ASTM B803/B803M-08(2016)
(Specification)Standard Specification for High-Strength Zinc–5 % Aluminum-Mischmetal Alloy-Coated Steel Core Wire for Use in Overhead Electrical Conductors
Standard Specification for High-Strength Zinc–5 % Aluminum-Mischmetal Alloy-Coated Steel Core Wire for Use in Overhead Electrical Conductors
ABSTRACT
This specification covers round, high-strength, zinc-aluminum-mischmetal (Zn-5Al-MM) alloy-coated, steel core wire with Class A Zn-5Al-MM alloy coating used for mechanical reinforcement in the manufacture of special aluminum and aluminum-alloy conductors, steel reinforced. The base metal shall be steel produced by the open-hearth, electric furnace, or basic oxygen process. The wire shall be cold drawn and coated with Zn-5Al-MM alloy to produce the desired properties. Chemical requirements of the steel, such as carbon, manganese, phosphorus, sulfur, and silicon shall meet the requirements prescribed in this specification. The Zn-5Al-MM-coated steel core wire shall conform to the tensile and elongation requirements. Test methods for tensile, wrap, coating and adherence shall be also be performed.
SCOPE
1.1 This specification covers round, high strength, zinc–5 % aluminum-mischmetal (Zn–5Al–MM) alloy-coated, steel core wire with one class of Zn–5Al–MM coating (MA3) for use in overhead electrical conductors.
1.2 This specification covers wire of diameter from 0.0500 to 0.1900 in. inclusive or 1.27 to 4.82 mm inclusive.
1.3 The values stated in either SI units or inch-pound units are to be regarded separately as standard. The values stated in each system may not be exact equivalents; therefore, each system shall be used independently of the other. Combining values from the two systems may result in non-conformance with the standard.
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Designation:B803/B803M −08 (Reapproved 2016)
Standard Specification for
High-Strength Zinc–5% Aluminum-Mischmetal Alloy-Coated
Steel Core Wire for Use in Overhead Electrical Conductors
This standard is issued under the fixed designation B803/B803M; 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 E1277 Test Method for Analysis of Zinc-5 % Aluminum-
Mischmetal Alloys by ICP Emission Spectrometry
1.1 This specification covers round, high strength, zinc–5 %
E29 Practice for Using Significant Digits in Test Data to
aluminum-mischmetal (Zn–5Al–MM) alloy-coated, steel core
Determine Conformance with Specifications
wire with one class of Zn–5Al–MM coating (MA3) for use in
2.3 Other Standard:
overhead electrical conductors.
GF-1 Standard Practice for Determination of Cerium and
1.2 This specification covers wire of diameter from 0.0500
Lanthanum Compositions in GalfanAlloy (5 %Al-0.04 %
to 0.1900 in. inclusive or 1.27 to 4.82 mm inclusive.
La-0.04 % Ce-Bal SHG Zn)
1.3 The values stated in either SI units or inch-pound units
3. Terminology
are to be regarded separately as standard. The values stated in
each system may not be exact equivalents; therefore, each 3.1 Abbreviations:
3.1.1 MM—mischmetal
system shall be used independently of the other. Combining
values from the two systems may result in non-conformance
3.1.2 Zn–5Al–MM—zinc–5 % aluminum mischmetal alloy
with the standard.
3.2 Definitions:
3.2.1 lot—unless otherwise specified in the contract or
2. Referenced Documents
order, a lot shall consist of all coils of wire of the same
2.1 The following documents of the issue in effect on date
diameter and unit lengths submitted for inspection at the same
of material purchase form a part of this specification to the
time.
extent referenced herein.
3.2.2 product code—Defines product coating type, coating
2.2 ASTM Standards:
class and strength grade. This specification covers only High
A90/A90M Test Method for Weight [Mass] of Coating on
StrengthClassA Zn–5Al–MMcoatedproductsandidentifiedas
Iron and Steel Articles with Zinc or Zinc-Alloy Coatings
product code MA3.
