Table 1 0 or to the Schedule B continuous length requirements of
Table 1 1 , as applicable. Unless the contract or order that was used to produce the lot specifies otherwise, the footage of
the individual continuous lengths in each spool or reel shall be marked on the spool or reel in the sequence in which the
lengths will be unwound from the spool. The applicable schedule shall be as specified in the detail specification.
SAE INTERNATIONAL AS22759™D Page 1 5 of 45

Table 10 - Minimum continuous wire lengths (Schedule A requirements)

Required Minimum Percent of the Total Inspection
Wire Size Lot Footage in Continuous Lengths Greater Than
(Range) 300 feet 1 00 feet 50 feet 25 feet
30-20 50% 80% 1 00% —
1 8-1 4 30% 80% 1 00% —
1 2-1 0 — 50% 80% 1 00%
8-4 — 20% 50% 1 00%
2-1 — — 50% 1 00%
0-0000 — — 30% 1 00%

Table 11 - Minimum continuous wire lengths (Schedule B requirements)

Required Minimum Percent of the Total Inspection
Wire Size Lot Footage in Continuous Lengths Greater Than
Range 500 feet 250 feet 1 00 feet 50 feet 25 feet
30-6 85% — 1 00% — —
4-2 — 85% — 1 00% —
1 -0000 — — 85% — 1 00%

3.8 Wire Identification (see 5.6)

3.8.1 Wire Identification Printed Marking and Location (see 5.6.1 )

Unless otherwise specified in the detail specification, the wire shall be identified by a printed marking applied to the outer
surface of the wire for wire sizes 24 and larger. Wire sizes 26 and smaller do not require identification print marking. For
ink marking (see 3.8.1 .1 ) the printed identification shall be at intervals of 6 to 60 inches, as measured from the end of one
complete marking to the beginning of the succeeding complete marking. For UV Laser marking (see 3.8.1 .2), the interval
shall be at 7, 1 1 , or 1 3 inches. The identification mark shall not be applied by hot stamp marking or other methods that
significantly penetrate the insulation. The printed marking on the wire shall be as follows:
M22759/1 -22 -901 2 1 281 4 REV A
I I I I I
I I I I I________ Detail Specification Revision Letter (see 3.8.1 a)
I I I I_______________ Manufacturer Identification CAGE Code (see 3.8.1 b)
I I I______________________ Insulation Color Designators (Optional see 3.8.1 c)
I I____________________________ Wire Size (see detail specification)
I____________________________________ Applicable Detail Specification Designator (see 3.1 )

a. The wire shall be marked with the latest revision letter specified for the detail specification (see 1 0.2). If the detail
specification has no revision letter, the revision letter is not required.

b. The wire shall be marked with the manufacturer’s identification in accordance with the manufacturer’s Commercial
and Government Entity (CAGE) listed in “SAM”.

c. The insulation color designator (wire color, stripes, bands, or tracers) is not required in the printed marking but is
required in all reference documentation. At the option of the wire supplier, the color code portion of the part number
(see 1 .1 ) may be included but, if included, it shall be included in its entirety, not in part.
SAE INTERNATIONAL AS22759™D Page 1 6 of 45

3.8.1 .1 Identification Printed Ink Marking Characteristics and Color

Unless otherwise specified in the detail specification, the ink printing shall be green in color in accordance with MIL-STD-
1 04, Class 1 , except that when the wire is any color against which green is difficult to distinguish, the ink printing shall be
white. Identification printing shall be applied with the vertical axes of the printed characters lengthwise of the wire when
the nominal diameter of the wire is 0.050 inch or smaller. The vertical axes of the printed characters may be either
crosswise or lengthwise of the wire when the nominal diameter of the wire exceeds 0.050 inch. All printed characters shall
be complete and legible. Ink printing shall comply with the requirements of 3.8.3.
3.8.1 .2 Identification Printed UV Laser Marking Characteristics
As an alternate method to ink marking identified in 3.8.1 .1 , UV laser marking may also be used to apply the wire
identification mark as noted in 3.8.1 . The Identification printing shall be applied with the vertical axes of the characters
lengthwise on the wire when the nominal diameter of the wire is 0.050 inch or smaller. The vertical axes of the printed
characters may be either crosswise or lengthwise on the wire when the nominal diameter of the wire exceeds 0.050 inch.
All printed characters shall be complete and legible. Wire processors may want to reference ARP5607 when establishing
the appropriate character font and size to improve legibility. UV laser printing shall comply with the requirements of 3.8.4
and 3.9.1 7.
3.8.2 Wire Color Designators and Munsell Limits (see 1 .1 and 5.6.2)
The colors of the wire shall be as indicated by the insulation color designator (see 1 .1 ) of the wire part number. The first
digit of the designator shall indicate the background insulation color and the succeeding digits, if any, shall indicate the
colors of the stripes, bands, or tracers as indicated in 1 .1 .
3.8.2.1 Background Insulation Color Designator
The background insulation color designator of the wire shall be listed in MIL-STD-681 , System I (differentiation color
coding for chassis wiring). Unless otherwise specified in the detail specification, the preferred background insulation color
designator shall be white (-9). Any applicable restrictions on available colors shall be indicated in the detail specification.
Unless otherwise specified in the detail specification, the Munsell color limit of the background insulation shall be in
accordance with MIL-STD-1 04, Class 1 . When detail specification requires minimum UV Laser marking contrast levels,
the Munsell limits shall be as specified in Table 1 2.
Table 12 - Munsell color limits for UV laser mark-able wire

Color Hue Value Chroma

From To From To From To
Black 2.5N 8.5 n/a
Gray
Blue 5PB 7.5PB 6
Violet 2.5P 7.5R 7 8 4 8
Red 1 0RP 5R 6
Green 2.5G 7.5G 2 6
Brown 2.5YR 7.5R 9 2 4
Yellow 5Y 1 0Y 8 4 6
Orange 1 0R 2.5YR 6 7 8 10
3.8.2.2 Color Stripes, Bands, or Tracers Designation
The requirements and color designators for stripes and bands shall be in accordance with MIL-STD-681 . The color limits
for stripes, bands and tracers shall be in accordance with MIL-STD-1 04, Class 1 .
SAE INTERNATIONAL AS22759™D Page 1 7 of 45

3.8.3 Wire Identification Ink Mark, Stripe, or Band Durability (see 5.6.3)
The wire identification marking and color stripes (see 3.8.1 and 3.8.2.2), when applied to the outer surface of the wire with
ink, shall be capable of withstanding the durability test for the number of cycles and with the weight specified in the detail
specification. This test shall not be required when the identification marking, stripes, or bands are under a clear jacket, or
on braided tracers. If there is a continuous line of erasure or obliteration through the stripe, band, or printed identification
marking exposing the insulation, the specimen shall be considered as having failed.
3.8.4 UV Laser Marking (see 5.6.4)
When the UV laser marking is required in the detail specification or used to provide the wire identification mark, the wire
outer surface shall be ultraviolet (UV) laser mark-able. Unless otherwise specified in the detail specification, the mark shall
meet a minimum contrast level of 55%.
3.9 Insulated Wire Performance Requirements (see 5.7)
3.9.1 Mandrel Bend Mechanical Resistance for Tape/Braid Insulation (see 5.7.1 )
Wire with tapes, braids, or both tapes and braids as components of the insulation shall show no insulation cracking or
dielectric breakdown after being subjected to bending with the weight and mandrel size specified in the detail
specification.
3.9.2 Wrap Back Bend Mechanical Resistance for Extruded Insulation (5.7.2)
Wire insulation composed entirely of extruded material or polyimide-coated extruded material shall show no cracking or
splitting of the insulation and no dielectric breakdown after being subjected to the wrap back test at the temperature
specified in the detail specification.
3.9.3 Insulation Low Temperature Mechanical Resistance/Cold Bend (see 5.7.3)
The low temperature mechanical resistance (cold bend) test shall be performed at -65 °C ± 2 °C (-85 °F ± 3.6 °F) unless
otherwise specified in the detail specification with the specified mandrels and weights. The insulation shall have no visible
cracks or dielectric breakdown at the specified wet dielectric voltage.
3.9.4 Insulation Thermal Shock Mechanical Resistance (see 5.7.4)
The insulation shall not shrink more than that specified in the detail specification at the specified temperature. There shall
be no flaring of the insulation layers. The insulation is defined as all layers of non-conducting material covering the
electrical conductor, e.g., primary insulation, all tapes and braids, and the jacket.
3.9.5 Thermal Mechanical Resistance - Life Cycle (see 5.7.5)
The thermal mechanical resistance (life cycle) test shall be performed at the temperature specified in the detail
specification with the specified mandrels and weights. There shall be no change in color of the insulation. Change in
marking color shall not be considered. There shall be no observed cracks or splits and no wet dielectric breakdown of the
insulation when subjected to the ambient mechanical resistance bend test (see 3.9.6).
3.9.6 Ambient Mechanical Resistance - Mandrel Bend Test (see 5.7.6)
The ambient mechanical resistance - mandrel bend test shall be performed with the mandrels and weights specified in the
detail specification. There shall be no observed cracks or splits and no wet dielectric breakdown of the insulation.
3.9.7 Fluid Resistance - Immersion (see 5.7.7)
The wire shall not exceed the diameter specified in the detail specification by more than 5%. The wire shall exhibit no
cracking or insulation dielectric breakdown after immersion.
SAE INTERNATIONAL AS22759™D Page 1 8 of 45

3.9.8 Humidity Resistance (see 5.7.8)

The wire shall be in accordance with the insulation resistance value specified in the detail specification.
3.9.9 Smoke Resistance (see 5.7.9)
The wire shall exhibit no visible smoke at the temperature specified in the detail specification.
3.9.1 0 Flammability (see 5.7.1 0)
Unless otherwise specified in the detail specification, any flame in the wire insulation shall be self-extinguishing within a
maximum of 3 seconds after removal of the external flame source from the insulation. When specified in the detail
specification, the flame travel shall not exceed the specified length. Refer to Table 1 3, Initial and retention qualification
tests for the detailed specifications which require the use of a facial tissue with the requirement of no incendiary drips
allowed.
3.9.1 1 Wet Arc Propagation Resistance (see 5.7.1 1 )
Unless otherwise specified in the detail specification, the wet arc propagation resistance test, when required, shall be a
minimum of 67 total size 20 wires for medium weight wire and 64 total size 20 wires for light weight wire shall pass the wet
dielectric test. No more than three wires shall fail the wet dielectric test in any one bundle. The actual damage area shall
not be more than 3 inches in any one wire.
3.9.1 2 Dry Arc Propagation Resistance (see 5.7.1 2)
Unless otherwise specified in the detail specification, the dry arc propagation resistance test, when required, shall be a
minimum of 67 total size 20 wires for medium weight wire and 64 total size 20 wires for light weight wire shall pass the wet
dielectric test. No more than three wires shall fail the wet dielectric test in any one bundle. The actual damage area shall
not be more than 3 inches in any one wire.
3.9.1 3 Dynamic Cut-through Resistance (see 5.7.1 3)
When dynamic cut-through is required in the detail specification, the minimum average dynamic cut-through (pounds) at a
specified temperature and number of wire specimens shall be listed. The cutting blade edge shall be a
0.005 inch radius ± 0.001 inch radius.
3.9.1 4 Forced Hydrolysis Insulation Resistance (see 5.7.1 4)
When forced hydrolysis is required in the detail specification, the insulation shall exhibit no dielectric breakdown after the
required exposure at the temperature stated in the detail specification.
3.9.1 5 Longevity Resistance - Thermal Index (see 5.7.1 5)
When thermal index is required in the detail specification, the wire shall have the thermal index rating at the time and
temperature specified.
3.9.1 6 Abrasion Resistance - Needle (see 5.7.1 6)
When needle abrasion is required in the detail specification, the wire shall meet the minimum average abrasion cycles
specified.
3.9.1 7 UV Laser Contrast Marking Resistance after Thermal Aging (see 5.7.1 7)
When UV laser contrast after thermal aging is required in the detail specification, the wire shall meet a minimum contrast
level of 40% after thermal aging.
SAE INTERNATIONAL AS22759™D Page 1 9 of 45

4. QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for Inspection
Unless otherwise specified herein, the contract or purchase order, the supplier is responsible for the performance of all
contract inspection requirements. Except as otherwise specified herein, the contract or purchase order, the supplier may
use any facilities suitable for the performance of the inspection requirements. The Qualifying Activity has the right to
perform any of the inspections set forth in the standard where such inspections are deemed necessary to assure supplies
and services conform to prescribed requirements.
4.1 .1 Responsibility for Compliance
All items must meet all technical requirements of the product standard. The inspection set forth in this standard shall
become a part of the supplier’s overall inspection system or quality program. The absence of any inspection requirements
in the standard shall not relieve the supplier of the responsibility of assuring that all products comply with all requirements
of the contract or purchase order. Sampling in quality conformance does not authorize submission of known defective
material, either indicated or actual, nor does it commit the purchaser to acceptance of defective material.
4.1 .2 Test Equipment and Inspection Facilities
Test and measuring equipment and inspection facilities of sufficient accuracy, quality and quantity to permit performance
of the required inspection shall be established and maintained by the supplier. The establishment and maintenance of a
calibration system to control the accuracy of the measuring and test equipment shall be in accordance with NCSL Z540-3
or equivalent standards.
4.1 .3 AS9003 Quality Assurance Compliance
The supplier’s quality assurance program for wire production shall comply with the AS9003 Inspection and Test Quality
System. Independent certification of the processes is not required. Other established and industry recognized quality
assurance standards that assure all products produced conform to the contract requirements are acceptable. However, if
used, it is the responsibility of the supplier to provide evidence of compliance to AS9003. The Qualifying Activity (QA)
authority reserves the right to monitor, measure, and validate compliance at their discretion.
4.2 Classification of Inspections
The inspections specified herein are classified as follows:
a. Initial Qualification inspection (see 4.3).
b. Retention of Qualification inspection (see 4.4 and 4.5).
c. Quality Conformance Inspection (see 4.6).
4.2.1 Inspection Conditions
Unless otherwise specified herein or in the detail specification, all measurements and tests shall be made at temperatures
of 1 5 to 35 °C (59 to 95 °F) at air pressure of 650 to 800 mm of mercury, and a relative humidity of 45 to 75%. Whenever
these conditions must be closely controlled in order to obtain more reproducible results, the temperature, relative
humidity, and atmospheric pressure conditions of 25 +0, -2 °C (77 + 0, -3.6 °F), 50% ± 1 2% Relative Humidity, and 650 to
800 mm of mercury shall be used.
4.3 Initial Qualification Inspection
Initial qualification inspection shall be in accordance with Table 1 3. Sequential testing is not required except as specified
by a test method. Unless otherwise specified in the detail specification, the Qualifying Activity shall perform or witness the
tests specified in Table 1 3 and the supplier shall perform the remaining tests. All test laboratories require Qualifying
Activity approval.
SAE INTERNATIONAL AS22759™D Page 20 of 45

Table 13 - Initial and retention of qualification tests

Applicable Detail Test Method
Inspection Tests Specification Req. Paragraph Paragraph
Materials All (as Applicable) 3.3 5.1
Conductor Construction Prior to Insulation All 3.4.1 5.2.1
Insulated Conductor splices All 3.4.2 5.2.2
/1 6-/1 9, /32-/35, /43, /44,
Insulated Conductor Tin and Silver Solderability 1 / /47-/56, /81 , /83, /86, /89, 3.4.3 5.2.3
/91 , /93, /95, /1 81 , /1 83,
/1 86, /1 89, /1 91 , /1 93, /1 95
Insulated Conductor Geometric 1 / All 3.4.4 5.2.4
/5-/9, /1 1 , /20, /22, /28, /30,
/80, /81 , /85, /86, /88, /89,
Insulated Conductor Strand Blocking – Adhesion 1 / /91 , /93, /95, /1 80, /1 81 , 3.4.5 5.2.5
/1 85, /1 86, /1 88, /1 89,
/1 91 , /1 93, /1 95
Insulated Conductor Elongation 1 / All 3.4.6 5.2.6
/1 5, /1 7, /1 9-/23, /30, /31 ,
/33, /35, /42, /46, /47, /49,
Insulated Conductor Tensile Break Strength 1 / /51 , /53, /55-/58, /81 , /82, 3.4.6 5.2.6
/89, /90, /93-/96, /1 81 ,
/1 82, /1 89, /1 90, /1 93-/1 96
Insulation Construction and Mechanical Properties 1 / All 3.5.1 5.3.1 .1
Insulation Tensile Strength and Elongation 1 / /4-/23, /29-/35, /41 -/58 3.5.1 5.3.1 .2
Circumferential Elongation (PTFE extruded) 1 / /5-/1 2, /1 9-/23, /28-/31 3.5.1 5.3.1 .3
Insulation State of Sinter /80-/82, /86-/96, /1 80-/1 82, 3.5.5 5.3.4
/1 86-/1 96
Tape Overlap /80-/96, /1 80-/1 96 3.5.6 5.3.5
Outer Insulation Tape Layer Surface Smoothness 1 / /1 80-/1 96 3.5.7 5.3.6
Fluoride Off-gassing /47-/54 3.5.8 5.3.7
Lamination Sealing /80-/96, /1 80-/1 96 3.5.9 5.3.8
Polyimide Topcoat Cure 1 / /28-/31 3.5.1 0 5.3.9
Insulation Proof Test (Crosslink Proof / Accelerated Aging / /1 6-/1 9, /32-/35, /41 -/58, 3.5.1 1 5.3.1 0
Short-Term Thermal Stability) 1 / (as applicable)
Insulation Blocking 3/ All 3.5.1 2 5.3.1 1
SAE INTERNATIONAL AS22759™D Page 21 of 45

Table 13 - Initial and retention of qualification tests (continued)

Inspection Tests Applicable Detail Req. Paragraph Test Method
Specification Paragraph
Insulation Shrinkage 1 / All 3.5.1 3 5.3.1 2
Insulation Layer Wicking /1 -/8, /34, /35, /41 -/43, /49, 3.5.1 4 5.3.1 3
/50, /53, /54, /56, /57
Wire Conductor Electrical Resistance All 3.6.1 5.4.1
Wire Electrical Insulation Resistance All 3.6.2 5.4.2
Wire Electrical Surface Resistance /1 -/23, /28-/35, /41 -/58 3.6.3 5.4.3
Electrical Dielectric Resistance - Wet Dielectric Voltage 4/ All (as applicable) 3.6.4 5.4.4
Wire Diameter 1 / All 3.7.1 5.5.1
Wire Weight All 3.7.2 5.5.2
Wire Insulation Stripping 1 / All 3.7.3 5.5.3
Wire Insulation Strip Force 1 / /80-/82, /86-/96, /1 80-/1 82, 3.7.4 5.5.4
/1 86-/1 96
Wire Insulation Concentricity and Wall Thickness 1 / /1 -/23, /28-/35, /41 -/58 3.7.5 5.5.5
Workmanship All 3.7.6 5.5.6
Continuous Lengths All 3.7.7 5.5.7
Wire Identification Printed Marking and Location 1 / All 3.8.1 5.6.1
Wire Color Designators and Munsell Limits 1 / All 3.8.2 5.6.2
Wire Identification Mark, Stripe, or Band Durability 1 / All 3.8.3 5.6.3
UV Laser Marking 2/ /47-/54, /1 80-/1 82, /1 86-/1 96 3.8.4 5.6.4
Mandrel Bend Mechanical Resistance for Tape/Braid /1 -/4, /80-/96, /1 80-/1 96 3.9.1 5.7.1
Insulation 1 /
Wrap Back Bend Mechanical Resistance for Extruded /5-/23, /28-/35, /41 -/58 3.9.2 5.7.2
Insulation 1 /
Insulation Low Temperature Mechanical Resistance/ Cold All 3.9.3 5.7.3
Bend 1 /
Insulation Thermal Shock Mechanical Resistance 1 / All 3.9.4 5.7.4
Thermal Mechanical Resistance - Life Cycle 1 / All 3.9.5 5.7.5
Ambient Mechanical Resistance– Mandrel Bend Test 4/ All (as applicable) 3.9.6 5.7.6
Fluid Resistance - Immersion 2/ All 3.9.7 5.7.7
Humidity Resistance 3/ /1 -/8, /1 3-/1 9, /32-/35, /41 -/58, 3.9.8 5.7.8
/80-/96, /1 80-/1 96
Smoke Resistance 3/ All 3.9.9 5.7.9
Flammability 3/ All 3.9.1 0 5.7.1 0
Facial Tissue Required /32-/58, /80-/96, /1 80-/1 96
Wet Arc Propagation Resistance 1 /, 3/ /49, /50, /53, /54, /80-/96, 3.9.1 1 5.7.1 1
/1 80-/1 96
Dry Arc Propagation Resistance 3/ /49, /50, /53, /54, /80-/96, 3.9.1 2 5.7.1 2
/1 80-/1 96
Dynamic Cut-through Resistance 1 /, 3/ /49, /50, /53, /54, /80-/82, /86- 3.9.1 3 5.7.1 3
/96, /1 80-/1 82, /1 86-/1 96
Forced Hydrolysis Insulation Resistance 2/ /80-/82, /86-/96, /1 80-/1 82, 3.9.1 4 5.7.1 4
/1 86-/1 96
Longevity Resistance - Thermal Index 2/ /80-/96, /1 80-/1 96 3.9.1 5 5.7.1 5
Abrasion Resistance - Needle 1 /, 3/ /49, /50, /53, /54, /1 80-/1 82, 3.9.1 6 5.7.1 6
/1 86-/1 96
UV Laser Contrast Marking Resistance after Thermal Aging /47-/54, /1 80-/1 82, /1 86-/1 96 3.9.1 7 5.7.1 7
1 /, 3/
1 / Qualification tests shall only be performed by the Qualifying Activity unless otherwise specified in the detail specification
(see 4.3).
2/ Initial qualification only unless the material has been changed. Initial qualification approval shall not be withheld during the
thermal index test period. At the request of the Qualifying Activity, the supplier will provide a summary of results at regular
intervals.
3/ Retention of Qualification for the designated tests shall be performed every 6 years rather than the required 3 years after
initial qualification unless materials have been changed (see 2/).
4/ Capability required for all wire lengths, but not performed for qualification except as specified after test conditioning.
SAE INTERNATIONAL AS22759™D Page 22 of 45

