ASTM D1676-03(2011)

Standard Test Methods for Film-Insulated Magnet Wire

SIGNIFICANCE AND USE
Bond strength values obtained by flexural tests can provide information with regard to the bond strength of a particular self-bonding outer coating in combination with a particular round film-insulated magnet wire when measured under conditions described in this test method.
SCOPE
1.1 These test methods cover procedures for testing film-insulated magnet wire that is used in electrical apparatus. These test methods are intended primarily for the evaluation of the electrical insulating materials used. The intent is that these test methods be used, except where modified, by individual specifications for particular applications.
1.2 These test methods present different procedures for evaluating given properties of round, rectangular or square, copper or aluminum film-insulated magnet wire.
1.3 The values stated in inch-pound units are the standard. The SI units in parentheses are provided for information only.
1.4 The test methods appear in the following sections:
Sections Bond Strength 4-12 Burnout (AC Overload Resistance)13-21 Chemical Resistance22-28 Coefficient of Friction29-37 Continuity, DC High Voltage38-45 Continuity, DC Low Voltage46-53 Completeness of Cure54-60 Cut-Through Temperature (Thermoplastic Flow)61-68 Dielectric Breakdown AC Voltage69-75 Dielectric Breakdown AC Voltage after Bending76-82 Dielectric Breakdown AC Voltage at Elevated Temperatures83-89 Dielectric Breakdown AC Voltage after Conditioning in Refrigerant Atmosphere90-99 Dimensional Measurement100-106 Dissipation Factor Measurement107-114 Electrical Resistance115-121 Elongation122-129 Extractables, Refrigerant130-140 Film Adherence and Flexibility141-148 Formability:  a) Elastic Ratio152  b) Low Stress Elongation153  c) Spring Back154-155 Heat Shock156-162 Oiliness163-169 Scrape Resistance, Unidirectional170-177 Solderability178-185 Resistance to Insulating Liquids and Hydrolytic Stability186-195
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. Specific hazard statements are given in 9.5, 19.1, 19.3, 19.8, 52.1, 58, 59.1, 74.1, 112.1, 135.4, and 182.3.  
Note 1—This test method is related to IEC 60851. Since both methods contain multiple test procedures, many procedures are technically equivalent while others differ significantly.

General Information

• Status: Historical
• Publication Date: 31-Jul-2011
• ICS: 29.060.10 - Wires
• Technical Committee: D09 - Electrical and Electronic Insulating Materials
• Drafting Committee: D09.12 - Electrical Tests

Relations

• Replaces: ASTM D1676-03 - Standard Test Methods for Film-Insulated Magnet Wire
• Effective Date: 01-Aug-2011
• Replaced By: ASTM D1676-17 - Standard Test Methods for Film-Insulated Magnet Wire
• Effective Date: 01-Nov-2017
• Referred By: ASTM D5642-16(2022) - Standard Test Method for Sealed Tube Chemical Compatibility Test
• Effective Date: 01-Aug-2011
• Referred By: ASTM D1711-22 - Standard Terminology Relating to Electrical Insulation
• Effective Date: 01-Aug-2011
• Referred By: ASTM D3353-18 - Standard Test Methods for Fibrous-Insulated Magnet Wire
• Effective Date: 01-Aug-2011
• Referred By: ASTM D2305-18 - Standard Test Methods for Polymeric Films Used for Electrical Insulation
• Effective Date: 01-Aug-2011
• Referred By: ASTM D2307-21 - Standard Test Method for Thermal Endurance of Film-Insulated Round Magnet Wire
• Effective Date: 01-Aug-2011
• Referred By: ASTM D4880-18 - Standard Test Method for Salt Water Proofness of Insulating Varnishes Over Enamelled Magnet Wire
• Effective Date: 01-Aug-2011