A370 Test Methods and Definitions for Mechanical Testing
of Steel Products 4. Ordering Information
A751 Test Methods, Practices, and Terminology for Chemi-
4.1 Orders for material under this specification shall include
cal Analysis of Steel Products
the following information:
B193 Test Method for Resistivity of Electrical Conductor
4.1.1 Quantity of each size,
Materials
4.1.2 Wire diameter in inches or millimeters (Section 13),
B750 Specification for GALFAN
4.1.3 Certification, if required (Section 18),
E47 Test Methods for Chemical Analysis of Zinc Die-
4.1.4 Test report, if required (Section 18), and
Casting Alloys (Withdrawn 1997)
4.1.5 Package Size (Section 19).
4.1.6 Product Code (Paragraph 3.2.2).
4.1.7 Order Example: five multiple lengths of 12 000 ft.
This specification is under the jurisdiction of ASTM Committee B01 on
each, 0.1327 in. MA3 wire, packaged onto wooden non-
Electrical Conductors and is the direct responsibility of Subcommittee B01.05 on
Conductors of Ferrous Metals. returnable reels, with certified test report.
Current edition approved Oct. 1, 2016. Published October 2016. Originally
ɛ1
approved in 1989. Last previous edition approved in 2008 as B803/B803M – 08 .
5. Materials and Manufacture
DOI: 10.1520/B0803_B0803M-08R16.
5.1 The base metal shall be steel produced by the open-
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
hearth, electric furnace, or basic oxygen process.
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website.
The last approved version of this historical standard is referenced on Available from International Lead Zinc Research Organization (ILZRO), 1822
www.astm.org. NC Highway 54 East, Suite 120, Durham, NC 27713, http://www.ilzro.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
B803/B803M−08 (2016)
TABLE 2 Tensile Requirements
5.2 The wire shall be cold drawn and coated with
Zn–5Al–MM alloy to produce the desired properties. Stress at 1 % Ultimate Tensile Elongation in 10
Specified Diameter
Extension, min Strength, min in., min %
in. ksi ksi
6. Chemical Composition
0.0500 to 0.0899, incl 210 235 3.0
6.1 The steel shall conform to the requirements prescribed
0.0900 to 0.1199, incl 205 230 3.0
in Table 1. 0.1200 to 0.1399, incl 200 225 3.5
0.1400 to 0.1900, incl 195 220 3.5
6.2 Chemical analysis of the steel shall be conducted in
accordance with Test Methods, Practices, and Terminology
A751.
TABLE 3 Tensile Requirements [Metric]
Stress at 1 % Ultimate Tensile Elongation in 250
6.3 The ingot form of zinc-5 % aluminum-mischmetal alloy
Specified Diameter
Extension, min Strength, min mm, min %
shall conform to Specification B750.
mm MPa MPa
6.3.1 For a two-step coating operation where the first
1.27 to 2.28, incl 1450 1620 3.0
coating is zinc (hot-dip galvanized or electrogalvanized), the
2.29 to 3.04, incl 1410 1590 3.0
final bath may have an aluminum content of up to 7.2 %, to
3.05 to 3.55, incl 1380 1550 3.5
3.56 to 4.82, incl 1340 1520 3.5
prevent depletion of the aluminum content of the bath.
6.3.2 Method of Analysis—The determination of chemical
composition shall be made in accordance with suitable chemi-
TABLE 4 Initial Settings for Determining Stress at 1% Extension
cal (Test Methods E47 for Tin), ICP Argon Plasma Spectro-
Specified Diameter Initial Stress Initial Setting of Extensometer,
metric (Practice E1277), or other methods. In case of dispute,
in. ksi in./in.
the results secured by Practice E1277 shall be the basis of
0.0500 to 0.0899, incl 15 0.0005 (0.05 % Extension)
acceptance.
0.0900 to 0.1199, incl 30 0.0010 (0.10 % Extension)
0.1200 to 0.1900, incl 46 0.0015 (0.15 % Extension)
6.3.3 A Method of Coating Material Analysis—Refer to
Specification B750. In case of dispute, the results secured by
Practice E1277 shall be the basis of acceptance.
TABLE 5 Initial Settings for Determining Stress at 1% Extension
[Metric]
7. Tensile Test
Specified Diameter Initial Stress Initial Setting of Extensometer,
mm MPa mm/mm
7.1 The Zn–5Al–MM-coated steel core wire shall conform
1.27 to 2.28, incl 110 0.0005 (0.05 % Extension)
to the tensile and elongation requirements prescribed in Table
2.29 to 3.04, incl 210 0.0010 (0.10 % Extension)
2 or Table 3.
