ASTM B566-04a(2016)

Standard Specification for Copper-Clad Aluminum Wire

ABSTRACT
This specification covers bare round copper-clad aluminum wire for electrical applications. Four classes of copper-clad aluminum wire are covered such as Class 10A, Class 15A, Class 10H, Class 15H. The wire shall consist of a core of aluminum with a continuous outer cladding of copper throughly bonded to the core throughout and shall be of such quality as to meet the requirements of this specification. The copper-clad aluminum wire shall conform to the tensile strength and elongation requirements. The electrical resistivity shall be measured. The copper-clad aluminum wire, when tested shall be free from seams or splits. They shall be free from cladding delamination. The finished wire shall contain no joints or splices. The density of the wire shall be taken for calculating mass/unit length, cross section and so forth.
SCOPE
1.1 This specification covers bare round copper-clad aluminum wire for electrical applications.  
1.2 Four classes of copper-clad aluminum wire are covered as follows:
Class 10A—Nominal 10 volume % copper, annealed.
Class 15A—Nominal 15 volume % copper, annealed.
Class 10H—Nominal 10 volume % copper, hard-drawn.
Class 15H—Nominal 15 volume % copper, hard-drawn.  
1.3 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.  
1.3.1 Exception—The values stated in SI units for resistivity and density are to be regarded as standard.

General Information

• Status: Historical
• Publication Date: 31-Mar-2016
• ICS: 29.060.10 - Wires
• Technical Committee: B01 - Electrical Conductors
• Drafting Committee: B01.06 - Bi-Metallic Conductors

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NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.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:B566 −04a (Reapproved 2016)
Standard Specification for
Copper-Clad Aluminum Wire
This standard is issued under the fixed designation B566; 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.
This standard has been approved for use by agencies of the U.S. Department of Defense.
1. Scope 3.1.1 lot—a lot is any amount of wire of one class and size
presented for acceptance at one time; such amount, however,
1.1 This specification covers bare round copper-clad alumi-
not to exceed 100 production units.
num wire for electrical applications.
3.1.2 sample—a quantity of production units (coils, reels,
1.2 Four classes of copper-clad aluminum wire are covered
andsoforth)selectedatrandomfromthelotforthepurposeof
as follows:
determining conformance of the lot to the requirements of this
Class 10A—Nominal 10 volume % copper, annealed.
specification.
Class 15A—Nominal 15 volume % copper, annealed.
3.1.3 specimen—a length of wire removed for test purposes
Class 10H—Nominal 10 volume % copper, hard-drawn.
from any individual production unit of the sample.
Class 15H—Nominal 15 volume % copper, hard-drawn.
1.3 The values stated in inch-pound units are to be regarded
4. Ordering Information
as standard. The values given in parentheses are mathematical
4.1 Ordersformaterialunderthisspecificationshallinclude
conversions to SI units that are provided for information only
the following information:
and are not considered standard.
4.1.1 Quantity of each size and class;
1.3.1 Exception—ThevaluesstatedinSIunitsforresistivity
4.1.2 Wire size, diameter in inches (see Section 7 and Table
and density are to be regarded as standard.
1);
2. Referenced Documents 4.1.3 Class of wire (see 1.2 and Table 1);
4.1.4 Packaging and shipping (Section 14 and packaging
2.1 The following documents of the issue in effect on date
inspection if required, 13.1); and
of material purchase form a part of this specification to the
4.1.5 Place of inspection (see 13.1).
extent referenced herein:
2.2 ASTM Standards:
5. Materials and Manufacture
B193Test Method for Resistivity of Electrical Conductor
5.1 The wire shall consist of a core of aluminum with a
Materials
continuous outer cladding of copper thoroughly bonded to the
B258 Specification for Nominal Diameters and Cross-
core throughout and shall be of such quality as to meet the
SectionalAreasofAWGSizesofSolidRoundWiresUsed
requirements of this specification.
as Electrical Conductors
2.3 National Institute of Standards and Technology:
6. General Requirements
NBS Handbook 100— Copper Wire Tables
6.1 Tensile Strength and Elongation—The copper-clad alu-
3. Terminology minum wire shall conform to the tensile strength and elonga-
tion requirements of Table 1. For intermediate diameters not
3.1 Definitions of Terms Specific to This Standard:
listed in Table 1, the elongation requirements of the next
smaller size shall apply; in the case of tensile strength the
This specification is under the jurisdiction of ASTM Committee B01 on
requirements of the next larger size shall apply.
Electrical Conductors and is the direct responsibility of Subcommittee B01.06 on
Bi-Metallic Conductors.
