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ASTM D4881-05

(Test Method)

Standard Test Method for Thermal Endurance of Varnished Fibrous- or Film-Wrapped Magnet Wire

Standard Test Method for Thermal Endurance of Varnished Fibrous- or Film-Wrapped Magnet Wire

SIGNIFICANCE AND USE
Individual varnishes behave differently when applied to the same fibrous- or film-wrapped magnet wire when exposed to elevated temperatures. Likewise, a varnish does not always behave the same when applied to different types of fibrous or film-wrapped magnet wires and when exposed to elevated temperatures.
FIG. 1 Jig for Forming Wire
SCOPE
1.1 This test method covers the determination of thermal endurance of rectangular and square fibrous- or film-wrapped magnet wire coated with an insulating varnish.
1.2 The values given in SI units are the standard. The values given in parentheses are for information only.
1.3 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. A specific precautionary statement is given in Section 5.
Note 1—There is no similar or equivalent IEC Standard.

General Information

Status
Historical
Publication Date
31-Aug-2005
ICS
29.060.10 - Wires
Technical Committee
D09 - Electrical and Electronic Insulating Materials
Drafting Committee
D09.01 - Electrical Insulating Products
Current Stage
Ref Project

Relations

Replaces
ASTM D4881-01 - Standard Test Method for Thermal Endurance of Varnished Fibrous- or Film-Wrapped Magnet Wire
Effective Date
01-Sep-2005
Replaced By
ASTM D4881-05(2012) - Standard Test Method for Thermal Endurance of Varnished Fibrous- or Film-Wrapped Magnet Wire
Effective Date
01-Jan-2012
Referred By
ASTM D1711-22 - Standard Terminology Relating to Electrical Insulation
Effective Date
01-Sep-2005

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ASTM D4881-05 - Standard Test Method for Thermal Endurance of Varnished Fibrous- or Film-Wrapped Magnet WireASTM D4881-05 - Standard Test Method for Thermal Endurance of Varnished Fibrous- or Film-Wrapped Magnet Wire
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ASTM D4881-05 - Standard Test Method for Thermal Endurance of Varnished Fibrous- or Film-Wrapped Magnet Wire
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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
An American National Standard
Designation:D4881–05
Standard Test Method for
Thermal Endurance of Varnished Fibrous- or Film-Wrapped
1
Magnet Wire
This standard is issued under the fixed designation D4881; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 3.1.2 Refer to Terminology D1711 for definitions of other
terms.
1.1 This test method covers the determination of thermal
endurance of rectangular and square fibrous- or film-wrapped
4. Significance and Use
magnet wire coated with an insulating varnish.
4.1 Individual varnishes behave differently when applied to
1.2 The values given in SI units are the standard.The values
the same fibrous- or film-wrapped magnet wire when exposed
given in parentheses are for information only.
to elevated temperatures. Likewise, a varnish does not always
1.3 This standard does not purport to address all of the
behave the same when applied to different types of fibrous or
safety concerns, if any, associated with its use. It is the
film-wrapped magnet wires and when exposed to elevated
responsibility of the user of this standard to establish appro-
temperatures.
priate safety and health practices and determine the applica-
bility of regulatory limitations prior to use. A specific precau-
tionary statement is given in Section 5.
NOTE 1—There is no similar or equivalent IEC Standard.
2. Referenced Document
2
2.1 ASTM Standards:
D1711 Terminology Relating to Electrical Insulation
D2307 Test Method for Thermal Endurance of Film-
Insulated Round Magnet Wire
D3353 Test Methods for Fibrous-Insulated Magnet Wire
3. Terminology
3.1 Definitions of Terms Specific to This Standard:
3.1.1 varnish, electrical insulating, n— a liquid resin sys-
tem that is applied to and cured on electrical components
providing electrical, mechanical, and environmental protec-
tion.
3.1.1.1 Discussion—There are two types of electrical insu-
lating varnishes—solvent-containing and solventless. Solvent-
FIG. 1 Jig for Forming Wire
containing types are solutions, dispersions, or emulsions of a
polymer or a mixture of polymers in a volatile, nonreactable
5. Safety Precautions
liquid. Solventless types are liquid resin systems free of
volatile, nonreactable solvents.
5.1 It is unsafe to use varnish at temperatures above the
flash point without adequate ventilation, especially if the
1
possibility exists that flames or sparks are present. Store
This test method is under the jurisdiction of ASTM Committee D09 on
Electrical and Electronic Insulating Materials and is the direct responsibility of
varnish in sealed containers.
Subcommittee D09.01 on Electrical Insulating Varnishes, Powders, and Encapsu-
lating Compounds.
6. Test Specimens
Current edition approved Sept. 1, 2005. Published September 2005. Originally
6.1 Construction of Test Specimens:
approved in 1988. Last previous edition approved in 2001 as D4881 – 01. DOI:
10.1520/D4881-05.
6.1.1 Cut two 250-mm (10-in.) lengths of wire for each
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
specimen to be made.
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
6.1.2 Determine the thickness dimensions per Test Method
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website. D3353.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
1