3.05 to 4.82, incl 320 0.0015 (0.15 % Extension)
7.2 Tensile tests shall be conducted in accordance with Test
Methods and Definitions A370, using the initial settings for
determining stress at 1 % extension given in Table 4 or Table
9. Coating Test
5 of this specification.
9.1 TheZn–5Al–MMalloy-coatedwireshallconformtothe
7.3 Test Specimens—The test specimens shall be free of
coating requirements prescribed in Table 6 or Table 7.
bendsorkinksotherthanthecurvatureresultingfromtheusual
9.2 The coating test shall be conducted in accordance with
coiling operations.Any hand straightening necessary to permit
Test Method A90/A90M.
insertion of the specimen in the jaws of the testing machine
shall be performed by drawing between wood blocks or by
10. Adherence of Coating Test
some other equally satisfactory means.
10.1 TheZn–5Al–MMalloy-coatedwireshallbecapableof
being wrapped in a close helix at a rate not exceeding 15
8. Wrap Test
turns/min around a cylindrical mandrel having a diameter as
8.1 The material, as represented by the test specimens, shall
prescribedinTable8orTable9,withoutcrackingorflakingthe
not fracture when the Zn–5Al–MM alloy-coated wire is
coating to such an extent that any Zn–5Al–MM alloy can be
wrapped at a rate not exceeding 15 turns/min in a close helix
removed by rubbing with the bare fingers.
of at least eight turns around a cylindrical mandrel with a
diameter equal to three times the specified diameter of the wire
TABLE 6 Zn–5Al–MM Alloy Coating
under test, 65%.
Specified Diameter of Area Density of Zn–5Al–MM Alloy Coating min of
Coated Wire Uncoated Wire Surface, oz/ft
in. Class A
0.0500 to 0.0599, incl 0.60
TABLE 1 Chemical Requirements
0.0600 to 0.0749, incl 0.65
Element Composition, %
0.0750 to 0.0899, incl 0.70
Carbon 0.50 to 0.88 0.0900 to 0.1039, incl 0.75
Manganese 0.50 to 1.30 0.1040 to 0.1199, incl 0.80
Phosphorus, max 0.035 0.1200 to 0.1399, incl 0.85
Sulfur, max 0.045 0.1400 to 0.1799, incl 0.90
Silicon 0.10 to 0.35 0.1800 to 0.1900, incl 1.00
B803/B803M−08 (2016)
TABLE 7 Zn–5Al–MM Alloy Coating [Metric]
13. Dimensions and Permissible Variations
Specified Diameter of Area Density of Zn–5Al–MM Coating, min, of
13.1 The specified diameter of the Zn–5Al–MM alloy-
Coated Wire Uncoated Wire Surface, g/m
coated wire shall be expressed in decimal fractions of an
...
This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
´1
Designation: B803/B803M − 08 B803/B803M − 08 (Reapproved 2016)
Standard Specification for
High-Strength Zinc–5 % Aluminum-Mischmetal Alloy-Coated
Steel Core Wire for Use in Overhead Electrical Conductors
This standard is issued under the fixed designation B803/B803M; 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.
ε NOTE—Designation was corrected editorially in October 2013.
1. Scope*Scope
1.1 This specification covers round, high strength, zinc–5 % aluminum-mischmetal (Zn–5Al–MM) alloy-coated, steel core wire
with one class of Zn–5Al–MM coating (MA3) for use in overhead electrical conductors.
1.2 This specification covers wire of diameter from 0.0500 to 0.1900 in. inclusive or 1.27 to 4.82 mm inclusive.
1.3 The values stated in either SI units or inch-pound units are to be regarded separately as standard. The values stated in each
system may not be exact equivalents; therefore, each system shall be used independently of the other. Combining values from the
two systems may result in non-conformance with the standard.
2. Referenced Documents
2.1 The following documents of the issue in effect on date of material purchase form a part of this specification to the extent
referenced herein.