4.3.1 Initial Qualification Inspection Procedure

A request for qualification shall be made to the Qualifying Activity (see 9.1 ) prior to initiating testing. Testing cannot begin
until the supplier has received an authorization letter. The supplier is recommended to provide the Qualifying Activity a
test plan based on the authorization letter to ensure the supplier and Qualifying Activity maintain communication and
document changes as needed. The Qualifying Activity shall not approve a component that does not meet the
requirements specified herein. The Qualifying Activity has the authority to impose specific specification test requirements
to resolve test failures/discrepancies and to waive testing to verify specific product manufacturing changes or
qualifications by similarity (see 4.3.3). Any change in the supplier’s process control inspections, quality conformance
inspections, or manufacturing control drawings (editorial changes are acceptable) without the express approval of the
Qualifying Activity may result in loss of qualification for that product.
4.3.2 Initial Qualification Test Reports
The Qualifying Activity shall provide the supplier a data package of all tests performed in accordance with Table 1 3. The
Qualifying Activity test method procedures shall be made available to the supplier upon request. The supplier shall
provide a test report to the Qualifying Activity for the tests specified in Table 1 3. The test report shall be signed by the
manufacturing authority responsible for ensuring compliance with the specification requirements. The supplier may
combine the Qualifying Activity test data with the supplier’s test data into one final test report. The final test report and/or
data package shall remain on file with the supplier for a minimum period of 6 years and be available to the Qualifying
Activity upon request. The supplier test report shall contain as a minimum the following information.
a. Copy of all certifications specified herein.
b. The quantitative results for tests specified in Table 1 3 and the authorization letter.
c. A tabulated comparison between the insulation and conductor construction herein and each manufacturing control
drawing for components qualified by similarity.
d. Corrective Action Reports (as applicable).
4.3.3 Initial Qualification by Similarity
Qualification by similarity is applicable where a group of two or more detail specifications cover wires which are identical in
materials and construction except that the conductor is different in each detail specification. In such event, the
qualification applicant may select the samples specified in Table 1 4 for any size range or ranges of any detail specification
in the similar group listed in Table 1 4. Approval of the wire qualification sample shall also qualify the same wire size range
or ranges in each of the other detail specifications for which only the conductor is different. When a requirement is more
rigorous for a wire being qualified by similarity than for the wire undergoing complete test, the sample undergoing
complete test must meet the more rigorous requirement of the similar wire in order to qualify the similar wire (e.g., if the
wire sample is a 1 50 °C rated wire and the wire being qualified by similarity is rated at 200 °C, the wire sample must pass
the thermal shock test at 200 °C in order to qualify the 200 °C wire). Changes in the properties of the less rigorous
conductor construction shall not be considered as part of the more rigorous test results. Similarity groups not defined in
Table 1 4 shall be coordinated with the Qualifying Activity prior to testing.
Table 14 - Wire qualification similarity groups
Group Detail Specification Group Detail Specification Group Detail Specification
1 /1 , /2 9 /1 8, /1 9 17 /1 80-/1 82, /1 91 , /1 92, /1 93, /1 94
2 /3, /4 10 /28, /29, /30, /31 18 /1 83-/1 90, /1 95, /1 96
3 /5, /6 11 /32, /33, /44-/46, /55, /58
4 /7, /8 12 /34, /35, /41 -/43, /56, /57
5 /9, /1 0, /20, /21 13 /47, /48, /51 , /52 1 /
6 /1 1 , /1 2, /22, /23 14 /49, /50, /53, /54 1 /
7 /1 3, /1 4, /1 5 15 /80-/82, /91 , /92, /93, 94
8 /1 6, /1 7 16 /83-/90, /95, /96
1 / Certification of in-process control of the 80 microinch silver-coating is required .
SAE INTERNATIONAL AS22759™D Page 23 of 45
For purposes of determining identity of construction in detail specifications under the similarity provision, small differences
in specified wire diameter or weight that are obviously due to differences in the specified conductor shall not be
considered as constituting differences in the construction of the wires.
4.3.4 Initial Qualification Sample
For each wire tested the supplier shall use the same materials, manufacturing procedures, and methods of inspection as
would be used to provide the wire to a purchaser. A wire length shall be obtained from the continuous length qualification
lot (see 4.6). Except as provided under qualification by similarity in 4.3.3, a wire sample of the required length shall be
selected from Table 1 5 for each size range for which qualification is desired in the applicable detail specification. The
sample may be any size wire within the specified size range. Unless otherwise specified, three wire specimens shall be
tested for each required test.
Table 15 - Qualification wire length requirements
Wire Size Range Feet
30 through 28 200
26 through 20 200
1 8 through 1 4 200
1 2 through 1 0 1 00
8 through 4 1 00
2 and larger 1 00

4.3.4.1 Initial Qualification Qualifying Activity Sample

A duplicate group of qualification samples from the same lot as required for supplier tests shall be submitted to the
Qualifying Activity for the Qualifying Activity tests. The samples shall be identified by securely attached durable tags
marked with the information listed below. The tags must be stamped by the supplier’s and/or Qualifying Activity
designated Quality Assurance Representative (QAR) inspector as representative samples of the manufacturer’s normal
production capability. Samples submitted without the stamp will not be accepted.
a. Sample for qualification tests: WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, COPPER OR COPPER
ALLOY
b. Detail specification part number:
c. Manufacturer’s name and code number (Publication SAM):
d. Manufacturer’s part number:
e. Place and date of manufacture of sample:
f. Submission information: Submitted by (name) (date) for qualification tests in accordance with the requirements of
AS22759 under authorization (reference authorizing letter).
g. Material composition: When specifically requested, a comprehensive description and prime manufacturer’s name and
formulation number of the base materials from which the product is made shall be provided (This information will not
be divulged by the Qualifying Activity).
4.4 Retention of Qualification
Unless otherwise noted retention of qualification inspection shall occur every 36 months after the initial qualification date
and shall consist of the Qualifying Activity tests specified in Table 1 3 for Initial Qualification. Qualification cannot begin
until an authorization letter for testing has been issued by the Qualifying Activity. The Qualifying Activity may shift the
reporting date to accommodate testing schedules, but no later than 1 8 months from the retention of qualification due date.
Failure of the supplier to submit retention of qualification test report or certification within 30 days after the end of the
reporting period may result in the removal of the product or products from the Qualified Products List (QPL).
SAE INTERNATIONAL AS22759™D Page 24 of 45

4.4.1 Retention of Qualification No Production Certification

If no production of the qualified products has occurred for the entire reporting period, the Supplier may provide a
certification to the Qualifying Activity that no changes in the product materials, manufacturing processes, or site of
production has occurred since the initial Qualification Inspection (see 4.3). Certification for more than one reporting period
shall not be permitted. The Supplier shall contact the Qualifying Activity to determine the conditions of the Certification.
The Supplier may be required to submit the Certification on a specified form provided by the Qualifying Activity.
4.4.2 Retention of Qualification Sample
One wire size from each initial qualification approved similarity group listed in Table 1 4 shall be tested. The sample shall
be from a current production run. For each wire tested the supplier shall use the same materials, manufacturing
procedures, and methods of inspection as would be used to provide the wire to a purchaser. Unless otherwise specified,
three wire specimens shall be tested for each required test.
4.4.3 Retention of Qualification Test Report
The Qualifying Activity shall provide the supplier a data package of all tests performed in accordance with Table 1 3. The
Qualifying Activity test method procedures shall be made available to the supplier upon request. The supplier shall
provide a test report to the Qualifying Activity for the tests specified in Table 1 3. The test report shall be signed by the
manufacturing authority responsible for ensuring compliance with the specification requirements. The supplier may
combine the Qualifying Activity test data with the supplier’s test data into one final test report. The final test report and/or
data package shall remain on file with the supplier for a minimum period of 6 years and be available to the Qualifying
Activity upon request. The supplier test report shall contain as a minimum the following information.
a. A summary of Quality Conformance Inspection pass or fail results for tests specified in Table 1 6 and the authorization
letter. The results shall include detail data from the Group 5 test.
b. A tabulated comparison between the insulation and conductor construction herein and each manufacturing control
drawing for components qualified by similarity.
c. Corrective Action Reports (as applicable)
If a failure occurs in the tests for retention of qualification, no wire represented by the sample, nor any other wire
manufactured with the same materials and processes, which has not already been submitted for quality conformance
inspection, shall be offered for acceptance until the cause for failure has been determined and concurred with by the
Qualifying Activity as not affecting the ability of the wire to meet qualification inspection requirements.
4.5 Material and Process Changes during Retention of Qualification Intervals (see 7.6)
Except for changes approved by the purchase order, the wire supplied under purchase order shall be the same material
formulations, material sources, and manufacturing processes as approved by the Qualifying Activity. It is the responsibility
of the wire manufacturer to notify the Qualifying Activity when materials, material formulations, and manufacturing
processes need to be changed. The wire supplier is responsible for verifying and documenting all performance
characteristics including quality conformance and qualification requirements. The changes are categorized as minor and
major.
4.5.1 Minor Change
To address a minor change, the wire supplier will provide written notification of the change to the Qualifying Activity and
maintain documentation of compliance. The Qualifying Activity may request results of product testing to confirm
compliance and approve the change under the existing qualification. A minor change includes modification of processing
additives, colorants, braids, finishers, coatings and inks. It also includes manufacturing process parameters, integrating
processes and relocating equipment within the qualified manufacturing site.
SAE INTERNATIONAL AS22759™D Page 25 of 45

4.5.2 Major Change

To address a major change, a request for change will be submitted to the Qualifying Activity. The Qualifying Activity will
provide authorization to proceed and define the qualification submittal and third- party testing in accordance with Table 1 3.
All qualification tests identified shall be performed, either by the wire supplier, the Qualifying Activity or an approved third-
party laboratory at the discretion of the Qualifying Activity. A major change includes the conductor source and formulation
and the modification of insulating material to include resin change, source change (new resin producer) or alternate
production location for the resin.
4.6 Quality Conformance Inspection
For purposes of this specification, the following shall apply:
a. Lot: The Inspection lot shall include all wire of one part number subjected to inspection at one time.
b. Unit of product: The unit of product for determining lot size for sampling shall be one continuous length of wire as
offered for inspection.
c. Suppliers demonstrating statistical product acceptance requirements (see ARP901 3) may waive specific individual
quality conformance inspection tests shown in Table 1 6 when justified and approved by the Qualifying Activity (see
4.6.4.5). For initial or retention of qualification, all tests have to be performed. In no case shall Group 3 or 4 be waived.
The Qualifying Activity authority reserves the right to monitor, measure, and validate compliance at their discretion.
4.6.1 Quality Conformance Process Control Inspection Tests
Quality conformance process control inspection comprises quality conformance tests and examinations of such a nature
that the tests are impossible or impractical to perform on the wire and are therefore conducted at the most appropriate
stage of the receiving or manufacturing operations. Process control tests are listed under “In-process” in Table 1 6 and
shall be performed on every lot of wire acquired under this specification. For quality conformance of conductors prior to
insulation application use AS29606.
4.6.2 Samples for Quality Conformance Process Control Inspection
a. A conductor material sample prior to insulation shall be three ten-foot lengths of conductor selected in such manner
as to be representative of the material to be used in each inspection lot of wire (see 3.3.1 ).
b. A coated glass yarn (see 3.3.2), coated glass tape (see 3.3.3), and unsupported tapes (see 3.3.5) material sample
shall be three specimens’ representative of each inspection lot and shall be selected before application to the
conductor.
c. All conductor samples and insulation tape splices performed during the final insulation process shall be examined for
conformity of splices (see 3.4.2 and 3.5.2).
d. A tensile strength and elongation extrusion insulation sample (see 3.5.1 ) shall be three specimens of extruded
insulation on the wire representative of each inspection lot.
e. The circumferential elongation of Polytetrafluoroethylene (PTFE) or abrasion resistant (mineral filled) PTFE insulated
wire sample shall be five specimens’ representative of each inspection lot (see 3.5.1 ). Circumferential elongation
testing is not required for other insulation types.
f. A primary insulation flaw sample shall be 1 00% of the lot prior to the application of additional layers (jacket or
protected coating), when required (see 3.5.3).
g. Material certification and tracking numbers are required for each lot.
h. Tape overlap can either be certified as an in-process inspection or quality conformance inspection (see 3.5.6).
SAE INTERNATIONAL AS22759™D Page 26 of 45

