EN 4434:2005

Aerospace series - Copper or copper alloy lightweight conductors for electrical cables - Product standard (Normal and tight tolerances)

This standard specifies the dimensions, linear resistance, mechanical characteristics, construction and mass of lightweight conductors, normal and tight tolerances, in copper or copper alloy for electrical cables for aerospace applications.
It applies to stranded conductors, with a nominal cross-sectional area of 0,15 mm2 to 14 mm2 inclusive.
The conductors for thermocouple extension and fire-resistant cables are not covered by this standard.

Luft- und Raumfahrt - Leichter Leiter aus Kupfer oder Kupferlegierung für elektrische Leitungen - Produktnorm (Normale und enge Toleranzen)

Diese Norm legt die Maße, den ohmschen Widerstand, die mechanischen Eigenschaften, den Aufbau und die Masse von leichten Leitern aus Kupfer oder Kupferlegierung für elektrische Leitungen für Anwendungen in der Luft- und Raumfahrt fest.
Sie gilt für verseilte Leiter mit Nennquerschnittsflächen von 0,15 mm2 bis 14 mm2.
Leiter für Thermoelemente und feuerbeständige Leitungen beinhaltet diese Norm nicht.

Série aérospatiale - Conducteurs à tolérances réduites en cuivre ou alliage de cuivre pour câbles électriques - Norme de produit (Tolérances normales et réduites)

Aeronavtika – Lahki vodniki iz bakra ali bakrenih zlitin za električne kable – Standard za proizvod (običajne in ozke tolerance)

General Information

• Status: Published
• Publication Date: 15-Nov-2005
• Withdrawal Date: 30-May-2006
• ICS: 49.060 - Aerospace electric equipment and systems
• Technical Committee: ASD-STAN - Aerospace
• Drafting Committee: ASD-STAN/D 2 - Electrical
• Current Stage: 6060 - Definitive text made available (DAV) - Publishing
• Start Date: 16-Nov-2005
• Completion Date: 16-Nov-2005
• Ref Project: SIST EN 4434:2006 - Aerospace series - Copper or copper alloy lightweight conductors for electrical cables - Product standard (Normal and tight tolerances)

Relations

• Revised: prEN 4434 - Aerospace series - Copper or copper alloy lightweight conductors for electrical cables - Product standard (Normal and tight tolerances)
• Effective Date: 23-Jul-2025

Overview

EN 4434:2005 is a European product standard developed by CEN that defines the specifications for copper or copper alloy lightweight conductors used in electrical aerospace cables. This standard covers the dimensional, electrical, mechanical, and construction characteristics of stranded conductors with nominal cross-sectional areas ranging from 0.15 mm² to 14 mm². It sets requirements for both normal and tight tolerances to ensure high quality and consistent performance in aerospace electrical systems. Notably, this standard excludes conductors used specifically for thermocouple extension and fire-resistant cables.

Key Topics

• Scope and Application
  EN 4434:2005 applies specifically to lightweight stranded conductors made of high conductivity electrolytic copper or copper alloys. It governs conductors designed for aerospace use, ensuring suitability for critical electrical cabling in aircraft and aerospace equipment.

• Materials and Construction
  Conductors must be made from annealed copper or copper alloys with specified mechanical properties. Small cross-sections (0.15 and 0.25 mm²) require copper alloy material. Strands can be uncoated or plated with tin, silver, or nickel to enhance conductivity and resistance to oxidation and corrosion. The plating thickness is carefully controlled to meet testing standards.

• Mechanical Characteristics
  Mechanical properties such as tensile strength and elongation are defined, ensuring conductor durability and flexibility under operational stress. For copper, elongation must exceed 10% and tensile strength be at least 220 MPa. Copper alloys require higher strength and defined resistivity.

• Dimensional Tolerances
  The standard specifies both normal and tight tolerances for conductor diameter, linear resistance at 20°C, breaking load, and mass per unit length. This ensures reliable and consistent electrical performance and compatibility with aerospace connectors and tooling.

• Conductor Construction Details
  Defines strand lay length ratios, prohibits compaction or damage to strands or plating, and disallows joints in completed conductors except limited soldered or brazed butt joints in individual strands with minimum spacing.

• Testing Requirements
  Test methods referenced include standards for ohmic resistance measurement, plating continuity, and plating adherence, guaranteeing compliance with performance and durability criteria.

• Marking and Packaging
  Provides guidelines for conductor identification, including standard number, plating code, nominal area, and tolerance level. Packaging must protect the conductor while allowing uniform delivery on reels or spools with traceability markings such as length, date, and inspection.

Applications

EN 4434:2005 conductors are critical components in aerospace electrical wiring systems where lightweight, high conductivity, and reliability are paramount. Typical applications include:

• Aircraft internal electrical wiring for power and signal transmission
• Aerospace control and instrumentation cables requiring precise dimensional and mechanical properties
• Lightweight wiring harnesses in satellites and space vehicles
• Electrical cabling in avionics systems demanding strict tolerance and material specifications

By adhering to EN 4434:2005, manufacturers ensure conductors meet stringent aerospace industry requirements, guaranteeing enhanced safety, performance, and compatibility with other aerospace components.

Related Standards

• EN 2083 - Aerospace series product standard for copper or copper alloy conductors in electrical cables, complementary to EN 4434 with focus on general conductor specifications.
• EN 3475 Series - Test methods for aerospace electrical cables covering ohmic resistance, plating continuity, and plating adherence, crucial for verifying EN 4434 conductor compliance.
• IEC 60028 - International standard for resistance of copper conductors, providing fundamental copper conductivity data referenced by EN 4434.
• IEC 60344 - Guide for resistance calculation of plain and coated copper conductors, used for verifying conductor resistance in accordance with EN 4434.

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Keywords: EN 4434:2005, aerospace conductors, copper alloy conductors, lightweight electrical cables, aerospace electrical wiring, conductor tolerances, copper plating, stranded conductors, electrical cable standards, aerospace cable specifications, conductor resistance, mechanical properties aerospace

Standards Content (Sample)

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Aerospace series - Copper or copper alloy lightweight conductors for electrical cables - Product standard (Normal and tight tolerances)Série aérospatiale - Conducteurs a tolérances réduites en cuivre ou alliage de cuivre pour câbles électriques - Norme de produit (Tolérances normales et réduites)Luft- und Raumfahrt - Leichter Leiter aus Kupfer oder Kupferlegierung für elektrische Leitungen - Produktnorm (Normale und enge Toleranzen)Ta slovenski standard je istoveten z:EN 4434:2005SIST EN 4434:2006en49.060ICS:SLOVENSKI
STANDARDSIST EN 4434:200601-september-2006

EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 4434November 2005ICS 49.060 English VersionAerospace series - Copper or copper alloy lightweightconductors for electrical cables - Product standard (Normal andtight tolerances)Série aérospatiale - Conducteurs à tolérances réduites encuivre ou alliage de cuivre pour câbles électriques - Normede produit (Tolérances normales et réduites)Luft- und Raumfahrt - Leichter Leiter aus Kupfer oderKupferlegierung für elektrische Leitungen - Produktnorm(Normale und enge Toleranzen)This European Standard was approved by CEN on 19 September 2005.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the Central Secretariat or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia,Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2005 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 4434:2005: E
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