2.2 ASTM Standards:
A90/A90M Test Method for Weight [Mass] of Coating on Iron and Steel Articles with Zinc or Zinc-Alloy Coatings
A370 Test Methods and Definitions for Mechanical Testing of Steel Products
A751 Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products
B193 Test Method for Resistivity of Electrical Conductor Materials
B750 Specification for GALFAN
E47 Test Methods for Chemical Analysis of Zinc Die-Casting Alloys (Withdrawn 1997)
E1277 Test Method for Analysis of Zinc-5 % Aluminum-Mischmetal Alloys by ICP Emission Spectrometry
E29 Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications
2.3 Other Standard:
GF-1 Standard Practice for Determination of Cerium and Lanthanum Compositions in Galfan Alloy (5 % Al-0.04 % La-0.04 %
Ce-Bal SHG Zn)
3. Terminology
3.1 Abbreviations:
3.1.1 MM—mischmetal
3.1.2 Zn–5Al–MM—zinc–5 % aluminum mischmetal alloy
3.2 Definitions:
3.2.1 lot—unless otherwise specified in the contract or order, a lot shall consist of all coils of wire of the same diameter and
unit lengths submitted for inspection at the same time.
This specification is under the jurisdiction of ASTM Committee B01 on Electrical Conductors and is the direct responsibility of Subcommittee B01.05 on Conductors
of Ferrous Metals.
Current edition approved Nov. 1, 2008Oct. 1, 2016. Published December 2008October 2016. Originally approved in 1989. Last previous edition approved in 20022008
ɛ1
as B803 – 02.B803/B803M – 08 . DOI: 10.1520/B0803_B0803M-08E01.10.1520/B0803_B0803M-08R16.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM Standards
volume information, refer to the standard’sstandard’s Document Summary page on the ASTM website.
The last approved version of this historical standard is referenced on www.astm.org.
Available from International Lead Zinc Research Organization (ILZRO), 1822 NC Highway 54 East, Suite 120, Durham, NC 27713, http://www.ilzro.org.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
B803/B803M − 08 (2016)
3.2.2 Product Code—product code—Defines product coating type, coating class and strength grade. This specification covers
only High Strength Class A Zn–5Al–MM coated products and identified as product code MA3.
4. Ordering Information
4.1 Orders for material under this specification shall include the following information:
4.1.1 Quantity of each size,
4.1.2 Wire diameter in inches or millimeters (Section 13),
4.1.3 Certification, if required (Section 18),
4.1.4 Test report, if required (Section 18), and
4.1.5 Package Size (Section 19).
4.1.6 Product Code (Paragraph 3.2.2).
4.1.7 Order Example: five multiple lengths of 12 000 ft. each, 0.1327 in. MA3 wire, packaged onto wooden non-returnable
reels, with certified test report.
5. Materials and Manufacture
5.1 The base metal shall be steel produced by the open-hearth, electric furnace, or basic oxygen process.
5.2 The wire shall be cold drawn and coated with Zn–5Al–MM alloy to produce the desired properties.
6. Chemical Composition
6.1 The steel shall conform to the requirements prescribed in Table 1.
6.2 Chemical analysis of the steel shall be conducted in accordance with Test Methods, Practices, and Terminology A751.
6.3 The ingot form of zinc-5 % aluminum-mischmetal alloy shall conform to Specification B750.
6.3.1 For a two-step coating operation where the first coating is zinc (hot-dip galvanized or electrogalvanized), the final bath
may have an aluminum content of up to 7.2 %, to prevent depletion of the aluminum content of the bath.
6.3.2 Method of Analysis—The determination of chemical composition shall be made in accordance with suitable chemical (Test
Methods E47 for Tin), ICP Argon Plasma Spectrometric (Practice E1277), or other methods. In case of dispute, the results secured
by Practice E1277 shall be the basis of acceptance.
6.3.3 A Method of Coating Material Analysis—Refer to Specification B750. In case of dispute, the results secured by Practice
E1277 shall be the basis of acceptance.
7. Tensile Test
7.1 The Zn–5Al–MM-coated steel core wire shall conform to the tensile and elongation requirements prescribed in Table 2 or
Table 3.
7.2 Tensile tests shall be conducted in accordance with Test Methods and Definitions A370, using the initial settings for
determining stress at 1 % extension given in Table 4 or Table 5 of this specification.
7.3 Test Specimens—The test specimens shall be free of bends or kinks other than the curvature resulting from the usual coiling
operations. Any hand straightening necessary to permit insertion of the specimen in the jaws of the testing machine shall be
performed by drawing between wood blocks or by some other equally satisfactory means.
