oSIST prEN 4434:2025

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

This document 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 document.

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

Dieses Dokument 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.
Es gilt für verseilte Leiter mit Nennquerschnittsflächen von 0,15mm2 bis 14mm2.
Dieses Dokument enthält keine Leiter für Thermoelemente und feuerbeständige Leitungen.

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

Le présent document spécifie les dimensions, la résistance linéique, les caractéristiques mécaniques, la construction et la masse des conducteurs légers, à tolérances normales et serrées, en cuivre ou en alliage de cuivre pour les câbles électriques utilisés dans les applications aérospatiales.
Il s'applique aux conducteurs toronnés ayant une section nominale de 0,15 mm2 à 14 mm2 incluse.
Les conducteurs pour les extensions de thermocouples et câbles résistant au feu ne sont pas couverts par ce document.

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

General Information

• Status: Not Published
• Public Enquiry End Date: 30-Dec-2025
• ICS: 29.060.20 - Cables
• ICS: 49.060 - Aerospace electric equipment and systems
• ICS: 77.150.30 - Copper products
• Technical Committee: I13 - Imaginarni 13
• Current Stage: 4020 - Public enquire (PE) (Adopted Project)
• Start Date: 29-Oct-2025
• Due Date: 18-Mar-2026
• Completion Date: 05-Jan-2026
• Ref Project: prEN 4434 - Aerospace series - Copper or copper alloy lightweight conductors for electrical cables - Product standard (Normal and tight tolerances)

Relations

• Revises: SIST EN 4434:2006 - Aerospace series - Copper or copper alloy lightweight conductors for electrical cables - Product standard (Normal and tight tolerances)
• Effective Date: 23-Jul-2025

Overview

prEN 4434 (Aerospace series) is a CEN product standard for lightweight copper or copper-alloy conductors used in aerospace electrical cables. The draft standard (prEN 4434:2025) updates and is intended to supersede EN 4434:2005. It specifies dimensions, linear resistance, mechanical characteristics, construction rules and mass for stranded conductors with nominal cross-sections from 0.15 mm² to 14 mm². Conductors for thermocouple extension and fire‑resistant cables are explicitly excluded.

Key topics and technical requirements

• Materials: strands made from high‑conductivity annealed electrolytic copper (IEC 60028) or specified copper alloys. Conductors of 0.15 mm² and 0.25 mm² must use a copper alloy.
• Electrical properties: linear resistance limits at 20 °C defined (tables for normal and tight tolerances); resistance calculations per IEC 60344 and EN 3475‑301.
• Mechanical properties:
  • Copper strands: elongation ≥ 10% and tensile strength ≥ 220 MPa.
  • Copper alloy (for 0.15/0.25 mm²): max resistivity 2.46×10⁻⁸ Ω·m, tensile ≥ 350 MPa, elongation ≥ 6%.
• Plating options: uncoated (A), tin (B), silver (C), nickel (D). Minimum plating thicknesses: silver ≥ 1.0 µm, nickel ≥ 1.3 µm; tin thickness governed by EN 3475‑506/507 tests.
• Construction rules:
  • Concentric stranding up to 9 mm²; allowed bunched/concentric for 14 mm². Lay length of outer layer generally between 8× and 16× conductor diameter (limits for larger constructions noted). Outer lay must be left‑hand.
  • Conductors must be free from joints; individual strands may include soldered/brazed butt joints (for strand diameter ≥ 0.25 mm) with inter‑strand joint spacing > 3 m.
  • Compaction that deforms strands or damages plating is prohibited.
• Tolerance classes: normal and tight tolerances specified in Tables 1 and 2 covering diameter, resistance, breaking load and mass.
• Testing and marking: tests per EN 3475 series; delivery on spools/reels with identification, length, date and inspection marks.