---------------------- Page: 1 ----------------------
D4881–05
6.1.3 Form each length in a fixture as shown in Fig. 1. procedure in Test Method D2307 with the following excep-
6.1.4 Prepare a test specimen by placing the two formed tions:
wires together back to back and wrap tightly with a minimum 7.1.1 The described specimen holder and electrical connec-
of6turnsofglassyarnoverthemiddle6-in.(150-mm)section. tion device are not required. Instead, lay samples flat on a
The glass yarn shall have a gap between turns and there must vented tray during oven exposure.
be intimate contact of the two wires. 7.1.2 Test individual specimens by carefully attaching test
6.1.5 Prepare ten specimens for each test temperature. leads to each specimen.
6.2 Varnishing the Test Specimens:
8. Calculation
6.2.1 Adjust the consistency of a solvent-containing varnish
8.1 After all specimens have failed, calculate the endpoint
to give a 0.025 6 0.005-mm (0.0010 6 0.0002-in.) cured film
time at each test temperature in accordance with Test Method
on each side of a 0.13-mm (0.005-in.) copper strip withdrawn
D2307.
at a rate of 100 mm/min (4 in./min). Use solventless varnish as
8.2 Plot the results using the
...

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5.5.3 Oven construction:
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SCOPE
1.1 This test method covers determination of the thermal endurance of film-insulated round magnet wire in air at atmospheric pressure. It is not applicable to magnet wire with fibrous insulation, such as cotton or glass.  
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1.6 The values stated in inch-pound units are to be regarded as the standard. The SI units in parentheses are provided for information only and are not considered standard.  
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ABSTRACT
These test methods detail the standard procedures for testing hookup wire insulations including all components of the insulation system used on single insulated conductors or an assembly of single insulated conductors such as a cable bundle and harness or flat ribbon cable. The insulating materials include not only the primary insulation over the conductor, but also insulating jackets over shielded constructions. The test procedures covered here shall be performed in the conditions or shall determine the properties, as follows: axial stability (longitudinal change) after thermal exposure; bondability to potting compounds; capacitance; cold bend test; concentricity; crush resistance; dielectric breakdown voltage; dimensions; dry-arc tracking; dynamic cut-through; fluid immersion; high temperature shock; insulation-continuity proof tests; insulation resistance; partial discharge (corona) inception and extinction voltage; relative thermal life and temperature index; strip force; surface resistance; tensile properties; vertical flame test; voltage rating of hook-up wire; voltage withstand test; and wet arc-tracking.
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1.1 These test methods cover procedures for testing hookup wire.  
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Section  
Axial Stability (Longitudinal Change) After Thermal Exposure  
20  
Bondability of Insulation to Potting Compounds  
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Capacitance  
9 to 11  
Cold Bend Test  
25  
Concentricity  
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Crush Resistance  
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Dielectric Breakdown Voltage  
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Dimensions  
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Dry-arc Tracking  
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Dynamic Cut-through  
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Fluid Immersion  
22  
High Temperature Shock  
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Insulation-Continuity Proof Tests  
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Insulation Resistance  
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Partial Discharge (Corona) Inception and Extinction Voltage  
24  
Relative Thermal Life and Temperature Index  
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Strip Force  
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Surface Resistance  
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Tensile Properties  
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Vertical Flame  
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18.5
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Vertical Flame Test B  
17.6 – 17.11.4  
Voltage Rating of Hook-Up Wire  
Annex A1  
Voltage Withstand Test  
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Wet Arc-tracking  
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5.1 A major factor affecting the life of insulating materials is thermal degradation. It is possible that other factors, such as moisture and vibration, will cause failures after the material has been weakened by thermal degradation.  
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These test methods cover the testing of fibrous-insulated electrical conductors, commonly referred to as magnet wire, which are used in electrical apparatus. The test methods are intended primarily for evaluation of the electrical insulating materials used. It is intended that these test methods be used, except where modified by individual specifications for particular applications. This elongation testing method covers the determination of the elongation of fibrous insulated magnet wire that results in a fracture of the conductor. The electrical resistance testing method covers the determination of the electrical resistance of fibrous insulated magnet wire conductors. The fibrous coverage testing method covers the determination of the quality of fibrous servings on round magnet wire or bare conductor. The measurement of dimensions test methods determine the dimensions of the bare or film insulated conductor and the fibrous-insulated magnet wire. The adhesion and flexibility test method covers the evaluation of the flexibility and adherence of varnished fibrous glass, and varnished or unvarnished fibrous polyester-glass insulating material on either bare conductor, or film-insulated magnet wire. The dielectric breakdown voltage test method covers the determination of the dielectric breakdown voltage in air of insulation on round, rectangular, and square wires at commercial power frequencies.
SCOPE
1.1 These test methods cover the testing of fibrous-insulated electrical conductors, commonly referred to as magnet wire, which are used in electrical apparatus. The test methods are intended primarily for evaluation of the electrical insulating materials used. It is intended that these test methods be used, except where modified by individual specifications for particular applications.  
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7.1 Bond strength values obtained by flexural tests 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.  
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Dissipation Factor Measurement  
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Electrical Resistance  
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Extractables, Refrigerant  
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156 – 162  
Oiliness  
163 – 169  
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186 – 195  
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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.  
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ASTM D4881-05(2017)(Test Method)
Standard Test Method for Thermal Endurance of Varnished Fibrous- or Film-Wrapped Magnet Wire