6.2 Resistivity—The electrical resistivity at a temperature of
Current edition approved April 1, 2016. Published April 2016. Originally
20°C shall not exceed the values prescribed in Table 2. See
approved in 1972. Last previous edition approved in 2011 as B566–04a (2011).
DOI: 10.1520/B0566-04AR16. Note 1 for calculating electrical resistance.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
NOTE 1—Relationships which may be useful in connection with the
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM
values of electrical resistivity prescribed in this specification are shown in
Standards volume information, refer to the standard’s Document Summary page on
Table 3. Resistivity units are based on the InternationalAnnealed Copper
the ASTM website.
Available from National Institute of Standards and Technology (NIST), 100 Standard (IACS) adopted by IEC in 1913, which is ⁄58Ω·mm /m and the
Bureau Dr., Stop 1070, Gaithersburg, MD 20899-1070, http://www.nist.gov. value of 0.15328 Ω·g/m at 20°C are, respectively, the international
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
B566−04a (2016)
TABLE 1 Tensile and Elongation Requirements for Copper-Clad
6.3 Cohesion—The copper-clad aluminum wire, when
Aluminum Wire
tested in accordance with 10.4, shall be free from seams or
Elongation, min,
splits.Examinationofthewireshallbemadeatamagnification
Nominal
Tensile Strength %in10in.
Diameter
not to exceed 10×.
(or 250 mm)
Minimum All Maximum All 6.4 Adhesion—The copper-clad aluminum wire, when
All H All A
H Classes A Classes
in. (mm)
tested in accordance with 10.5, shall be free from cladding
Classes Classes
ksi (MPa) ksi (MPa)
delamination. Examination of the wire shall be made at a
0.3249 8.252 16 110 20 138 1.5 15
magnification not to exceed 10×.
0.2893 7.348 16 110 20 138 1.5 15
0.2576 6.543 18 124 20 138 1.5 15
6.5 Joints—The finished wire shall contain no joints or
0.2294 5.827 20 138 20 138 1.5 15
splices.
0.2043 5.189 22 152 20 138 1.5 15
6.6 Copper Thickness—The minimum copper thickness,
0.1819 4.620 23 159 20 138 1.5 15
when tested in accordance with 10.6, shall be not less than the
0.1620 4.115 24 166 20 138 1.5 15
0.1443 3.665 25 172 20 138 1.5 15 following:
6.6.1 Class 10A and 10H wire shall have a minimum
0.1285 3.264 26 179 20 138 1.0 15
thickness of not less than 3.5% of the wire radius.
0.1144 2.906 27 186 20 138 1.0 15
0.1019 2.588 28 193 20 138 1.0 15 6.6.2 Class 15A and 15H wire shall have a minimum
0.0907 2.30 29 200 20 138 1.0 15
thickness of not less than 5.0% of the wire radius.
0.0808 2.05 30 207 20 138 1.0 15
6.7 Copper Volume (Area)—The copper volume (area) per
0.0720 1.83 30 207 20 138 1.0 15
class, when tested in accordance with 10.6, shall meet the
0.0641 1.63 30 207 20 138 1.0 15
following tolerances:
0.0571 1.45 30 207 20 138 1.0 15
6.7.1 Class 10A and 10H wire shall contain not less than
0.0508 1.29 30 207 20 138 1.0 15
8% and not more than 12% copper by volume (area).
0.0453 1.15 30 207 20 138 1.0 15
6.7.2 Class 15A and 15H wire shall contain not less than
0.0403 1.02 30 207 20 138 1.0 15
0.0359 0.912 30 207 20 138 1.0 15
13% and not more than 17% copper by volume (area).
0.0320 0.813 30 207 20 138 1.0 15
7. Dimensions, Mass and Permissible Variations
0.0285 0.724 30 207 20 138 1.0 15
0.0253 0.643 30 207 20 138 1.0 15
7.1 The wire size shall be expressed as the diameter of the
0.0226 0.574 30 207 25 172 1.0 10
wire in decimal fractions of an inch to the nearest 0.0001 in.
0.0201 0.511 30 207 25 172 1.0 10
(0.003 mm) (Note 2). For diameters under 0.0100 in. (0.254
0.0179 0.455 30 207 25 172 1.0 10
mm), the wire shall not vary from the specified diameter by
0.0159 0.404 30 207 25 172 1.0 10
more than 60.0001 in. (60.003 mm) and for diameters of
0.0142 0.361 30 207 25 172 1.0 10
0.0100 in. (0.254 mm) and over, the wire shall not vary from
0.0126 0.320 30 207 25 172 1.0 5
the specified diameter by more than 61%, expressed to the
0.0113 0.287 30 207 25 172 1.0 5
nearest 0.0001 in. (0.003 mm).