Applications and practical value

• Used for specification, procurement and quality control of aerospace electrical cables where weight, electrical performance and mechanical reliability are critical.
• Guides cable manufacturers in choosing conductor constructions, plating and tolerance class (normal vs tight) for harnesses, avionics wiring and other aircraft electrical systems.
• Supports compatibility with existing tooling (many minimum diameters/masses align with EN 2083 for stripping and crimping).

Who should use this standard

• Cable and conductor manufacturers, aerospace OEMs and tier suppliers
• Electrical and wiring-harness design engineers
• Procurement/specification writers and quality assurance/testing laboratories
• Certification bodies assessing compliance with aerospace electrical equipment requirements

Related standards

• EN 4434:2005 (superseded)
• EN 3475 series (test methods)
• IEC 60344 (resistance calculation)
• EN 2083 (conductor tooling compatibility)

Keywords: prEN 4434, aerospace conductors, copper alloy conductors, stranded conductors, conductor tolerances, linear resistance, aerospace cable standards.

Standards Content (Sample)

SLOVENSKI STANDARD
01-december-2025
Aeronavtika - Lahki vodniki iz bakra ali bakrenih zlitin za električne kable -
Standard za proizvod (običajne in ozke tolerance)
Aerospace series - Copper or copper alloy lightweight conductors for electrical cables -
Product standard (Normal and tight tolerances)
Luft- und Raumfahrt - Leichter Leiter aus Kupfer oder Kupferlegierung für elektrische
Leitungen - Produktnorm (Normale und enge Toleranzen)
Série aérospatiale - Conducteurs a tolérances réduites en cuivre ou alliage de cuivre
pour câbles électriques - Norme de produit (Tolérances normales et réduites)
Ta slovenski standard je istoveten z: prEN 4434
ICS:
29.060.20 Kabli Cables
49.060 Letalska in vesoljska Aerospace electric
električna oprema in sistemi equipment and systems
77.150.30 Bakreni izdelki Copper products
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

DRAFT
EUROPEAN STANDARD
NORME EUROPÉENNE
EUROPÄISCHE NORM
October 2025
ICS 49.060 Will supersede EN 4434:2005
English Version
Aerospace series - Copper or copper alloy lightweight
conductors for electrical cables - Product standard
(Normal and tight tolerances)
Luft- und Raumfahrt - Leichter Leiter aus Kupfer oder
Kupferlegierung für elektrische Leitungen -
Produktnorm (Normale und enge Toleranzen)
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee ASD-
STAN.
If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations
which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC
Management Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and
United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2025 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 4434:2025 E
worldwide for CEN national Members.

Contents Page
European foreword . 3
1 Scope . 4
2 Normative references . 4
3 Terms and definitions . 4
4 Conductor materials and construction . 4
4.1 Materials . 4
4.2 Metal plating . 4
4.3 Electrolytic copper . 5
4.4 Copper alloy . 5
4.5 Construction of conductors . 5
4.5.1 Lay length . 5
4.5.2 Joints . 6
4.5.3 Compaction . 6
5 Required characteristics . 6
5.1 General. 6
5.2 Normal tolerances . 6
5.3 Tight tolerances . 8
6 Test methods . 8
7 Designation . 9
8 Marking, packaging and delivery lengths . 9
Bibliography . 10

European foreword
This document (prEN 4434:2025) has been prepared by ASD-STAN.
After enquiries and votes carried out in accordance with the rules of this Association, this document has
received the approval of the National Associations and the Official Services of the member countries of
ASD-STAN, prior to its presentation to CEN.
This document is currently submitted to the CEN Enquiry.
This document will supersede EN 4434:2005.
— addition of: “The elongation prior to rupture, for stranded copper conductor, shall not be less than
10 %.” in 4.3;
— in Table 1, addition the minimal breaking load for 9 mm section is “1000N”;
— in Table 2, addition the minimal breaking load for 9 mm section is “1000N”.
1 Scope
This document 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.
2 2
It applies to stranded conductors, with a nominal cross-sectional area of 0,15 mm to 14 mm inclusive.
The conductors for thermocouple extension and fire-resistant cables are not covered by this document.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edi
...