4.6.3 Rejection and Retest in Process Control Inspection

4.6.3.1 Rejection of Conductor and Insulation Materials (see 4.6.2 a, b, c)
If conductor or material samples (prior to insulation) fail, the lot shall be rejected. The supplier shall determine corrective
action acceptance.
4.6.3.2 Rejection and Retest of Process Control Insulated Wire (see 4.6.2 d, e, f, and h)
When a process control sample selected during a production run fails to meet the specified requirements, further
processing of that lot shall cease until the extent and cause of the failure have been determined and resolved. If corrective
action is taken on the same lot in which the failure occurred, the appropriate process control tests shall be repeated.
Corrective actions taken on failing lots shall be communicated to the purchaser or the Qualifying Activity if the lot is being
submitted for qualification.
a. If the tensile strength and elongation extrusion insulation sample fails, the lot shall be rejected with no corrective
action.
b. The failed portions of the primary insulation flaw sample that shows dielectric breakdown shall be cut out or removed
and testing of the balance of production shall be resumed.
4.6.4 Quality Conformance Inspection of Insulated Wire
The quality conformance inspection of wire shall consist of the examinations and tests listed in Table 1 6 (groups 1 thru 5).
Unless otherwise specified herein or in the detail specification or by the Qualifying Activity, the inspection shall be
performed on every lot of wire acquired under the specification. The Group 5 test shall be performed on the first lot
produced in any 3-month period, regardless of part number.
4.6.4.1 Samples for Quality Conformance Inspection of Insulated Wire
a. The sample unit for Groups 1 , 2, and 5 tests, except for the Group 1 insulation resistance test, shall consist of a single
piece of wire chosen at random from the inspection lot and of sufficient length to permit all applicable examinations
and tests. Unless otherwise specified, the length of the sample unit for Group 1 and 5 tests other than insulation
resistance shall be 20 feet and the length of the sample unit for Group 2 tests shall be 25 feet. Not more than one
sample unit for each group of tests shall be taken from a single unit of product. Unless otherwise specified, three wire
specimens shall be tested for each required test.
b. The sample unit for the Group 1 insulation resistance test shall be a specimen at least 26 feet in length selected at
random from wire which has passed the Group 3 dielectric test. It is optional whether the specimen is tested on the
reel or removed from the reel for the test, provided the length of the specimen can be determined.
4.6.4.2 Wire Inspection Levels and Acceptable Quality Levels (AQL) (as applicable)
a. For Group 1 characteristics, including the insulation resistance test, the inspection level shall be S-2 and the AQL
shall be 6.5% defective units in accordance with ANSI/ASQC-Z1 .4 and the AQL defects types herein (see 7.1 4).
b. For Group 2 and Group 5 characteristics, the inspection level shall be S-3 and the AQL shall be 1 .5% defective units
in accordance with ANSI/ASQC-Z1 .4 and the AQL defects types herein (see 7.1 4).
c. For Group 3 insulation flaws, one hundred percent of the wire and every length of the wire shall be subjected to the
impulse or spark tests. Insulation breakdowns resulting from the test and ends or portions not subjected to the test
shall be marked or cut out of the wire. When specified in the contract or order, dielectric failure, untested portions, or
portions that have been exposed to fewer or more than the specified number of pulses or cycles are permitted to be
marked by stripping the insulation or any other method specified in the contract in lieu of being cut out from the wire
length.
d. For Group 4 continuous length characteristics the inspection level and acceptable quality level for this examination
shall be as required for the applicable procedure of 5.5.7.
SAE INTERNATIONAL AS22759™D Page 27 of 45

4.6.4.3 Effect of a Quality Conformance Inspection Failure on Wire

Quality conformance testing of the wire may be continued during the investigation of a quality conformance inspection
failure on a wire sample, but there shall be no final acceptance of the finished product until it is determined that the lot
meets all the quality conformance requirements of Table 1 6. If a Group 5 failure occurs, the Supplier is required to
perform the test on the next five production lots in the 3-month period for which it failed (see 4.6.4).
4.6.4.4 Nonconforming Inspection Lots
Disposition of inspection lots found unacceptable under quality conformance inspection shall be in accordance with
ASQC Z1 .4.
4.6.4.5 Quality Conformance Inspection Repeatability of Results (see 4.6c)
When a qualified supplier can demonstrate to the Qualifying Activity consistent repeatable results for a specific quality
conformance inspection property by tight process controls (statistical, etc.), the supplier can recommend and be approved
by the Qualifying Activity to move tests from Group 2 to Group 1 or test from Group 1 to Retention of Qualification only,
Consideration can also be given to reduced inspection times or sampling as well as alternative In-process inspections. For
qualification submittal samples all inspections shall be performed as required.
Table 16 - Quality conformance inspection tests
Quality Conformance Test Method
Inspections Inspection Tests Applicable Detail Requirement Paragraph
In-process Groups Specification Paragraph
4.6.2a --- Conductor Material All 3.3.1 5.1 .1
4.6.2b --- Yarn and Tape Material /1 -/4, /80-/92, /1 80-/1 92 3.3.2 thru 3.3.6 5.1 .2 thru
5.1 .5
4.6.2c --- Conductor and Tape Splices All conductors and /1 -/4, 3.4.2 & 3.5.2 5.2.2 & 5.3.2
/80-/92, /1 80-/1 92
4.6.2d --- Extruded insulation tensile and /4-/23, /28-/35, /41 -/58 3.5.1 5.3.1 .2
elongation
4.6.2e --- Circumferential Elongation /5-/1 2, /1 9-/23, /28-/31 3.5.1 5.3.1
4.6.2f --- Primary Insulation Flaws /1 3-/1 5, /28-/31 , /34, /35, 3.5.3 5.3.3
/41 -/43, /49, /50, /53, /54, /56, /57
4.6.2g --- Material Verification All 3.3 5.1
--- 1 Conductor Construction Prior to All 3.4.1 5.2.1
Insulation 1 /
/1 6, 1 8, /32, /34, /43, /44,
--- 1 Conductor Tin & Silver Solderability /47-/56, /81 , /83, /86, /89, /91 , /93, /95, 3.4.3 5.2.3
/1 81 , /1 83, /1 86, /1 89, /1 91 , /1 93, /1 95
--- 1 Conductor Geometric 1 / All 3.4.4 5.2.4
--- 1 Conductor Elongation All 3.4.6 5.2.6
/1 5, /1 7, /1 9-/23, /30, /31 , /33, /35, /42,
--- 1 Conductor Tensile Break Strength /46, /47, /49, /51 , /53, /55-/58, /81 , /82, 3.4.6 5.2.6
/89, /90, /93-/96, /1 81 , /1 82, /1 89, /1 90,
/1 93-/1 96
Insulation Construction 1 / All 5.3.1 .1
--- 1 Tensile Strength & Elongation /4-/23, /29-/35, /41 -/58 3.5.1 5.3.1 .2
Circumferential Elongation /5-/1 2, /1 9-/23, /28-/31 5.3.1 .3
--- 1 Insulation State of Sinter 1 / /80-/82, /86-/96, /1 80-/1 82, /1 86-/1 96 3.5.5 5.3.4
4.6.2h 1 Tape Overlap /80-/96, /1 80-/1 96 3.5.6 5.3.5
--- 1 Tape Layer Surface Smoothness /1 80-/1 96 3.5.7 5.3.6
--- 1 Lamination Sealing 1 / /80-/96, /1 80-/1 96 3.5.9 5.3.8
--- 1 Polyimide Topcoat Cure 1 / /28-/31 3.5.1 0 5.3.9
--- 1 Conductor Electrical Resistance All 3.6.1 5.4.1
--- 1 Insulation Resistance 1 / All 3.6.2 5.4.2
--- 1 Wire Diameter All 3.7.1 5.5.1
--- 1 Wire Weight 1 / All 3.7.2 5.5.2
--- 1 Insulation Stripping All 3.7.3 5.5.3
--- 1 Insulation Strip Force /80-/82, /86-/96, /1 80-/1 82, /1 86-/1 96 3.7.4 5.5.4
--- 1 Workmanship All 3.7.6 5.5.6
--- 1 Wire Identification All 3.8 5.6
--- 1 Color Designators and Munsell Limits All 3.8.2 5.6.2
--- 1 Mark, Stripe, or Band Durability All 3.8.3 5.6.3
--- 1 UV Laser Wire Identification Marking All 3.8.4 5.6.4
SAE INTERNATIONAL AS22759™D Page 28 of 45
Table 16 - Quality conformance inspection tests (continued)
Quality Conformance Inspections Inspection Tests Applicable Detail Requirement Test Method
In-process Groups Specification Paragraph Paragraph
--- 1 UV Laser Marking /47-/54, /1 80-/1 82, /1 86-/1 92 3.8.4 5.6.4
/5-/9, /1 1 , /20, /22, /28, /30,
Conductor Strand Blocking – /80, /81 , /85, /86, /88, /89,
--- 2 Adhesion 1 / /91 , /93, /95 /1 80, /1 81 , /1 85, 3.4.5 5.2.5
/1 86, /1 88, /1 89, /1 91 , /1 93,
/1 95
Insulation Proof Test
--- 2 (Crosslink Proof / /1 6-/1 9, /32-/35, /41 -/58 3.5.1 1 5.3.1 0
Accelerated Aging / Short- (as applicable)
Term Thermal Stability)
--- 2 Insulation Shrinkage All 3.5.1 3 5.3.1 2
--- 2 Insulation Layer Wicking /1 -/8, /34, /35, /41 -/43, /49, 3.5.1 4 5.3.1 3
/50, /53, /54, /56, /57
--- 2 Concentricity and Wall /1 -/23, /28-/35, /41 -/58 3.7.5 5.5.5
Thickness 1 /
---
--- 2 Bend, Mandrel (Tape/Braid) /1 -/4, /80-/92, /1 80-/1 92 3.9.1 5.7.1
--- 2 Bend (Wrap Back) /5-/23, /28-/35, /41 -/58 3.9.2 5.7.2
--- 2 Bend (Cold) All 3.9.3 5.7.3
--- 2 Thermal (Shock) All 3.9.4 5.7.4
--- 3 Wire Insulation Flaws All 3.5.4 5.3.3.2 &
5.3.3.3
--- 4 Continuous Lengths All 3.7.7 5.5.7
--- 5 Fluoride Off-gassing /47-/54 3.5.8 5.3.7
1 / Performed test on one insulated conductor specimen.