Standards Content (Sample)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
Designation: D1676 − 03 (Reapproved 2011)
Standard Test Methods for
Film-Insulated Magnet Wire
This standard is issued under the fixed designation D1676; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 1.5 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
1.1 These test methods cover procedures for testing film-
responsibility of the user of this standard to establish appro-
insulatedmagnetwirethatisusedinelectricalapparatus.These
priate safety and health practices and determine the applica-
test methods are intended primarily for the evaluation of the
bility of regulatory limitations prior to use. Specific hazard
electrical insulating materials used.The intent is that these test
statements are given in 9.5, 19.1, 19.3, 19.8, 52.1, 58, 59.1,
methods be used, except where modified, by individual speci-
74.1, 112.1, 135.4, and 182.3.
fications for particular applications.
NOTE 1—This test method is related to IEC 60851. Since both methods
1.2 These test methods present different procedures for
contain multiple test procedures, many procedures are technically equiva-
evaluating given properties of round, rectangular or square,
lent while others differ significantly.
copper or aluminum film-insulated magnet wire.
2. Referenced Documents
1.3 The values stated in inch-pound units are the standard.
2.1 ASTM Standards:
The SI units in parentheses are provided for information only.
A228/A228MSpecification for Steel Wire, Music Spring
1.4 The test methods appear in the following sections:
Quality
Sections
B3Specification for Soft or Annealed Copper Wire
Bond Strength 4–12
B43Specification for Seamless Red Brass Pipe, Standard
Burnout (AC Overload Resistance) 13–21
Chemical Resistance 22–28 Sizes
Coefficient of Friction 29–37
B193Test Method for Resistivity of Electrical Conductor
Continuity, DC High Voltage 38–45
Materials
Continuity, DC Low Voltage 46–53
B279Test Method for Stiffness of Bare Soft Square and
Completeness of Cure 54–60
Cut-Through Temperature (Thermoplastic Flow) 61–68
RectangularCopperandAluminumWireforMagnetWire
Dielectric Breakdown AC Voltage 69–75
Fabrication
Dielectric Breakdown AC Voltage after Bending 76–82
Dielectric Breakdown AC Voltage at Elevated Temperatures 83–89 B324Specification for Aluminum Rectangular and Square
Dielectric Breakdown AC Voltage after Conditioning in Refriger-
Wire for Electrical Purposes
ant Atmosphere 90–99
B609/B609M Specification for Aluminum 1350 Round
Dimensional Measurement 100 – 106
Dissipation Factor Measurement 107 – 114 Wire, Annealed and Intermediate Tempers, for Electrical
Electrical Resistance 115 – 121
Purposes
Elongation 122 – 129
D149Test Method for Dielectric Breakdown Voltage and
Extractables, Refrigerant 130 – 140
Film Adherence and Flexibility 141 – 148
DielectricStrengthofSolidElectricalInsulatingMaterials
Formability:
at Commercial Power Frequencies
a) Elastic Ratio 152
D150Test Methods forAC Loss Characteristics and Permit-
b) Low Stress Elongation 153
c) Spring Back 154-155 tivity (Dielectric Constant) of Solid Electrical Insulation
Heat Shock 156 – 162
D374Test Methods for Thickness of Solid Electrical Insu-
Oiliness 163 – 169
lation (Withdrawn 2013)
Scrape Resistance, Unidirectional 170 – 177
Solderability 178 – 185
D877Test Method for Dielectric Breakdown Voltage of
Resistance to Insulating Liquids and Hydrolytic Stability 186 – 195
Insulating Liquids Using Disk Electrodes
D1533Test Method for Water in Insulating Liquids by
Coulometric Karl Fischer Titration
D1711Terminology Relating to Electrical Insulation
These test methods are under the jurisdiction of ASTM Committee D09 on
D2475Specification for Felt
Electrical and Electronic Insulating Materials and are the direct responsibility of
Subcommittee D09.12 on Electrical Tests.
Current edition approved Aug. 1, 2011. Published August 2011. Originally
approved in 1959. Last previous edition approved in 2003 as D1676-03. DOI: The last approved version of this historical standard is referenced on
10.1520/D1676-03R11. www.astm.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D1676 − 03 (2011)
D2519Test Method for Bond Strength of Electrical Insulat- 7. Significance and Use
ing Varnishes by the Helical Coil Test
7.1 Bond strength values obtained by flexural tests can
D5423Specification for Forced-Convection Laboratory Ov-
provide information with regard to the bond strength of a
ens for Evaluation of Electrical Insulation
particular self-bonding outer coating in combination with a
E4Practices for Force Verification of Testing Machines
particular round film-insulated magnet wire when measured
E6Terminology Relating to Methods of Mechanical Testing
under conditions described in this test method.
E8Test Methods for Tension Testing of Metallic Materials