8. Wrap Test
8.1 The material, as represented by the test specimens, shall not fracture when the Zn–5Al–MM alloy-coated wire is wrapped
at a rate not exceeding 15 turns/min in a close helix of at least eight turns around a cylindrical mandrel with a diameter equal to
three times the specified diameter of the wire under test, 65 %.
9. Coating Test
9.1 The Zn–5Al–MM alloy-coated wire shall conform to the coating requirements prescribed in Table 6 or Table 7.
9.2 The coating test shall be conducted in accordance with Test Method A90/A90M.
TABLE 1 Chemical Requirements
ElementElement Composition, %
Carbon 0.50 to 0.88
Manganese 0.50 to 1.30
Phosphorus, max 0.035
Sulfur, max 0.045
Silicon 0.10 to 0.35
B803/B803M − 08 (2016)
TABLE 2 Tensile Requirements
Stress at 1 % Ultimate Tensile Elongation in 10
Specified Diameter
Extension, min Strength, min in., min %
in. ksi ksi
0.0500 to 0.0899, incl 210 235 3.0
0.0900 to 0.1199, incl 205 230 3.0
0.1200 to 0.1399, incl 200 225 3.5
0.1400 to 0.1900, incl 195 220 3.5
TABLE 3 Tensile Requirements [Metric]
Stress at 1 % Ultimate Tensile Elongation in 250
Specified Diameter
Extension, min Strength, min mm, min %
mm MPa MPa
1.27 to 2.28, incl 1450 1620 3.0
2.29 to 3.04, incl 1410 1590 3.0
3.05 to 3.55, incl 1380 1550 3.5
3.56 to 4.82, incl 1340 1520 3.5
TABLE 3 Tensile Requirements [Metric]
Stress at 1 % Ultimate Tensile Elongation in 250
Specified Diameter
Extension, min Strength, min mm, min %
mm MPa MPa
1.27 to 2.28, incl 1450 1620 3.0
2.29 to 3.04, incl 1410 1590 3.0
3.05 to 3.55, incl 1380 1550 3.5
3.56 to 4.82, incl 1340 1520 3.5
TABLE 4 Initial Settings for Determining Stress at 1 % Extension
Specified Diameter Initial Stress Initial Setting of Extensometer,
in. ksi in./in.
0.0500 to 0.0899, incl 15 0.0005 (0.05 % Extension)
0.0900 to 0.1199, incl 30 0.0010 (0.10 % Extension)
0.1200 to 0.1900, incl 46 0.0015 (0.15 % Extension)
TABLE 5 Initial Settings for Determining Stress at 1 % Extension
[Metric]
Specified Diameter Initial Stress Initial Setting of Extensometer,
mm MPa mm/mm
1.27 to 2.28, incl 110 0.0005 (0.05 % Extension)
2.29 to 3.04, incl 210 0.0010 (0.10 % Extension)
3.05 to 4.82, incl 320 0.0015 (0.15 % Extension)
TABLE 5 Initial Settings for Determining Stress at 1 % Extension
[Metric]
Specified Diameter Initial Stress Initial Setting of Extensometer,
mm MPa mm/mm
1.27 to 2.28, incl 110 0.0005 (0.05 % Extension)
2.29 to 3.04, incl 210 0.0010 (0.10 % Extension)
3.05 to 4.82, incl 320 0.0015 (0.15 % Extension)
10. Adherence of Coating Test
10.1 The Zn–5Al–MM alloy-coated wire shall be capable of being wrapped in a close helix at a rate not exceeding 15 turns/min
around a cylindrical mandrel having a diameter as prescribed in Table 8 or Table 9, without cracking or flaking the coating to such
an extent that any Zn–5Al–MM alloy can be removed by rubbing with the bare fingers.
NOTE 1—Loosening or detachment during the adhesion test of superficial, small particles of Zn–5Al–MM alloy formed by mechanical polishing of
the surface of the coated wire shall not be considered cause for rejection.
11. Joints
11.1 No joints shall be made in the finished wire.
11.2 Joints may be made at any stage of processing prior to final cold drawing by the electric butt-weld or flash or flash-welding
process.
B803/B803M − 08 (2016)
TABLE 6 Zn–5Al–MM Alloy Coating
Specified Diameter of Area Density of Zn–5Al–MM Alloy Coating min of
Coated Wire Uncoated Wir
...
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