SIGNIFICANCE AND USE
4.1 Individual varnishes behave differently when applied to the same fibrous- or film-wrapped magnet wire when exposed to elevated temperatures. Likewise, a varnish does not always behave the same when applied to different types of fibrous or film-wrapped magnet wires and when exposed to elevated temperatures.
FIG. 1 Jig for Forming Wire
SCOPE
1.1 This test method covers the determination of thermal endurance of rectangular and square fibrous- or film-wrapped magnet wire coated with an insulating varnish.  
1.2 The values given in SI units are the standard. The values given in parentheses are for information only.  
1.3 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. A specific precautionary statement is given in Section 5.  
Note 1: There is no similar or equivalent IEC Standard.  
1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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SCOPE
1.1 This specification covers nickel-coated, round, copper-clad steel wire for electronic application.  
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1.3.4 Class N40A—Nominal 40 % conductivity, annealed.  
1.4 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.  
1.4.1 Exception—The SI values for resistivity are to be regarded as standard.  
1.5 The following safety hazards caveat pertains only to the test method described in this specification. 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, health, and environmental practices and determine the applicability of regulatory limitations prior to use.(Warning—Consideration should be given to toxicity and flammability when selecting solvent cleaners.)  
1.6 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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ABSTRACT
This specification covers round, aluminum-clad steel core wire used for mechanical reinforcement in the manufacture of aluminum conductors, aluminum-clad steel reinforced. The base metal shall be steel produced by the openhearth, electric-furnace, or basic-oxygen process and shall be of such composition that the finished clad wire shall have the properties and characteristics prescribed in this specification. The aluminum used for cladding shall have a purity and quantity sufficient to meet thickness and resistance requirements of this specification. The material shall conform to the required tensile properties such as stress, tensile strength, and elongation. The aluminum-clad steel core shall undergo elongation test, tension test, and torsion test. The elongation test shall be determined by an extensometer equipped with a vernier or other instrument reading. In the torsion test, a small tensile load shall be applied to the specimen during testing. The specimen shall be twisted by rotating one of the vises in the same direction until fracture occurs.
SCOPE
1.1 This specification covers round, aluminum-clad steel core wire with two designations of tensile strengths, AW2 (Normal Strength) and AW3 (High Strength).  
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ASTM
ASTM B869-07(2023)(Specification)
Standard Specification for Copper-Clad Steel Electrical Conductor for CATV Drop Wire

ABSTRACT
This specification covers hard-drawn round copper-clad steel electrical conductor for CATV drop wire (coaxial cable center conductor). The wire shall be composed of a steel core with a substantially uniform and continuous copper cladding thoroughly bonded to it throughout. The size shall be expressed as the diameter of the wire. The steel wire shall conform to the prescribed tensile strength, elongation, and breaking strength. Requirements for (1) tension and torsion tests, (2) method of determining the electrical resistance, (3) cladding uniformity in terms of thickness, and (4) joint construction are detailed. The prescribed density of the wire to be taken for calculating mass/unit length, cross section, and so forth is given.
SCOPE
1.1 This specification covers 21 % conductivity hard-drawn round copper-clad steel wire for coaxial cable center conductors (Note 1).  
Note 1: Wire ordered to this specification is not intended for redrawing since it is furnished in the hard-drawn temper. If wire is desired for the purpose, the manufacturer should be consulted.  
1.2 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.  
1.3 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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