E220Test Method for Calibration of Thermocouples By
8. Apparatus
Comparison Techniques
8.1 Testing Machine—Tensile testing machines used for
E1356Test Method for Assignment of the Glass Transition
bond strength test shall conform to the requirements of
Temperatures by Differential Scanning Calorimetry
Practices E4.
E1545Test Method for Assignment of the Glass Transition
Temperature by Thermomechanical Analysis
8.2 Test Fixture—The test fixture shall conform to the test
2.2 Other Documents: fixture for bond strength tests required byTest Method D2519.
Federal Specification CCCM-911for Bleached Muslin
8.3 Mandrel Holder—The mandrel holder shall be a metal
IEC 60851Methods of Test for Winding Wire
block of sufficient size and thickness with a hole capable of
supporting the winding mandrel in a vertical position during
3. Terminology
the bonding cycle of the helical coil.
3.1 Definitions:
8.4 Winding Tensions—The winding tensions are listed in
3.1.1 conductor, n—a wire or combination of wires not
Table 1.
insulatedfromeachother,suitableforcarryingelectriccurrent.
8.5 Bonding Weights—Bonding weights (listed in Table 1)
3.1.2 magnet wire, n—a metal electrical conductor, covered
should be made with a hole through the center to allow the
with electrical insulation, for use in the assembly of electrical
weight to slip freely over the winding mandrel and load a
inductive apparatus such as coils for motors, transformers,
helical coil during bonding of coil.
generators, relays, magnets, etc.
8.6 Forced-Air Oven—See Specification D5423.
3.1.3 For definition of other terms used in this test method
refer to Terminology D1711.
3.2 Definitions of Terms Specific to This Standard:
3.2.1 film coating, n—cured enamel coating.
TABLE 1 Helical Coil Bond Parameters
3.2.2 film insulated wire, n—a conductor insulated with a
Recommended
A A
film coating.
Mandrel Diameter Bond Weights
Wire Size,
Winding Tension
AWG
in. mm g N g N
BOND STRENGTH OF ROUND FILM-INSULATED
44 0.011 0.28 2.5 0.025 0.80 0.008
SELF-BONDING MAGNET WIRE BY THE HELICAL
43 0.011 0.28 2.5 0.025 0.80 0.008
COIL TEST
42 0.016 0.41 5.0 0.50 1.60 0.016
41 0.016 0.41 5.0 0.50 1.60 0.016
40 0.022 0.56 10.0 0.098 3.15 0.031
4. Scope
39 0.022 0.56 10.0 0.098 3.15 0.031
4.1 This test method covers the determination of the bond 38 0.022 0.56 10.0 0.098 3.15 0.031
37 0.032 0.81 20.0 0.196 6.30 0.062
strengthofaself-bondingoutercoatingonroundfilm-insulated
36 0.032 0.81 20.0 0.196 6.30 0.062
magnet wires (AWG 14 through 44). Both thermal and solvent
35 0.032 0.81 20.0 0.196 6.30 0.062
bonding methods are defined.
34 0.044 1.12 40.0 0.392 12.5 0.123
33 0.044 1.12 40.0 0.392 12.5 0.123
32 0.044 1.12 40.0 0.392 12.5 0.123
5. Terminology
31 0.063 1.60 80.0 0.785 25.0 0.245
30 0.063 1.60 80.0 0.785 25.0 0.245
5.1 Definitions of Terms Specific to This Standard:
29 0.063 1.60 80.0 0.785 25.0 0.245
5.1.1 bond strength, n—a measure of the force required to
28 0.088 2.24 160.0 1.569 50.0 0.490
separate surfaces which have been bonded together.
27 0.088 2.24 160.0 1.569 50.0 0.490
26 0.088 2.24 160.0 1.569 50.0 0.490
5.1.1.1 Discussion—For magnet wire which has been self
25 0.124 3.15 315.0 3.089 100.0 0.981
bonded or varnish treated, the bond strength is reported as the
24 0.124 3.15 315.0 3.089 100.0 0.981
force required to break a test specimen in flexure.
23 0.124 3.15 315.0 3.089 100.0 0.981
22 0.177 4.50 630.0 6.178 200.0 1.961
21 0.177 4.50 630.0 6.178 200.0 1.961
6. Summary of Test Method
20 0.177 4.50 630.0 6.178 200.0 1.961
19 0.248 6.30 1250.0 12.258 400.0 3.923
6.1 Flexural strength tests are made on bonded helical coils
18 0.248 6.30 1250.0 12.258 400.0 3.923
todeterminetheforcerequiredtobreakthecoilunderspecified
17 0.248 6.30 1250.0 12.258 400.0 3.923
conditions.
16 0.354 8.99 2500.0 24.517 800.0 7.845
15 0.354 8.99 2500.0 24.517 800.0 7.845
14 0.354 8.99 2500.0 24.517 800.0 7.845
A
AvailablefromStandardizationDocumentsOrderDesk,Bldg.4SectionD,700
± 2 % on all mandrels and bond weights.
Robbins Ave., Philadelphia, PA 19111-5094, Attn: NPODS.
D1676 − 03 (2011)
9. Test Specimen Preparation 10.2 Prepare sufficient specimens to obtain six data points
for each wire sample. One or more of the specimens may be
9.1 Select the appropriate mandrel from Table 1, spray it
destroyed in adjusting the rate of loading.
with a suitable release agent (fluorocarbon or silicone spray is
10.3 Break specimens according to the test procedures
adequate),andallowittodry.Carefullywindontotheprepared
described in Test Method D2519.
mandrel a length of wire, long enough to wind a helical coil at
least 3 in. (76 mm) long. The winding tension shall be as
10.4 Testsatotherthanroomtemperaturecanbeperformed,
prescribed in Table 1. Ensure that the coil is wound without
ifdesired,usinganinsulatedheat-resistantenclosure,designed
