ASTM D5642-16(2022)

Standard Test Method for Sealed Tube Chemical Compatibility Test

SIGNIFICANCE AND USE
5.1 This test method is useful for evaluating a combination of materials for potential use in an electrical insulation system.
SCOPE
1.1 This test method covers procedures for evaluating the interaction of electrical insulation components used, or intended to be used, in electrical insulation systems.  
1.2 This test method is useful for determining compatibility but additional testing will potentially be required for some applications.  
1.3 This test method also provides useful information about the behavior of selected insulating materials when compared to a reference value as opposed to a reference system.  
1.4 This test method does not cover systems which operate in liquids or gases other than air.  
1.5 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.6 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. See also 8.2.4, 8.3.1, and 8.3.2.1.  
1.7 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.

General Information

• Status: Published
• Publication Date: 30-Apr-2022
• ICS: 29.035.30 - Glass and ceramic insulating materials
• Technical Committee: D09 - Electrical and Electronic Insulating Materials
• Drafting Committee: D09.17 - Fire and Thermal Properties

Relations

• Refers: ASTM D1711-24 - Standard Terminology Relating to Electrical Insulation
• Effective Date: 01-Mar-2024
• Refers: ASTM D149-20 - Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies
• Effective Date: 01-Jan-2020
• Refers: ASTM D1676-17 - Standard Test Methods for Film-Insulated Magnet Wire
• Effective Date: 01-Nov-2017
• Refers: ASTM D1711-15 - Standard Terminology Relating to Electrical Insulation
• Effective Date: 01-Nov-2015
• Refers: ASTM D1711-14a - Standard Terminology Relating to Electrical Insulation
• Effective Date: 01-Nov-2014
• Refers: ASTM D1711-14 - Standard Terminology Relating to Electrical Insulation
• Effective Date: 01-May-2014
• Refers: ASTM D1711-13 - Standard Terminology Relating to Electrical Insulation
• Effective Date: 01-Nov-2013
• Refers: ASTM D1711-11a - Standard Terminology Relating to Electrical Insulation
• Effective Date: 01-Aug-2011
• Refers: ASTM D1676-03(2011) - Standard Test Methods for Film-Insulated Magnet Wire
• Effective Date: 01-Aug-2011
• Refers: ASTM D1711-08 - Standard Terminology Relating to Electrical Insulation
• Effective Date: 01-May-2008
• Refers: ASTM D149-97a(2004) - Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies
• Effective Date: 01-Mar-2004
• Refers: ASTM D1676-03 - Standard Test Methods for Film-Insulated Magnet Wire
• Effective Date: 10-Apr-2003
• Refers: ASTM D1676-99 - Standard Test Methods for Film-Insulated Magnet Wire
• Effective Date: 10-Mar-2002
• Refers: ASTM D1676-01 - Standard Test Methods for Film-Insulated Magnet Wire
• Effective Date: 10-Mar-2002
• Refers: ASTM D1676-02 - Standard Test Methods for Film-Insulated Magnet Wire
• Effective Date: 10-Mar-2002

Overview

ASTM D5642-16(2022) - Standard Test Method for Sealed Tube Chemical Compatibility Test is an internationally recognized procedure developed by ASTM for evaluating the chemical compatibility of electrical insulation materials. This test method is crucial for manufacturers, designers, and evaluators of electrical insulation systems looking to assess how different materials interact under controlled conditions. By subjecting material combinations to elevated temperatures in a sealed tube, users can gather valuable insights into the suitability of materials for use in electrical insulation systems without exposing them to liquids or gaseous environments other than air.

Keywords: electrical insulation system, chemical compatibility, sealed tube, dielectric breakdown voltage, ASTM D5642, aging test.