5. TEST METHODS
Unless otherwise specified all samples shall be examined carefully to determine conformance to the specification herein
and to the applicable detail specifications with regard to requirements not covered by specific test methods (i.e.,
Workmanship, AS9003 compliance, etc.). Certification to the requirements not covered by specific test methods herein is
required for qualification. The Qualifying Activity reserves the right to request documentation to substantiate the
certification.
5.1 Materials (see 3.3)
5.1 .1 Conductor Material (see 3.3.1 )
Tests shall be performed in accordance with AS29606 or by control processes used to demonstrate compliance with
conductor material requirements. Certification data from the original material supplier may also be used as an alternative
to performing the tests.
5.1 .2 PTFE Coated Fibrous Glass Yarns Material (see 3.3.2)
A weighed specimen of the coated fibrous glass yarn shall be ignited for 4 hours in a muffle furnace at 700 °C. The
residue shall be cooled and weighed and the loss in weight calculated as PTFE content of the coated tape yarn.
Certification by the material supplier may be used as alternative to the test method (see 3.3.2). Certification to a PTFE
layer added after each braid application is required.
5.1 .3 PTFE Coated Fibrous Glass Tapes Material (see 3.3.3)
Certification data from the original material supplier shall be used to verify the 50% PTFE weight requirement.
5.1 .4 Fluoropolymer (FP)/Polyimide/Fluoropolymer (FP) and Unsupported PTFE Tapes Material (see 3.3.4 and 3.3.5)
Certification by the material supplier may be used as alternative to the test methods specified.
SAE INTERNATIONAL AS22759™D Page 29 of 45

5.1 .4.1 Tensile strength and longitudinal elongation tape samples shall be subjected to the tensile strength tests and
elongation tests of ASTM D882, except that there shall be no limitation as to width of the tape.
5.1 .4.2 Dielectric strength tape samples shall be subjected to the short-time test of ASTM D1 49. Stainless steel
electrodes 1 /4 inch in diameter and having edges rounded to 1 /32-inch radius shall be used. The radius must
be accurate and should be checked on an optical comparator. Voltage shall be increased at approximately 500
V per second. Tapes shall be tested with oil as the medium. The oil shall be as specified in MIL-PRF-23699.
5.1 .4.3 Specific gravity tape samples shall be subjected to test Method A of ASTM D792. A suitable wetting agent shall
be added to the water to assist in complete wetting of the surfaces of the specimen.
5.1 .4.4 Tape thickness shall be measured on the first 1 0 feet of the tape spool every 1 2 inches with a microscope or
comparator equipped with devices capable of making measurements reproducible to at least 0.0005 inches.
5.1 .5 Fluoropolymer Insulation Resin Material (see 3.3.6)
Certification data provided by the material supplier shall be used to verify these requirements.
5.2 Conductor Construction (see 3.4)
5.2.1 Conductor Construction Prior to Insulation Application (see 3.4.1 )
The conductor construction prior to insulation application shall be tested in accordance with AS29606. Tests may be
performed by the conductor supplier, but the detail results shall be provided to the insulation supplier upon request.
Conductor supplier certification may be used as an alternative to the tests results.
5.2.2 Insulated Conductor Splice (see 3.4.2)
Conductor splices in the wire shall be certified in conformance with AS29606.
5.2.3 Insulated Conductor Tin and Silver Solderability (see 3.4.3 and 7.2)
Conductor tin and silver solderability on the wire shall be performed in accordance with AS4373 Method 1 05 using the
soldering pot method and test condition C. Unless otherwise specified in the detail specification, five specimens, size 1 0
and smaller, shall be tested. The soldered area shall be examined in accordance with J-STD-002.
5.2.4 Insulated Conductor Geometric Characteristics (see 3.4.4)
Conductor geometric characteristics on the wire (conductor diameter, strand diameters and strand count) shall be
performed in accordance with AS4373 Method 401 . Strands may be counted with 2X magnification.
5.2.5 Insulated Conductor Strand Blocking - Adhesion (see 3.4.5)
Conductor strand blocking (adhesion) of a wire shall be performed in accordance with AS4373 Method 404.
5.2.6 Insulated Conductor Elongation and Tensile Break Strength (see 3.4.6)
Conductor elongation and tensile break strength shall be performed in accordance with AS4373 Method 402. Only
elongation shall be performed on soft or annealed copper conductor. The results of three specimens shall be recorded
and the average determined.
5.3 Wire Insulation Properties (see 3.5)
5.3.1 Insulation Construction and Mechanical Properties (see 3.5.1 )
5.3.1 .1 Insulation Construction
Examine the wire insulation construction with 2X magnification.
SAE INTERNATIONAL AS22759™D Page 30 of 45

5.3.1 .2 Insulation Tensile Strength and Elongation

Tensile strength and elongation specimens shall be carefully removed from the conductor and tested in accordance with
AS4373 Method 705, except that the rate of travel of the power-actuated grip of the tensile machine shall be
1 0 inches ± 2 inches per minute for the PVF2 specimens. The average of three specimens shall be recorded.
5.3.1 .3 Circumferential Elongation (PTFE extruded)
Circumferential elongation specimens of extruded PTFE or Mineral Fill PTFE primary insulation or jacket shall be carefully
removed from the conductor and tested in accordance with AS4373 Method 71 3.
5.3.2 Primary and Jacket Insulation Tape Splices (see 3.5.2)
Certification of conformity to the insulation tape splicing requirements is required. Test data or control processes used to
demonstrate compliance with insulation splice requirements shall be provided to the Qualifying Activity or purchaser upon
request.
5.3.3 Wire Primary and Final Insulation Flaws (see 3.5.3 and 3.5.4)
One of the following methods shall be used to determine the presence of faulty areas in the primary insulation and final
insulation. One hundred percent of the wire shall be tested. Unless otherwise specified in the detail specification, the test
voltage shall be as specified in Table 7 or 8.
5.3.3.1 The spark test on the primary insulation shall be performed after the application of the primary insulation and
prior to the application of any other material. The 60-Hz spark test shall be performed in accordance with
AS4373 Method 505, Method 2 except it shall be performed as an in-process test.
5.3.3.2 The impulse dielectric test shall be performed in accordance with AS4373 Method 503.
5.3.3.3 The high frequency spark test shall be performed in accordance with AS4373 Method 505, Method 1 .
5.3.4 Insulation State of Sinter (see 3.5.5)
The insulation state of sinter shall be performed in accordance with AS4373 Method 81 3.
5.3.5 Tape Overlap (see 3.5.6)
Tape overlap shall be performed in accordance with detail specification and AS4373 Method 1 09.
5.3.6 Outer Insulation Tape Layer Surface Smoothness (see 3.5.7)
The outer insulation tape layer surface smoothness shall be performed in accordance with AS4373 Method 1 1 0.
5.3.7 Fluoride Off-gassing (see 3.5.8)
The fluoride off-gassing shall be performed in accordance with AS4373 Method 608.
5.3.8 Lamination Sealing (see 3.5.9)
Lamination sealing shall be performed in accordance with detail specification and AS4373 Method 809. Three samples
shall be tested.
5.3.9 Polyimide Topcoat Cure (see 3.5.1 0)
The polyimide topcoat cure shall be performed in accordance with AS4373 Method 81 0.
SAE INTERNATIONAL AS22759™D Page 31 of 45

5.3.1 0 Insulation Proof Test (Crosslink Proof / Accelerated Aging / Short-Term Thermal Stability - see 3.5.1 1 )
The test(s) shall be performed in accordance with AS4373 Method 81 1 . The mandrel sizes and weights shall be as
specified in the detail specification. The bend test shall be performed in accordance with 5.7.6. The dielectric test shall be
performed in accordance with 5.4.4.
5.3.1 1 Insulation Blocking (see 3.5.1 2)
The blocking test shall be performed in accordance with AS4373 Method 808. The temperature shall be as specified in
the detail specification.
5.3.1 2 Insulation Shrinkage (see 3.5.1 3)
The shrinkage test shall be performed in accordance with AS4373 Method 1 04. The shrinkage of the insulation shall be
measured as the greatest additional distance that any layer of the insulation, including jacket if present, has receded from
either end of the conductor. Measuring expansion is not required.
5.3.1 3 Insulation Layer Wicking (see 3.5.1 4)
Wicking shall be performed in accordance with AS4373 Method 607.
5.4 Wire Electrical Properties (see 3.6)
5.4.1 Wire Conductor Electrical Resistance (see 3.6.1 )
The Direct Current (DC) resistance of the conductor on a wire shall be measured in accordance with AS4373 Method 403.
5.4.2 Wire Electrical Insulation Resistance (see 3.6.2)
The insulation resistance test shall be performed in accordance with AS4373 Method 504.
5.4.3 Wire Electrical Surface Resistance (see 3.6.3)
The surface resistance test shall be performed in accordance with AS4373 Method 506.
5.4.4 Electrical Dielectric Resistance - Wet Dielectric Voltage (see 3.6.4)
The dielectric test shall be performed in accordance with AS4373 Method 51 0 at the specified withstand voltage.
5.5 Wire Physical Properties (see 3.7)
5.5.1 Wire Diameter (see 3.7.1 )
The wire diameter shall be measured in accordance with AS4373 Method 901 . For a qualification submittal, an in-process
method for measuring the diameter maybe used and a summary of the results submitted to the Qualifying Activity.
5.5.2 Wire Weight (see 3.7.2)
The weight of each lot of wire shall be determined by Procedure I of AS4373 Method 902 for qualification submittal and for
Lot inspection. Inspection Lots failing to meet the wire weight requirement of the applicable detail specification when
tested in accordance with Procedure I shall be subjected to Procedure II of AS4373 Method 902. All reels or spools failing
to meet the requirements of the applicable detail specification shall be rejected. The quality conformance sampling plans
are not applicable when Procedure II is used. For qualification the results of both methods, as applicable, shall be
submitted to the Qualifying Activity including any required corrective action.
SAE INTERNATIONAL AS22759™D Page 32 of 45

5.5.3 Wire Insulation Stripping (see 3.7.3)

The insulation shall be removed in accordance with the tool specified in AS5768/1 or AS5768/2. Without touching the
conductor after the insulation is removed, the conductor shall be examined in accordance with AS5768. The tool and
blade used shall be recorded.
5.5.4 Wire Insulation Strip Force (see 3.7.4)
A 0.25-inch insulation slug shall be stripped from the wire with an AS5768 blade and the pull-off force measured in
accordance with AS4373 Method 1 03.
5.5.5 Wire Insulation Concentricity and Wall Thickness (see 3.7.5)
The concentricity and wall thickness of the primary insulation and of the wire shall be determined in accordance with
AS4373 Method 1 01 .
5.5.6 Workmanship (see 3.7.6)
Examine the wire in accordance with 5.3.1 , 5.3.3, 5.3.5, 5.3.6, 5.5, and 5.6.1 .
5.5.7 Continuous Lengths (see 3.7.7, 6.1 , and 7.1 3)
The requirements for continuous wire lengths shall be satisfied by the supplier’s certificate of conformity for the
qualification submittal lot (see 4.3 and 4.4) and for the production lot (4.6). However, the Qualifying Activity reserves the
right to examine wire lots or supplier processes, if deemed necessary to assure that the lengths actually conform to the
requirement. In measuring continuous wire lengths where the wire has been marked or stripped of insulation in lieu of
being cut to mark insulation failures or identify untested or improperly tested areas, such marking or stripping shall be
considered equivalent to complete severance of the wire at the two ends of each marked or stripped area. Unless
otherwise specified, the fault or area shall be removed from the wire length and the conductor severed at that location
prior to final spooling (see 6.1 ).
5.6 Wire Identification (see 3.8)
5.6.1 Wire Identification Printed Marking and Location (see 3.8.1 )
Visually examine for marking requirements and record wire identification mark. Measure the distance between marks
within ± one inch. Verify and record the measuring standard used, marking characteristics and color.
5.6.2 Wire Color Designators and Munsell Limits (see 1 .1 and 3.8.2)
Visually compare the background color to MIL-STD-1 04 limit cards or the UV Munsell color limit cards and verify the color
designator. Visually compare the color of the stripes, bands, or tracers to MIL-STD-1 04 limit cards and color designators.
Record the results.
5.6.3 Wire Identification Mark, Stripe, or Band Durability (see 3.8.3)
The durability of product identification and color markings applied to the wire for coding shall be evaluated at 20 to 25 °C
(68 to 77 °F) in accordance with AS4373 Method 71 0. The tolerance of the weight shall be ±0.01 pounds. If there is a
continuous line of erasure or obliteration through the stripe, band, or printed identification marking exposing the insulation,
the specimen shall be considered as having failed. Three specimens shall be tested from each sample unit and failure of
any specimen shall constitute failure of the sample unit.
5.6.4 UV Laser Marking (see 3.8.4)
The contrast level shall be determined in accordance with AS4373 Method 1 001 . Record results as required.
SAE INTERNATIONAL AS22759™D Page 33 of 45