space between turns.
to fit around the test fixture and in the stress strain analyzer.
Place the specimens in the fixture in the oven for 15 min but
9.2 Prepare six or more coils from each wire sample.
not more than 30 min after the oven has recovered to the set
9.3 Thermal Bonding—Mount the mandrel supporting the
temperature 6 2°C. Break the specimens according to the test
coil vertically in the mandrel holder and loaded with the
proceduresdescribedinTestMethodD2519.Thespecifiedtest
bonding weight specified in Table 1. Place the mandrel holder
temperature and minimum bond strength shall be agreement
and coil into a forced-air oven at a specified temperature for a
upon between the manufacturer and the user.
specified time, after which the assembly is removed from the
oven and cooled to room temperature. Remove the coil from
11. Report
the mandrel and inspect the coil for breaks or physical damage
11.1 Report the following:
prior to testing.
11.1.1 Identification of size, build and type of insulation
used,
9.4 Solvent Bonding—After winding, immerse the coil and
mandrel into the specified solvent for 5 s. Immediately 11.1.2 Heat or solvent bonding (including temperature or
type of solvent, or both),
thereafter, secure the mandrel supporting the coil in the
mandrel holder and load the coil with the bonding weight 11.1.3 Test temperature, and
11.1.4 Atablelistingtheindividualvaluesinpounds,grams
specified in Table 1. Dry the coils for1hat room temperature.
Carefully remove the coils from the mandrels and further dry or newtons of bond strength and their averages.
in a forced air oven for 15 6 2 min at 100 6 3°C (unless
12. Precision and Bias
otherwisespecified).Coolthecoiltoroomtemperature,inspect
for breaks or physical damage, and test. 12.1 In comparing two averages of six observations, the
differences should not exceed the critical difference in Table 2,
9.5 Resistance Bonding—Mountthemandrelsupportingthe
in95outof100caseswhenalloftheobservationsaretakenby
coilverticallyinamandrelholderandloadedwiththebonding
the same well-trained operator using the same piece of test
weight specified in Table 1. Energize the coil with enough
equipment and specimens randomly drawn from the same
current and time to allow bonding. Remove the coil from the
sample of material.
mandrel and inspect for breaks or physical damage, and test.
12.2 Precision—Twoaveragesofobservedvaluesshouldbe
Specific bonding conditions shall be agreed upon between the
manufacturer and the user. (Warning—Lethal voltages are a considered significantly different at the 95% probability level
ifthedifferenceequalsorexceedsthecriticaldifferenceslisted
potential hazard during the performance of this test. It is
essential that the test apparatus, and all associated equipment in Table 2.
electrically connected to it, be properly designed and installed
12.3 Bias—This test method has no bias because the value
for safe operation. Solidly ground all electrically conductive
of bond strength is determined solely in terms of this test
parts which it is possible for a person to contact during the
method.
test. Provide means for use at the completion of any test to
BURNOUT (AC OVERLOAD RESISTANCE)
ground any parts which were at high voltage during the test or
have the potential for acquiring an induced charge during the
13. Scope
test or retaining a charge even after disconnection of the
voltage source. Thoroughly instruct all operators as to the
13.1 This test method and equipment described herein is
correct procedures for performing tests safely. When making
usedtodeterminetheacoverloadresistanceof18AWGheavy
high voltage tests, particularly in compressed gas or in oil, it
is possible for the energy released at breakdown to be suffıcient
to result in fire, explosion, or rupture of the test chamber.
Supporting data are available fromASTM International Headquarters. Request
RR:D09-1007.
Design test equipment, test chambers, and test specimens so as
tominimizethepossibilityofsuchoccurrencesandtoeliminate
TABLE 2 Critical Differences, Percent of Average Pounds to
the possibility of personal injury. If the potential for fire exists,
A
Break
have fire suppression equipment available.)
Number of Single- Within- Between-
Observations in Operator Laboratory Laboratory
10. Procedure
each Average Precision Precision Precision
610 11 12
10.1 Use a rate of loading such that the duration of the test
A
The critical differences were calculated usingt=1.960, which is based on infinite
shall be greater than the full-scale response time of the load
degrees of freedom
recording instrument.
D1676 − 03 (2011)
build film-insulated round copper magnet wire by measuring 16.3 Test condition #1 was developed for faster and more
the
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