Key Topics

• Purpose: To determine the compatibility of electrical insulation materials by measuring the change in dielectric breakdown voltage after exposure to high temperatures in a sealed tube environment.
• Scope:
  • Applicable to materials used or intended for use in electrical insulation systems.
  • Does not cover systems operating in liquids or gases other than air.
  • Provides a means for comparing candidate material systems to a reference value rather than to a complete reference system.
  • Requires additional tests for comprehensive evaluations in specific cases.
• Test Apparatus: Utilizes sealed glass tubes, temperature-controlled ovens, suitable gasket materials, and standard test equipment for dielectric breakdown voltage (as per ASTM D149).
• Material Specimens: Includes all non-metallic components and insulated conductors, with minimum specimen masses and preparation guidelines established by agreement.
• Procedure:
  • Sealed tubes are prepared and conditioned at elevated temperatures.
  • After aging (minimum of 336 hours at appropriate temperature), the dielectric breakdown voltage of conductors is measured.
  • Results are interpreted by comparing the average breakdown voltage of candidate and reference systems.

Applications

ASTM D5642-16(2022) is highly relevant in several practical scenarios:

• Product Development & Material Selection: Electrical equipment manufacturers use this test to ensure new or modified combinations of insulation materials are chemically compatible and suitable for long-term system integrity.
• Quality Assurance: Routine quality checks for raw materials and finished insulation systems rely on this method to identify potential incompatibility issues before products go to market.
• System Upgrades & Maintenance: When upgrading or replacing components in existing electrical insulation systems, this method helps teams verify that new materials will not negatively interact with legacy materials.
• Comparative Performance Evaluation: This method assists in benchmarking insulating materials by providing direct comparison data between candidate systems and reference values under identical conditions.
• Regulatory & Safety Compliance: Conformance with ASTM D5642 is often required to meet both internal company standards and international trade requirements, ensuring that insulation systems perform reliably and safely.

Related Standards

The sealed tube chemical compatibility test has connections with several other ASTM standards and technical documents, especially in the field of electrical insulation. Key related standards include:

• ASTM D149: Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials. Used in conjunction with D5642 to measure post-aging dielectric strength.
• ASTM D1676: Test Methods for Film-Insulated Magnet Wire. Guidelines for preparing insulated wire specimens utilized in D5642 testing.
• ASTM D1711: Terminology Relating to Electrical Insulation. Standardizes terms and definitions used in D5642.

Adhering to these and related standards ensures consistency, reliability, and global acceptance of chemical compatibility testing practices in electrical and electronic insulation systems. For further information and access to referenced documents, visit ASTM International.

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ASTM D5642-16(2022) is an essential reference for organizations striving for optimal material compatibility and long-term reliability in electrical insulation systems, supporting informed material selection and compliance with international best practices.

Standards Content (Sample)