0.0100 0.254 30 207 25 172 1.0 5
0.0089 0.226 30 207 25 172 1.0 5
NOTE 2—The values of the wire diameters in Table 1 are given to the
nearest 0.0001 in. (0.003 mm) and correspond to the standard sizes given
0.0080 0.203 30 207 25 172 1.0 5
0.0071 0.180 30 207 25 172 1.0 5
inSpecificationB258.Theuseofgagenumberstospecifywiresizesisnot
0.0063 0.160 30 207 25 172 1.0 5
recognized in this specification because of the possibility of confusion.A
0.0056 0.142 30 207 25 172 1.0 5
discussionofwiregagesandrelatedsubjectsiscontainedin“CopperWire
0.0050 0.127 30 207 25 172 1.0 5
Tables,” NBS Handbook 100.
8. Workmanship, Finish, and Appearance
TABLE 2 Resistivity
8.1 The wire, when tested in accordance with 8.2, shall be
Resistivity, max, at 20°C
free from pits, slivers, exposed aluminum, or other imperfec-
Class of Wire Ω·mm /m
tions not consistent with good commercial practice.
10A and 10H 0.02743
15A and 15H 0.02676 8.2 For wire diameters of 0.0720 in. (1.829 mm) and larger,
surface finish inspection shall be made with the unaided eye
(normal spectacles excepted), and for wire diameters smaller
equivalent of volume and weight resistivity of annealed copper equal to
than 0.0720 in., surface finish inspection shall be made at a
100%conductivity.Thelatertermmeansthatacopperwire1minlength
magnification not to exceed 10×.
andweighing1gwouldhavearesistanceof0.15328Ω.Thisisequivalent
toaresistivityvalueof875.20Ω·lb/mile ,whichsignifiestheresistanceof
9. Sampling
a copper wire 1 mile in length weighing 1 lb. It is also equivalent, for
example,to1.7241µΩ/cmoflengthofacopperbar1cm incrosssection.
9.1 The number of production units in a sample shall be as
Acomplete discussion of this subject is contained in NBS Handbook 100.
follows:
The use of five significant figures in expressing resistivity does not imply
9.1.1 For tensile strength, elongation, resistivity, adhesion,
the need for greater accuracy of measurement than that specified in Test
cohesion, and dimensional measurements, the sample shall
Method B193. The use of five significant figures is required for complete
reversible conversion from one set of resistivity units to another. consist of a quantity of production units shown in Table 4
B566−04a (2016)
TABLE 3 Equivalent Resistivity Values
Volume Resistivity Equivalents at 20°C
Class Conductivity at Volume Mass/Unit Length
2 2
20°C % IACS Ω·mm /m Ω·cmil/ft µΩ·in. µΩ·cm Ω·lb/mile2 Ω·g/m
10A and 10H 62.854 0.027430 16.500 1.0799 2.7430 526.26 0.092164
15A and 15H 64.416 0.026765 16.100 1.0537 2.6765 560.88 0.098227
TABLE 4 Sampling for Mechanical and Electrical Tests
shall be the distance between the jaws at the time of rupture.
First Sample Second Sample The fracture shall be between gage marks in the case of
specimens so marked or between the jaws of the testing
Allowable
Allowable
Number of
machine and not closer than 1 in. (25 mm) to either gage mark
Number of Number
Number
Number of Defects
Defects in of Uni
...

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.
Designation: B566 − 04a (Reapproved 2011) B566 − 04a (Reapproved 2016)
Standard Specification for
Copper-Clad Aluminum Wire
This standard is issued under the fixed designation B566; 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.
This standard has been approved for use by agencies of the U.S. Department of Defense.
1. Scope
1.1 This specification covers bare round copper-clad aluminum wire for electrical applications.
1.2 Four classes of copper-clad aluminum wire are covered as follows:
Class 10A—Nominal 10 volume % copper, annealed.
Class 15A—Nominal 15 volume % copper, annealed.
Class 10H—Nominal 10 volume % copper, hard-drawn.
Class 15H—Nominal 15 volume % copper, hard-drawn.
1.3 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.
1.3.1 Exception—The values stated in SI units for resistivity and density are to be regarded as 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:
B193 Test Method for Resistivity of Electrical Conductor Materials
B258 Specification for Nominal Diameters and Cross-Sectional Areas of AWG Sizes of Solid Round Wires Used as Electrical
Conductors
2.3 National Institute of Standards and Technology:
NBS Handbook 100 — Copper Wire Tables
3. Terminology
3.1 Definitions of Terms Specific to This Standard:
3.1.1 lot—a lot is any amount of wire of one class and size presented for acceptance at one time; such amount, however, not
to exceed 100 production units.