5.7 Insulated Wire Performance Requirements (see 3.9)

5.7.1 Mandrel Bend Mechanical Resistance for Tape/Braid Insulation (see 3.9.1 )
The mandrel bend resistance test shall be performed in accordance with AS4373 Method 71 4 followed by the wet
dielectric test (see 5.4.4).
5.7.2 Wrap Back Bend Mechanical Resistance for Extruded Insulation (3.9.2)
The wrap back bend resistance test shall be performed in accordance with AS4373 Method 708. The oven conditioning
time shall be 2 hours unless otherwise specified in the detailed specification sheet. For wires size 4 and smaller the
specimen shall be wrapped back on itself followed by the wet dielectric test. For wire size 2 and larger the mandrel test
specified in Method 708 shall be performed followed by the wet dielectric test (see 5.4.4).
5.7.3 Insulation Low Temperature Mechanical Resistance/Cold Bend (see 3.9.3)
The low temperature mechanical resistance (cold bend) test shall be performed in accordance with AS4373 Method 702
followed by a wet dielectric test (see 5.4.4).
5.7.4 Insulation Thermal Shock Mechanical Resistance (see 3.9.4)
The thermal shock mechanical resistance shall be performed in accordance with AS4373 Method 805. Insulation
shrinkage shall be measured in accordance with 5.3.1 2.
5.7.5 Thermal Mechanical Resistance - Life Cycle (see 3.9.5)
The life cycle test shall be performed in accordance with AS4373 Method 807 for 1 20 hours (unless otherwise specified)
at the temperature specified in the detail specification. The specimen shall be examined for color retention (see 5.6.2)
prior to the ambient mechanical resistance test - mandrel bend. The mandrel bend test (see 5.7.6) shall be performed
followed by the wet dielectric test (see 5.4.4).
5.7.6 Ambient Mechanical Resistance - Mandrel Bend Test (see 3.9.6 and 7.1 .5)
The ambient mandrel bend test shall be performed in accordance with AS4373 Method 71 2 followed by a wet dielectric
test (see 5.4.4). The ambient mandrel bend test is typically used as post performance evaluation tool.
5.7.7 Fluid Resistance - Immersion (see 3.9.7)
The fluid resistance - immersion test shall be performed in accordance with AS4373 Method 601 using the fluids specified
in Table 1 7.
SAE INTERNATIONAL AS22759™D Page 34 of 45

Table 17 - Wire test fluids

Test Immersion
Temperature Time
Test Fluids °C (°F) (hours)
a. AMS1 424 Deicing/Anti-Icing Fluid, Aircraft Fluid, Undiluted 48-50 (1 1 8-1 22) 20
b. AMS1 424 Deicing/Anti-Icing Fluid, Aircraft Fluid, Diluted 60/40 (fluid/water ratio) 48-50 (1 1 8-1 22) 20
c. A-A-59921 Cleaning Compound, Aircraft Surface, Type I 48-50 (1 1 8-1 22) 20
d. ASTM D1 1 53 Methyl Isobutyl Ketone (For Use In Organic Coatings) 20-25 (68-77) 1 68
e. AS1 241 Fire Resistant Hydraulic Fluid for Aircraft 48-50 (1 1 8-1 22) 20
f. MIL-PRF-7808 Lubricating Oil, Aircraft, Turbine Engine, Synthetic Base 1 1 8-1 21 (244-250) 0.5
g. MIL-PRF-87937 Cleaning Compound, Aerospace Equipment, Type II or Type IV, undiluted 63-68 (1 45-1 54) 20
h. MIL-PRF-87937 Cleaning Compound, Aerospace Equipment, Type II or Type IV,
diluted 25/75 (fluid/water ratio) 63-68 (1 45-1 54) 20
i. ASTM D471 Standard Test Method for Rubber Property, Fuel A 20-25 (68-77) 1 68
j. ASTM D471 Standard Test Method for Rubber Property, Fuel D 20-25 (68-77) 1 68
k. ASTM D471 Standard Test Method for Rubber Property, Oil Number 1 20-25 (68-77) 1 68
l Silicate ester per MIL-PRF-87252 or equivalent 20-25 (68-77) 1 68
m. ASTM D481 4, "Standard Specification for Automotive Spark-Ignition Engine Fuel 20-25 (68-77) 1 68
n. Lubricating oil, aircraft, turbine engine, synthetic base, MIL-PRF-23699 48-50 (1 1 8-1 22) 20
o. Hydraulic fluid, petroleum base, aircraft missile, and ordnance, MIL-PRF-5606 48-50 (1 1 8-1 22) 20
p. Isopropyl alcohol, ASTM D770 1 8-20 (64-72) 20
q. Turbine fuel, aviation, Grade JP-4, MIL-DTL-5624 or turbine fuel, aviation,
kerosene type, JP-8, MIL-DTL-831 33 or Jet A, ASTM D1 655 Standard Specification for
Aviation Turbine Fuels 1 8-20 (64-72) 20

5.7.8 Humidity Resistance (see 3.9.8)

The humidity test shall be performed in accordance with AS4373 Method 603 followed by an insulation resistance test
(see 5.4.2).
5.7.9 Smoke Resistance (see 3.9.9)
The smoke test shall be performed in accordance with AS4373 Method 51 3.
5.7.1 0 Flammability Test (see 3.9.1 0)
The flammability test shall be performed in accordance with AS4373 Method 801 .
5.7.1 1 Wet Arc Propagation Resistance (see 3.9.1 1 )
The wet arc propagation resistance test shall be performed in accordance with AS4373 Method 509 followed by the wet
dielectric test (see 5.4.4).
5.7.1 2 Dry Arc Propagation Resistance (see 3.9.1 2)
The dry arc propagation resistance test shall be performed in accordance with AS4373 Method 508 followed by the wet
dielectric test (see 5.4.4).
SAE INTERNATIONAL AS22759™D Page 35 of 45

5.7.1 3 Dynamic Cut-through Resistance (see 3.9.1 3)

The dynamic cut-through resistance test shall be performed in accordance with AS4373 Method 703. Record the
minimum average value.
5.7.1 4 Forced Hydrolysis Insulation Resistance (see 3.9.1 4)
The forced hydrolysis resistance test shall be performed in accordance with AS4373 Method 602 followed by a wet
dielectric test at 2500 VAC (see 5.4.4).
5.7.1 5 Longevity Resistance - Thermal Index (see 3.9.1 5)
The longevity resistance - thermal index test shall be performed on a size 20 wire in accordance with AS4373
Method 804.
5.7.1 6 Abrasion Resistance - Needle (see 3.9.1 6)
The abrasion resistance-needle test shall be performed in accordance with AS4373 Method 301 . Record all results and
calculate the average abrasion cycle value.
5.7.1 7 UV Laser Contrast Marking Resistance after Thermal Aging (see 3.9.1 7)
The UV laser contrast marking resistance after thermal aging shall be performed in accordance with AS4373 Method 81 5.
6. PACKAGING (see 8.2)
The packaging of materials ready for shipment shall be examined to determine conformity to the requirements herein.
When a test report is specified by the purchase order, the test report shall include all applicable inspection results for
quality conformance Groups 1 through 3 in Table 1 6. The quality conformance in-process and Group 4 tests in Table 1 6
shall be satisfied by the supplier’s certificate of conformity for the production lot. Group 5 test results shall be made
available upon request. It shall also include the most recent qualification test results when specifically requested. All
exposed wire ends shall be sealed to prevent fluid or humidity ingress into the conductor stranding which may facilitate
corrosion. Unless otherwise specified, wire packaging containers shall be marked as follows:
a. Part Number: M22759/1 -22 - 9
b. Manufacturer’s identification code: 1 281 4
c. Detail specification Revision: A
d. Detail specification date: 2001 -07
6.1 Continuous Length Package (see 4.6.4.2d)
Unless otherwise specified by contract or purchase order, the applicable schedule for continuous length shall be as
specified in the detail specification and the footage of the individual continuous lengths in each spool or reel shall be
marked on the spool or reel in the sequence in which the lengths will be unwound by the user. In measuring continuous
wire lengths where the wire has been marked or stripped of insulation in lieu of being cut to mark insulation failures or
identify untested or improperly tested areas, such marking or stripping shall be considered equivalent to complete
severance of the wire at the two ends of each marked or stripped area.
SAE INTERNATIONAL AS22759™D Page 36 of 45

6.2 United States Government Acquisition

The packaging requirements shall be as specified in MIL-DTL-1 2000 unless otherwise specified in the contract or order.
Unless otherwise specified the barrel diameter of the spools shall be in accordance with Table 1 8. When actual packaging
of material is to be performed by military personnel, these personnel need to contact the responsible packaging activity to
ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s
packaging activity within the Military Department or Defense Agency, or within the Military Department’s System
Command. Packaging data retrieval is available from the managing Military Department or Defense Agency’s automated
packaging files, CD-ROM products, or by contacting the responsible packaging activity.
Table 18 - Barrel diameter of spools and reels
Minimum Diameter of Barrel as X Times Minimum
Wire Size Diameter of the Wire (Except see 6.2)
30-1 4 50X
1 2-1 0 40X
8-1 30X
0-0000 20X

6.3 Non-government Acquisition (Commercial)

For non-governmental acquisition, product shall be supplied in accordance with the purchase order.
7. NOTES
7.1 Intended Use of Insulated Wire
The electrical wires covered herein are intended for use in any application where the wire performance characteristics are
appropriate. The wires are suitable for installation on aerospace electrical systems in accordance with AS50881 within the
limitations of applicable performance requirements.
7.1 .1 U.S. Air Force Fluid Applications
MIL-A-8243D, dated 26 October 1 985, is cancelled and superseded by AMS1 424. The U.S. Air Force endorses the use of
AMS1 424 in lieu of MIL-A-8243; however, the U.S. Air Force shall not procure any deicing/anti-icing fluids that contain
ethylene glycol (USAF/CE; March 31 , 1 992; "Prohibition on Purchase of Environmentally Hazardous Deicing Chemicals").
Proposed changes by DoD activities must be submitted to the DoD Adopting Activity, U.S. Air Force, ASC/ENOI, 2530
Loop Road West, Wright-Patterson AFB, OH 45433-71 01 .
7.1 .2 Low Fluoride Applications
The industry has identified fluoride off-gassing of cross linked ETFE as a potential serious issue in enclosed environments
such as air tight bags, satellites, spacecraft and missiles. The evolution of fluoride gas can accelerate corrosion of metal
surfaces and etching of optics. It can also accelerate copper oxidation. When these applications are required low Fluoride
material wires are recommended (see 2.1 ).
7.1 .3 ARP6400 - Handling Silver Plated Conductors Wires and Shields (Red Plague)
ARP6400 specifies the recommended methods of handling silver coated conductors and shield, by the conductor
fabricator, wire insulator, distributors, harness or assembly houses, and OEMs. Red plague mitigation depends upon each
link in the chain of supply handling the wire and cable properly (also see AIR571 7).
SAE INTERNATIONAL AS22759™D Page 37 of 45