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.
Designation: D5642 − 16 (Reapproved 2022)
Standard Test Method for
Sealed Tube Chemical Compatibility Test
This standard is issued under the fixed designation D5642; 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 at Commercial Power Frequencies
D1676 Test Methods for Film-Insulated Magnet Wire
1.1 This test method covers procedures for evaluating the
D1711 Terminology Relating to Electrical Insulation
interaction of electrical insulation components used, or in-
tended to be used, in electrical insulation systems.
3. Terminology
1.2 This test method is useful for determining compatibility
3.1 Definitions:
but additional testing will potentially be required for some
3.1.1 magnet wire—See Terminology D1711 for the defini-
applications.
tion of this term.
1.3 This test method also provides useful information about
3.2 Definitions of Terms Specific to This Standard:
the behavior of selected insulating materials when compared to
3.2.1 aging test, n—a process of exposure, to a specified set
a reference value as opposed to a reference system.
of conditions for a defined period of time, which results in an
irreversible change in one or more physical, chemical,
1.4 This test method does not cover systems which operate
electrical, or thermal characteristics of a material.
in liquids or gases other than air.
3.2.2 candidate system, n—the proposed electrical insula-
1.5 The values stated in SI units are to be regarded as
tion system to be evaluated.
standard. No other units of measurement are included in this
standard. 3.2.3 electrical insulation system, n—an intimate combina-
tion of insulating materials with conductors, as used in elec-
1.6 This standard does not purport to address all of the
trical equipment.
safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appro- 3.2.4 insulation system class, n—a standardized designation
priate safety, health, and environmental practices and deter- of the temperature capability of the electrical insulation sys-
mine the applicability of regulatory limitations prior to use. tem. It is expressed by both numbers and letters as follows:
See also 8.2.4, 8.3.1, and 8.3.2.1.
System Class
105 (A)
1.7 This international standard was developed in accor-
120 (E)
dance with internationally recognized principles on standard-
130 (B)
ization established in the Decision on Principles for the
155 (F)
Development of International Standards, Guides and Recom- 180 (H)
200 (N)
mendations issued by the World Trade Organization Technical
220 (R)
Barriers to Trade (TBT) Committee.
240 (S)
3.2.5 reference system, n—an electrical insulation system
2. Referenced Documents
which has been previously evaluated and found acceptable.
2.1 ASTM Standards:
3.2.6 twisted pair, n—film-insulated round magnet wire that
D149 Test Method for Dielectric Breakdown Voltage and
has been prepared in accordance with Test Methods D1676.
Dielectric Strength of Solid Electrical Insulating Materials
4. Summary of Test Method
4.1 Acombinationofspecificmaterialsissealedinalimited
This test method is under the jurisdiction of ASTM Committee D09 on
space and subjected to a specific elevated temperature for a
Electrical and Electronic Insulating Materials and is the direct responsibility of
specified time. Following this exposure the dielectric break-
Subcommittee D09.17 on Fire and Thermal Properties.
down voltage of the insulated conductors is used as a basis for
Current edition approved May 1, 2022. Published May 2022. Originally
approved in 1994. Last previous edition approved in 2016 as D5642 – 16. DOI:
judging the compatibility of the candidate system.
10.1520/D5642-16R22.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or 5. Significance and Use
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM
5.1 This test method is useful for evaluating a combination
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website. of materials for potential use in an electrical insulation system.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D5642 − 16 (2022)
6. Apparatus sufficient drying prior to 8.1.2 and 8.1.3. Concurrently condi-
tion tubes and gaskets.
6.1 Oven, capable of maintaining the required exposure
8.1.5 Certain materials, including but not limited to hygro-
temperature within 63 °C.
scopic papers, require additional conditioning to remove mois-
6.2 Glass Tubes with inside volume not exceeding 900 mL
ture. If agreed upon by interested parties, the use of higher
that can be sealed. Two general types are described as follows:
temperatures and times for drying is acceptable. Select a time
6.2.1 Flanged High Temperature Glass Tubes which are
and temperature that do not cause loss of other volatile
designed to be sealed with metal rings and gaskets are
materials or cause thermal decomposition.
preferred.
8.1.6 Seal tubes within 3 min after conditioning, and leak
6.2.2 Glass Tubes, which can be fusion sealed after the
test immediately thereafter in accordance with 8.1.6.2.
addition of all materials are acceptable alternatives.
8.1.6.1 Seal flanged glass tubes by applying a sufficient
torque to ensure a seal that is leak free.Atorque of 3.4 N·m (30
6.3 Gasket Materials for use with tubes described in 6.2.1.
inch-pounds) in increments of 0.56 N·m (5 inch-pounds),
6.3.1 Type TFE (Tetrafluoroethylene) or FEP (Perfluoroeth-
alternating between bolts to tighten evenly and securely has
ylene Propylene) Fluorocarbon.
been found acceptable for this purpose.
6.3.2 Hexafluoropropylene—vinylidene fluoride elastomer
8.1.6.2 Check glass tubes for leaks using the following
can be used for exposure temperatures not exceeding 155 °C.
procedure: Submerge the still warm tubes into room tempera-
6.4 Apparatus in conformance with Test Method D149 to
ture tap water for a minimum of 2 min. Observe the tubes after
measure dielectric breakdown voltage.
they have reached room temperature for condensation on the
inner walls. Condensation is a result of leakage.
7. Material Specimens
8.1.6.3 Do not use tubes that exhibit leakage.
7.1 The specific list of materials to be tested is to be
8.2 Aging:
established by agreement between interested parties.
8.2.1 Place the tubes into an oven that is at room tempera-
7.2 Represent each of the non-metallic components of the
ture.
electrical insulation system, with the exception of an impreg-
8.2.2 Apply power to the oven and allow it to attain the
nating varnish and insulated conductors, with a specimen
aging temperature.
having a minimum mass of 250 mg.
8.2.2.1 Place sealed tubes into a heated oven but be aware
that the thermal shock will cause str
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