3.1.2 sample—a quantity of production units (coils, reels, and so forth) selected at random from the lot for the purpose of
determining conformance of the lot to the requirements of this specification.
3.1.3 specimen—a length of wire removed for test purposes from any individual production unit of the sample.
4. Ordering Information
4.1 Orders for material under this specification shall include the following information:
4.1.1 Quantity of each size and class;
4.1.2 Wire size, diameter in inches (see Section 7 and Table 1);
4.1.3 Class of wire (see 1.2 and Table 1);
This specification is under the jurisdiction of ASTM Committee B01 on Electrical Conductors and is the direct responsibility of Subcommittee B01.06 on Bi-Metallic
Conductors.
Current edition approved April 1, 2011April 1, 2016. Published September 2011April 2016. Originally approved in 1972. Last previous edition approved in 20042011 as
B566 – 04a.B566 – 04a (2011). DOI: 10.1520/B0566-04AR11.10.1520/B0566-04AR16.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM Standards
volume information, refer to the standard’s Document Summary page on the ASTM website.
Available from National Institute of Standards and Technology (NIST), 100 Bureau Dr., Stop 1070, Gaithersburg, MD 20899-1070, http://www.nist.gov.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
B566 − 04a (2016)
TABLE 1 Tensile and Elongation Requirements for Copper-Clad
Aluminum Wire
Elongation, min,
Nominal
Tensile Strength % in 10 in.
Diameter
(or 250 mm)
Minimum All Maximum All
All H All A
H Classes A Classes
in. (mm)
Classes Classes
ksi (MPa) ksi (MPa)
0.3249 8.252 16 110 20 138 1.5 15
0.2893 7.348 16 110 20 138 1.5 15
0.2576 6.543 18 124 20 138 1.5 15
0.2294 5.827 20 138 20 138 1.5 15
0.2043 5.189 22 152 20 138 1.5 15
0.1819 4.620 23 159 20 138 1.5 15
0.1620 4.115 24 166 20 138 1.5 15
0.1443 3.665 25 172 20 138 1.5 15
0.1285 3.264 26 179 20 138 1.0 15
0.1144 2.906 27 186 20 138 1.0 15
0.1019 2.588 28 193 20 138 1.0 15
0.0907 2.30 29 200 20 138 1.0 15
0.0808 2.05 30 207 20 138 1.0 15
0.0720 1.83 30 207 20 138 1.0 15
0.0641 1.63 30 207 20 138 1.0 15
0.0571 1.45 30 207 20 138 1.0 15
0.0508 1.29 30 207 20 138 1.0 15
0.0453 1.15 30 207 20 138 1.0 15
0.0403 1.02 30 207 20 138 1.0 15
0.0359 0.912 30 207 20 138 1.0 15
0.0320 0.813 30 207 20 138 1.0 15
0.0285 0.724 30 207 20 138 1.0 15
0.0253 0.643 30 207 20 138 1.0 15
0.0226 0.574 30 207 25 172 1.0 10
0.0201 0.511 30 207 25 172 1.0 10
0.0179 0.455 30 207 25 172 1.0 10
0.0159 0.404 30 207 25 172 1.0 10
0.0142 0.361 30 207 25 172 1.0 10
0.0126 0.320 30 207 25 172 1.0 5
0.0113 0.287 30 207 25 172 1.0 5
0.0100 0.254 30 207 25 172 1.0 5
0.0089 0.226 30 207 25 172 1.0 5
0.0080 0.203 30 207 25 172 1.0 5
0.0071 0.180 30 207 25 172 1.0 5
0.0063 0.160 30 207 25 172 1.0 5
0.0056 0.142 30 207 25 172 1.0 5
0.0050 0.127 30 207 25 172 1.0 5
4.1.4 Packaging and shipping (Section 14 and packaging inspection if required, 13.1); and
4.1.5 Place of inspection (see 13.1).
5. Materials and Manufacture
5.1 The wire shall consist of a core of aluminum with a continuous outer cladding of copper thoroughly bonded to the core
throughout and shall be of such quality as to meet the requirements of this specification.
6. General Requirements
6.1 Tensile Strength and Elongation—The copper-clad aluminum wire shall conform to the tensile strength and elongation
requirements of Table 1. For intermediate diameters not listed in Table 1, the elongation requirements of the next smaller size shall
apply; in the case of tensile strength the requirements of the next larger size shall apply.