7.1 .4 AIR571 7 - Mitigating Wire Insulation Damage during Processing and Handling
AIR571 7 discusses the various forms of wire and cable damage that may occur in an aerospace manufacturing
environment. Characteristics of the different types of processes and/or equipment are described and associated with the
types of damage as applicable. Mitigating actions are suggested where possible.
7.1 .5 Bend Tests
A mandrel bend test (ambient, cold bend, etc.) is typically used as post performance evaluation tool.
7.2 Wire Solderability (see 3.4.3)
The tin conductor as specified herein is expected to be solderable for a reasonable period of time after application of the
insulation, but eventually it will oxidize and no longer be solderable without an active flux. Suppliers and users should
avoid elevated temperatures when considering storage or shelf life. Best practice would be to re-inspect material to the
solder conformance criteria. See AS4461 for further guidance.
7.3 Marking Identification
In addition to the marking identification required herein, other identification may be imposed by the purchaser
(see AS50881 ).
7.3.1 Conductor Termination
Conductors defined in accordance with AS29606 are compatible with SAE aerospace termination standards.
7.3.2 Conductor Size and Designation
The conductor sizes and the corresponding wire size designations herein are in accordance with established usage for
stranded copper conductors for hookup wire in the electronic and aircraft industries (see ASTM B286). It should be noted
that these sizes and size designations are not identical with American Wire Gage (AWG) sizes for solid wire and strands.
The diameters and cross-sectional areas of the stranded conductors are, in most sizes, only roughly approximate to those
of AWG solid conductors of the same numerical size designation.
7.3.3 Conductor Pitting
Conductor pitting is defined as small holes or cavities in the conductor surface that are large enough to be seen with the
unaided eye. Discoloration (such as the formation of inter-metallic compounds) or surface changes caused by the flow of
tin are not considered pitting.
NOTE: Conductor pitting was added as a post-flammability requirement for a 60-degree angle flame exposure in
AS22759A [dated 2006-1 2], however it is no longer required for the flame test now imposed in this specification
(see 3.9.1 0 and 5.7.1 0).
7.4 Wire Propellant Resistance
Wire propellant resistance of Polytetrafluoroethylene (PTFE) insulation is no longer required to be verified herein. The
propellant material is considered a hazard material for test purposes (see AS4373 Method 605). The propellant was
previously used in missile applications. It is the responsibility of a user to determine applicability.
7.5 Materials
7.5.1 Materials and Material Formulations
Material and material formulations include conductor, resin (polymer chemistry), processing additives, colorants, braids
(glass and aromatic polyamide), finishers, coatings and inks.
SAE INTERNATIONAL AS22759™D Page 38 of 45

7.5.2 Material Sources

Materials sources include the manufacturer and physical location where the product is produced.
Manufacturing processes include the equipment and profiles needed to produce conforming product at a specific
manufacturing location.
7.6 Wire
A wire construction consists of a conductor covered by primary insulation layer(s) and/or a jacket.
7.7 Conductor
A wire conductor is a conductive material which carries the electrical load from one end of the wire to the other end of
the wire.
7.8 Wire Primary Insulation
The wire primary insulation is the center core insulation layer (extrusion or tape) next to the conductor that provides most
or all of the electrical protection and some or all mechanical protection.
7.9 Wire Jacket Insulation
The Wire Jacket Insulation is an outer layer of electrical non-conductive or semi-conductive insulation (extruded or tape)
that provides mostly mechanical protection for the wire.
7.1 0 Wire Temperature Rating
Wire temperature ratings as listed in detail specifications represent the lower of the maximum recommended operating
temperature of either the conductor or the insulation system. The maximum ambient temperature should be the rated
maximum temperature of the wire diminished by the operating rise in temperature of the conductor. These ratings are the
accepted upper limits for the use of the respective wire types. Users need to consider the time-temperature relationship of
these temperature ratings for their application. AS50881 is a document that provides recommendations for the application
of temperature ratings.
7.1 1 Wire Voltage Rating (see detail specification)
Wire types listed herein have been applied in aerospace applications using 1 1 5 V (phase to neutral), 400 Hz AC and
28 V DC. Verification of the suitability of the wire in other electrical system configurations is the responsibility of the user.
7.1 2 Wire Length (see 3.7.7)
Wire length is considered finite and defined only in term of minimum production continuous lengths. To meet application
needs the minimum continuous lengths at the time of packaging are defined and reported.
7.1 3 Acceptable Quality Levels (AQL) Inspection Defects
7.1 3.1 Defect
A defect is any nonconformance of the unit of product with specified requirements.
7.1 3.2 Critical Defect
A critical defect is a defect that judgment and experience indicate would result in hazardous or unsafe conditions for
individuals using, maintaining, or depending upon the product, or a defect that judgment and experience indicates is likely
to prevent performance of the actual function of a major end item such as a ship, aircraft, tank, missile, or space vehicle.
SAE INTERNATIONAL AS22759™D Page 39 of 45

7.1 3.3 Major Defect

A major defect is a defect, other than critical, that is likely to result in failure, or to reduce the usability of the unit of product
for its intended purpose.
7.1 3.4 Minor Defect
A minor defect is a defect that is not likely to reduce materially the usability of the unit of product for its intended purpose
or is a departure from established standards having little bearing on the effective use or operation of the unit.
8. ORDERING DATA
Suppliers are recommended to order conductor in accordance with AS29606.
8.1 Acquisition Information (see Section 6)
Unless otherwise specified, product will be supplied to the latest revision in effect at issuance of purchase order
(see 1 0.2).
8.2 Acquisition documents should specify the following:
a. Title, number including revision letter, and date of this specification
b. Applicable detail specification number including revision letter, title, and date
c. Applicable detail specification part number (see 1 .1 )
d. Color required (see 3.8.2)
e. Quantity of wire required (see 6.1 and 6.2)
f. Packaging and packing required (see Section 6)
g. Exceptions, if any, to the optional provisions of this specification such as:
1 . Responsibility for inspection, if other than specified in 4.1 .
2. Statement, if applicable, that certification of conformity will not be accepted. Statement should include testing
schedule to be substituted.
3. Marking of dielectric test failures or irregularities by stripping of insulation or by other method specified in the
contract in lieu of cutting of the wire, if applicable (see 4.6.4.2c and 6.1 ).
4. Special preparation for delivery requirements, if applicable (see Section 6).
9. QUALIFICATION (see 4.2)
With respect to products requiring qualification by the government or commercial (unless waived by the Purchaser),
awards will be made only for products, which are at the time set for opening of bids, qualified for inclusion in the
applicable Qualified Products List (QPL), whether or not such products have actually been so listed by that date. The
attention of the contractors (purchasers) is called to these requirements, and manufacturers (suppliers) are urged to
arrange to have the products that they propose to offer to the Federal Government tested for qualification in order that
they may be eligible to be awarded contracts for the products delineated in this specification. Qualification is required for
U.S. Government procurement.
SAE INTERNATIONAL AS22759™D Page 40 of 45

9.1 QPL Evaluating Activity

The QPL Evaluating Activity (Qualifying Activity), for U.S. Department of Defense procurement purposes, is the Naval Air
Systems Command (Code 4.4.5.3), 48298 Shaw Rd., Building 1 461 , Patuxent River, MD 20670-1 900. Application for
qualification tests shall be made in accordance with provisions governing qualification in SD-6 (see 2.2).
9.2 QPL Publication
The Qualifying Activity is required to provide a summarized list of all qualified sources on a public accessible electronic
site. The summary shall include but is not limited to the supplier approved part number and related specification part
number, a dedicated approval reference number, a supplier location where purchases maybe requested and the
manufacturing location of the component. The suppliers and products qualified to this specification are available on the
Qualifying Activity website (http://www.navair.navy.mil/qpl/).
1 0. SUPERSESSION INFORMATION
AS22759 was adopted by the government and supersedes MIL-W-22759. The part number format remains unchanged.
1 0.1 AS22759 Revision D Objectives
a. Update references.
b. Add Quality Conformance requirement for Fluoride Off-gassing test.
c. Add UV laser marking.
d. Add minor technical changes as needed.
1 0.2 Deletion of Stock
The qualified supplier and distributers (not specified by QPL listing) have 1 2 months from the date of this specification or
the date of a revised detail specification to delete qualified stock that is not compliance with the requirement herein.
1 0.3 Revision Indicator
A change bar (l) 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 COMMITTEE AE8 AEROSPACE ELECTRICAL/ELECTRONIC DISTRIBUTION SYSTEMS

SAE INTERNATIONAL AS22759™D Page 41 of 45
APPENDIX A - DETAIL WIRE SPECIFICATION TEMPLATE (TO BE PUT ON SAE COMPONENT TEMPLATE)

INSTRUCTION: COMPLETE REQUIREMENTS SHOWN IN RED (??, ETC.). WHEN TESTS ARE NOT REQUIRED REMOVE .

RATIONALE

REVISION REQUIRED UPDATING REFERENCES, REMOVING GOVERNMENT TERMINOLOGY, REMOVING REQUIREMENTS SPECIFIED BY
THE BASIC, AND ESTABLISHING A COMMON FORMAT IS ALL DETAIL SPECIFICATIONS.
NOTICE
THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE
LATEST ISSUE OF AS22759.

FIGURE 1 - AS22759/?? WIRE CONSTRUCTION (EXAMPLE)

TABLE 1 - CONSTRUCTION DETAILS FOR FINISHED WIRE
DIAMETER OF
STRANDED
STRANDING CONDUCTOR
(NUMBER (INCHES) 2/ FINISHED WIRE
OF STRANDS RESISTANCE AT
X AWG 20 °C (68 °F) WEIGHT
WIRE GAUGE OF (OHMS/1 000 FEET) DIAMETER (LB/1 000 FEET)
PART NO. 1 / SIZE STRANDS) (MIN) (MAX) MAX (INCHES) (MAX)
M22759/54-30-* 30 7 X 38 .01 05 .01 24 1 00.7 .032 ± .002 1 .0
M22759/54-28-* 28 7 X 36 .01 35 .01 54 74.4 .035 ± .002 1 .3
M22759/54-26-* 26 1 9 X 38 .01 75 .01 94 38.4 .040 ±.002 1 .7
M22759/54-24-* 24 1 9 X 36 .0225 .0244 24.3 .045 ± .002 2.3
M22759/54-22-* 22 1 9 X 34 .0285 .0304 1 5.1 .050 ± .002 3.3
M22759/54-20-* 20 1 9 X 32 .0365 .0384 9.1 9 .058 ± .002 4.7
M22759/54-1 8-* 18 1 9 X 30 .0455 .0484 5.79 .070 ± .002 7.2
M22759/54-1 6-* 16 1 9 X 29 .051 5 .0544 4.52 .077 ± .003 9.0
M22759/54-1 4-* 14 1 9 X 27 .0645 .0684 2.88 .094 ± .003 1 3.8
M22759/54-1 2-* 12 37 X 28 .0835 .0874 1 .90 .1 1 1 ± .003 20.5
M22759/54-1 0-* 10 37 X 26 .1 06 .1 1 2 1 .1 9 .1 34 ± .004 32.4

1 / PART NUMBER: THE ASTERISKS IN THE PART NUMBER COLUMN, TABLES 1 AND 3 SHALL BE
REPLACED BY COLOR CODE DESIGNATORS. EXAMPLES: SIZE 20, WHITE-M22759/??-20-9; WHITE
WITH ORANGE STRIPE – M22759/??-20-93.
2/ CONDUCTOR SHALL CONFORM TO AS29606 TYPE SCC SMALL DIAMETER SILVER PLATED COPPER
CONDUCTOR.
SAE INTERNATIONAL AS22759™D Page 42 of 45

