ENGINEERING DESIGN HANDBOOK

ELECTRICAL WIRE AND CABLE

CHAPTER 1 CONDUCTORS

1-1 Material Elements .. .......................... 1-1
1--1.1 Copper (ETP and OFHC) .. ..................... 1-1
1--1.2 Copper (Hot Rolled) .. ........................ 1-1
1-2 Wire Size (Solid) .. .......................... 1-1
1-2.1 Gaging Systems ........................... 1-1
1-2.2 Circular Mil Area (CMA) ....................... 1-1
o 1-2.3 Copper Wire Dimensions ....................... 1-2
1-2.4 DC Resistance .. ........................... 1-2
1-3 Coatings ... ............................... 1-2
1-3.1 Methods of Coating ........................... 1-2
1-3.1.1 Tin ... .................................. 1-2
1-3.1.2 Silver .......... ........................ : 1-3
1-3.1.3 Nickel .. ................................. 1-4
1-3.2 Dual Coating ............................... 1-4
1-3.3 Claddings .. ............................... 1-5
1-4 Aluminum ........... ................. i-5
1-4.1 Uses .. .................................. 1-5
1-4.2 Coatings ................................ 1-S
1-5 Alloys ................................. 1-5
I, 0 1-5.1 General Propeties .. ......................... 1-5
" 1-5.2 High Conductivity Types ....................... 1-5
1-5.3 High Conductivity-High Strength Types ............. 1-6
1-6 Stranding ...... ........................... 1-6
1-6.1 Bunched Stranding .. ......................... I-
1-6.2 Concentric Stranding .......................... 1-8
11-k6 .3 Rope Stranding ........................... 1-8
1-7 Soldenng ............................... 1-8
1-7.1 Soldering Stranded Wire .. ...................... 1-9
1-7.2 Heavy Tinned Stra.iding .. ...................... 1-9 [
1-7.3 Silver-coated Stranding ........................ 1-9
1-7.4 Nickel-coated Stranding . ...................... 1-10
1-7.5 Composite Stranding ......................... 1-10
1-8 Terminations .............................. 1-10
1-8.1 Crimp Termination...........................1-10
1-8.2 Wire Wrap Termination.. ....................... 1-10
1-9 Shielding .................................. 1-11
1-9.1 General .. ................................ 1-11
1-9.2 Braid Terminology........................... 1-11
1-9.3 Computation of Braid Angle and Coverage............. 1-12
1-9.4 Served Shields.............................. 1-13
1-9.5 Shielding Effectiveness......................... 1-13
1-10 Flex-life Comparison-Copper vs Alloy 63..............1-19
U.1-10.1 Test Method........................ ....... 1-19
1-10.2 Comparative Data .. ................... 1-19
References. .. .. .. .. .. .. .. .. ... .. ... .... 1-25V

CHAPTrER 2 INSULATION MATERIALS
2-1 Introductioa............................... 2-1
2-2 The.zmiplastic Insulation Materials.................. 2-1
2-2.1 Polyvinylchioride............................ 2-1
2-2.2 Polyolefins................................ 2-2
2-2.2.1 Low-density Polyethylene....................... 2-2
2-2.2.2 High-density Polyethylene....................... 2-2
2-2.2.3 Polypropylene.............................. 2-3 .12-2.3 Cros.Iinked Polyolefins........................ 2-3
2-2.4 Nylon.................................... 2-6
2-3 Fluorocarbons.............................. 2-7
2-3.1 Polytetrafluoroethylene (TFE).................... 2-7
2-3.2 Copolymtr of Teirafluoroethylene and
Perfluoropropylene (FEP)...................... 2-7
2-3.4 Polyvinlidenetfluorie (F)...................2-8C . 2-3.3 Polyvihlroerifluorehy e (TFE.................... 2-8
2-4 Polyurethanes:.............................. 2-8
2-4.1 Physical Properties .......................... 2-8
2-4.2 Thermal Properties........................... 2-9
2-4.3 Uses..................................... 2-9
2-5 Rubber................................... 2-9
2-5.1 Natural Rubber (Polyisoprene).................... 2-9
2-5.2 Styrene-butadiene Rubbers. .. .. .. .. .. .. .. .. .. ... 2-9
2-5i.3 Chloroprene Rubber. .. .. .. .. .. .. .. .. .. .. .. ... 2-10
2-5.4 Butyl Rubber. .. .. .. .. .. .. .. .. .. .. .. .. .. ... 2-10
2-5.5 Silicone Rubber............................. 2-10
2-5.6 Chlorosulfonated Polyethylene..................... 2-13 I
2.-5.7 Ethylene Propylene Rubber...................... 2-13
2-5.8 Fluorocarbon Rubber......................... 2-13
2-6 Films................................... 2-14 V
2-6.1 Cellulosics................................ 2-14
2-6.2 P31lvcsters................................ 2-14
2-6.3 Fluorocarbons............................. 2-16
2-6.4 Polyimide................................ 2-16
2-7 Fibers................................... 2-17
2-7.1 Cotton....................................2-17
2-7.2 Rayon.................................. 2-17
2-7.3 Nylon................................... 2-17

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