6.2 Resistivity—The electrical resistivity at a temperature of 20°C shall not exceed the values prescribed in Table 2. See Note
1 for calculating electrical resistance.
NOTE 1—Relationships which may be useful in connection with the values of electrical resistivity prescribed in this specification are shown in Table
3. Resistivity units are based on the International Annealed Copper Standard (IACS) adopted by IEC in 1913, which is ⁄58 Ω·mm /m and the value of
B566 − 04a (2016)
TABLE 2 Resistivity
Resistivity, max, at 20°C
Class of Wire Ω·mm /m
10A and 10H 0.02743
15A and 15H 0.02676
0.15328 Ω·g/m at 20°C are, respectively, the international equivalent of volume and weight resistivity of annealed copper equal to 100 % conductivity.
The later term means that a copper wire 1 m in length and weighing 1 g would have a resistance of 0.15328 Ω. This is equivalent to a resistivity value
of 875.20 Ω·lb/mile , which signifies the resistance of a copper wire 1 mile in length weighing 1 lb. It is also equivalent, for example, to 1.7241 μΩ/cm
of length of a copper bar 1 cm in cross section. A complete discussion of this subject is contained in NBS Handbook 100. The use of five significant
figures in expressing resistivity does not imply the need for greater accuracy of measurement than that specified in Test Method B193. The use of five
significant figures is required for complete reversible conversion from one set of resistivity units to another.
6.3 Cohesion—The copper-clad aluminum wire, when tested in accordance with 10.4, shall be free from seams or splits.
Examination of the wire shall be made at a magnification not to exceed 10×.
6.4 Adhesion—The copper-clad aluminum wire, when tested in accordance with 10.5, shall be free from cladding delamination.
Examination of the wire shall be made at a magnification not to exceed 10×.
6.5 Joints—The finished wire shall contain no joints or splices.
6.6 Copper Thickness—The minimum copper thickness, when tested in accordance with 10.6, shall be not less than the
following:
6.6.1 Class 10A and 10H wire shall have a minimum thickness of not less than 3.5 % of the wire radius.
6.6.2 Class 15A and 15H wire shall have a minimum thickness of not less than 5.0 % of the wire radius.
6.7 Copper Volume (Area)—The copper volume (area) per class, when tested in accordance with 10.6, shall meet the following
tolerances:
6.7.1 Class 10A and 10H wire shall contain not less than 8 % and not more than 12 % copper by volume (area).
6.7.2 Class 15A and 15H wire shall contain not less than 13 % and not more than 17 % copper by volume (area).
7. Dimensions, Mass and Permissible Variations
7.1 The wire size shall be expressed as the diameter of the wire in decimal fractions of an inch to the nearest 0.0001 in. (0.003
mm) (Note 2). For diameters under 0.0100 in. (0.254 mm), the wire shall not vary from the specified diameter by more than
60.0001 in. (60.003 mm) and for diameters of 0.0100 in. (0.254 mm) and over, the wire shall not vary from the specified diameter
by more than 61 %, expressed to the nearest 0.0001 in. (0.003 mm).
NOTE 2—The values of the wire diameters in Table 1 are given to the nearest 0.0001 in. (0.003 mm) and correspond to the standard sizes given in
Specification B258. The use of gage numbers to specify wire sizes is not recognized in this specification because of the possibility of confusion. A
discussion of wire gages and related subjects is contained in “Copper Wire Tables,” NBS Handbook 100.
8. Workmanship, Finish, and Appearance
8.1 The wire, when tested in accordance with 8.2, shall be free from pits, slivers, exposed aluminum, or other imperfections not
consistent with good commercial practice.
8.2 For wire diameters of 0.0720 in. (1.829 mm) and larger, surface finish inspection shall be made with the unaided eye (normal
spectacles excepted), and for wire diameters smaller than 0.0720 in., surface finish inspection shall be made at a magnification not
to exceed 10×.
9. Sampling
9.1 The number of production units in a sample shall be as follows:
9.1.1 For tensile strength, elongation, resistivity, adhesion, cohesion, and dimensional measurements, the sample shall consist
of a quantity of production units shown in Table 4 under heading “First Sample.” From each unit, one test specimen of sufficient
length shall be removed for the performance of the required tests.
9.1.2 For surface finish and packaging inspection (when specified by the purchaser at the time of placing the order), the sample
shall consist of a quantity of production units as shown in Table 5.
10. Test Methods
10.1 Tensile Strength and Elongation—The tensile strength, expressed in pounds-force per square inch (or megapascals), shall
be obtained by dividing the maximum load attained by the specimen during the tension test, by the origina
...