REQUIREMENTS: ALL REQUIREMENTS SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759.
1. WIRE CONSTRUCTION:
WIRE CONSTRUCTION SHALL BE IN ACCORDANCE WITH FIGURE 1 , TABLE 1 AND TABLE 2, ETC. UNLESS OTHERWISE SPECIFIED,
TOLERANCES SHALL BE ETC.
LIST WIRE PRIMARY INSULATION FLAW ALTERNATIVE STRIP LENGTH, (WHEN REQUIRED).
2. WIRE PERFORMANCE RATING:
TEMPERATURE RATING: ??? °C (??? °F) MAXIMUM CONTINUOUS CONDUCTOR TEMPERATURE.
VOLTAGE RATING: 600 V (RMS) AT SEA LEVEL. THIS INSULATION SYSTEM HAS BEEN USED IN AEROSPACE APPLICATIONS USING 1 1 5 V
(PHASE TO NEUTRAL), 400 HERTZ AC AND 28 V DC. VERIFICATION OF THE SUITABILITY OF THIS PRODUCT FOR USE IN OTHER
ELECTRICAL SYSTEM CONFIGURATIONS IS THE RESPONSIBILITY OF THE USER.
3. MATERIALS AND PHYSICAL PROPERTIES:
INSPECTION CONDITION (WHEN REQUIRED)
LIST ONLY THE EXCEPTIONS OR ADDITION TO THE BASIC AS NEEDED (ALWAYS USE MATERIAL REFERENCES WHENEVER POSSIBLE) IF
NO EXCEPTION STATE “SEE AS22759 FOR MATERIAL REQUIREMENTS”.
LIST ROHS REQUIREMENT WHEN APPLICABLE
4. FINISHED WIRE INSULATION PROPERTIES:
INSPECTION CONDITION (WHEN REQUIRED)
FINISHED WIRE INSULATION PROPERTIES SHALL BE IN ACCORDANCE WITH TABLE 2.
TABLE 2 - FINISHED WIRE INSULATION PROPERTIES REQUIREMENTS
INSULATION PROPERTIES
SPARK TEST VOLTAGE ?? V (RMS) AT 60 HERTZ
IMPULSE TEST VOLTAGE ?? KILO VOLTS (PEAK)
HIGH FREQUENCY TEST VOLTAGE ?? V (RMS)
INSULATION STATE OF SINTER (TAPE) ?? °C ± ? °C (?? °F ± ?? °F)
TAPE OVERLAP ?? % MIN
FLUORIDE OFF-GASSING REQUIRED OR REMOVE
LAMINATION SEALING REQUIRED OR REMOVE
POLYIMIDE TOPCOAT CURE REQUIRED OR REMOVE
INSULATION PROOF ?? °C ± ? °C (?? °F ± ?? °F)
ACCELERATED AGING ?? °C ± ? °C (?? °F ± ?? °F)
SHORT-TERM THERMAL STABILITY ?? °C ± ? °C (?? °F ± ?? °F)
THERMAL MECHANICAL RESISTANCE (LIFE CYCLE) ??HRS, ?? °C ± ? °C (?? °F ± ?? °F)
UV LASER CONTRAST MARKING RESISTANCE AFTER THERMAL AGING ??HRS, ?? °C ± ? °C (?? °F ± ?? °F)
INSULATION BLOCKING ?? °C ± ? °C (?? °F ± ?? °F)
SHRINKAGE ?? MAX SHRINKAGE
?? °C ± ? °C (?? °F ± ?? °F)
LAYER WICKING ?? INCHES MAX
?? POUND WEIGHT GAIN
PROCEDURE ??
ELECTRICAL RESISTANCE (IR ) REMOVE UNLESS DIFFERENT
THAN AS22759
ELECTRICAL SURFACE RESISTANCE ?? OHMS INITIAL & ?? OHMS FINAL
VALUES
WET DIELECTRIC VOLTAGE ?? V (RMS), 60 HERTZ
INSULATION STRIP FORCE ?? POUNDS MAX
WALL THICKNESS (WHEN REQUIRED) ?? INCHES MIN
CONTINUOUS LENGTH SCHEDULE A OR B
SAE INTERNATIONAL AS22759™D Page 43 of 45

5. FINISHED WIRE IDENTIFICATION:

WIRE IDENTIFICATION EXCEPTIONS: ??
WIRE IDENTIFICATION DURABILITY: ?? CYCLES (?? STROKES) WITH ?? GRAMS WEIGHT
UV LASER MARKING: WHEN REQUIRED PROVIDE WIRE SIZE ??, SAMPLE SIZE??, AND CONTRAST ??% MINIMUM (INITIAL AND AFTER
TEMPERATURE EXPOSURE) AND OTHER EXCEPTIONS AS NEEDED
6. FINISHED WIRE PERFORMANCE:
FINISHED WIRE FIXTURES APPLICABLE TO EACH WIRE SIZE SHALL BE IN ACCORDANCE WITH TABLE 3.
TABLE 3 - MANDREL SIZES AND WEIGHTS
BEND TEST MANDRELS AND WEIGHTS
MANDREL DIAMETER TEST LOAD WEIGHT
(INCHES (±3%) (LB) (±3%)
CROSSLINKING
PROOF, IMMERSION COLD CROSSLINKING PROOF, COLD
AND BEND IMMERSION AND BEND
PART NO. LIFE CYCLE TESTS TEST WRAP TEST LIFE CYCLE TESTS TEST
M22759/54-30-* .375 1 .00 TO .250 1 .00
M22759/54-28-* .375 1 .00 BE .500 2.00
M22759/54-26-* .375 1 .00 ADDED .500 3.00
M22759/54-24-* .375 1 .00 FOR .750 3.00
M22759/54-22-* .500 1 .00 WIRE 1 .00 3.00
M22759/54-20-* .500 1 .00 EXTRUSION 1 .50 4.00
M22759/54-1 8-* .750 1 .50 SIZES 2.00 4.00
M22759/54-1 6-* 1 .00 1 .50 > 10 2.00 5.00
M22759/54-1 4-* 1 .00 2.00 3.00 5.00
M22759/54-1 2-* 1 .50 2.00 3.00 5.00
M22759/54-1 0-* 2.00 3.00 3.00 5.00
SAE INTERNATIONAL AS22759™D Page 44 of 45

7. FINISHED WIRE PERFORMANCE CHARACTERISTICS SHALL BE IN ACCORDANCE WITH TABLE 4.

TABLE 4 - FINISHED WIRE PERFORMANCE CHARACTERISTICS
PERFORMANCE CHARACTERISTICS REQUIREMENT
MANDREL BEND RESISTANCE (TAPES/BRAIDS) REQUIRED OR REMOVE
WRAP BACK BEND RESISTANCE (EXTRUSION) HIGH TEMPERATURE EXPOSURE ?? °C ± ? °C (?? °F ± ?? °F)
THERMAL SHOCK MECHANICAL RESISTANCE INSULATION ELONGATION ?? INCHES WIRE SIZES 26-1 2
INSULATION SHRINKAGE ?? INCHES WIRE SIZES 26-1 2
THERMAL MECHANICAL RESISTANCE (LIFE CYCLE) TEMPERATURE EXPOSURE ?? °C ± ? °C (?? °F ± ? °F)
EXPOSURE TIME ?? HOURS
FLUID RESISTANCE (WHEN REQUIRED) DIAMETER INCREASE ?? %
SMOKE RESISTANCE TEMPERATURE EXPOSURE ?? °C ± ? °C (?? °F ± ?? °F)
FLAME RESISTANCE SELF EXTINGUISH TIME: 3 SECONDS
BURN LENGTH ?? INCHES
- A MINIMUM OF ?? WIRES PASS THE DIELECTRIC TEST.
-?? WIRES OR LESS FAIL THE DIELECTRIC TEST IN ANY ONE
WET ARC PROPAGATION RESISTANCE BUNDLE.
-ACTUAL DAMAGE TO THE WIRE IS NOT MORE THAN ?? INCHES
IN ANY TEST BUNDLE.
- A MINIMUM OF ?? WIRES PASS THE DIELECTRIC TEST.
-?? WIRES OR LESS FAIL THE DIELECTRIC TEST IN ANY ONE
DRY ARC PROPAGATION RESISTANCE BUNDLE.
-ACTUAL DAMAGE TO THE WIRE IS NOT MORE THAN ?? INCHES
IN ANY TEST BUNDLE.
?? SAMPLE SIZE
?? POUNDS MIN AT 23 °C ± 5 °C (73.5 °F ± 9 °F) FOR WIRE SIZE 26
?? POUNDS MIN AT 70 °C ± 5 °C (1 58 °F ± 9 °F) FOR WIRE SIZE 26
?? POUNDS MIN AT 1 50 °C ± 5 °C ( 302 °F ± 9 °F) FOR WIRE SIZE 26
?? POUNDS MIN AT 200 °C ± 5 °C ( 392 °F ± 9 °F) FOR WIRE SIZE 26
?? POUNDS MIN AT 23 °C ± 5 °C (73.5 °F ± 9 °F) FOR WIRE SIZE 20
DYNAMIC CUT-THROUGH FORCE ?? POUNDS MIN AT 70 °C ± 5 °C (1 58 °F ± 9 °F) FOR WIRE SIZE 20
?? POUNDS MIN AT 1 50 °C ± 5 °C ( 302 °F ± 9 °F) FOR WIRE SIZE 20
?? POUNDS MIN AT 200 °C ± 5 °C ( 392 °F ± 9 °F) FOR WIRE SIZE 20
?? POUNDS MIN AT 23 °C ± 5 °C (73.5 °F ± 9 °F) FOR WIRE SIZE 1 6
?? POUNDS MIN AT 70 °C ± 5 °C (1 58 °F ± 9 °F) FOR WIRE SIZE 1 6
?? POUNDS MIN AT 1 50 °C ± 5 °C ( 302 °F ± 9 °F) FOR WIRE SIZE 1 6
?? POUNDS MIN AT 200 °C ± 5 °C ( 392 °F ± 9 °F) FOR WIRE SIZE 1 6
FORCED HYDROLYSIS INSULATION RESISTANCE ?? WIRE SIZE
?? SAMPLE SIZE
LONGEVITY RESISTANCE REQUIRED OR REMOVED
?? WIRE SIZE
?? SAMPLE SIZE
ABRASION RESISTANCE - NEEDLE ?? MIN CYCLES TO FAILURE AT ?? °C ± ? °C (?? °F ± ?? °F)
?? MIN CYCLES TO FAILURE AT ?? °C ± ? °C (?? °F ± ?? °F)
?? MIN CYCLES TO FAILURE AT ?? °C ± ? °C (?? °F ± ?? °F)

8. REQUIREMENT EXCEPTION TO THE AS22759

INSERT NEW REQUIREMENT AS NEEDED. ADD METHOD IF NEEDED.
9. QUALIFICATION EXCEPTIONS (WHEN REQUIRED)
NUMBER OF SPECIMENS TESTED IN A SAMPLE GROUP, ETC.
SAE INTERNATIONAL AS22759™D Page 45 of 45

APPLICATION NOTES:
THE DETAIL SPECIFICATION IS INTENDED TO ONLY LIST EXCEPTIONS OR DETAIL TECHNICAL REQUIREMENTS NOT COVERED BY THE
AS22759 BASIC SPECIFICATION (SEE TABLES 1 THRU 4).
INSERT OTHER APPLICATION NOTES AS NEEDED.
SPECIFICATION NOTES:
1. REVISION INDICATOR:
A CHANGE BAR (l) 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.