Why is Military wire so much different than every other wiring or cabling product?
Military wire or Mil-Spec wire is unique because it’s one of the only wiring products with its own designation, unlike hook-up wire or high-temperature wire both of which are designated by UL and CSA. Similar to UL and CSA, Mil-Spec wire has a specific set of standards that must be followed in order for that product to be considered “real” mil-spec wire.
Sycor’s mil-spec wire is typically used in demanding military applications, where reliability is essential. These products are relied on for difficult and demanding applications, because of how they’re able to handle high-frequency applications, which more than likely will be subject to extreme temperatures and harsh environments. Applications that require this type of wiring range from point-to-point wiring, antennas, bonding moving parts, airframe wiring and where durable shielding is required.
Over the years many different standards have been used to separate the different attributes that each wire offers. There is a wide variety of different types of mil-spec wire such as:
Sycor’s largest Mil-Spec categories are the Mil-W-22759 (M22759) & Mil-W-16878 (M16878) designations. The M16878 and M22759 wires follow the same trend as all other mil-spec products and are specific for every product with a different slant. This slant's important to note because although they may be able to serve similar applications, each slants construction will change slightly.
Sycor Technology has added 2 easy to navigate areas on our new website in order to help the experienced customers find what they need quickly and inexperienced customers better understand what is different between the products (slants).
2 Customer-friendly Mil-Spec additions:
1. For experienced customers, we've added the "Mil-Spec Quick Navigation" page. This page is updated continuously with every military wire that Sycor Stocks is an extremely organized fashion.
2. The second new addition is aimed at more unexperienced mil-spec wire personnel. This new addition breaks each cable down by its core components: conductor plating, voltage, temperature, type, insulation and even the NEMA specification. This enables new wire and cable purchasers to see each slants construction and capabilities in a single place.
|M22759/1||EA||Silver||600V||200ºC||PTFE and PTFE Coated Glass|
|M22759/2||E||Nickel||600V||260ºC||PTFE and PTFE Coated Glass|
|M22759/3||RA||Nickel||600V||260ºC||TFE Glass TFE|
|M22759/5||VA||Silver||600V||200ºC||Abrasion Resistant Mineral Filled TFE|
|M22759/6||WA||Nickel||600V||260ºC||Abrasion Resistant Mineral Filled TFE|
|M22759/7||SA||Silver||600V||200ºC||Abrasion Resistant Mineral Filled TFE|
|M22759/8||TA||Nickel||600V||260ºC||Abrasion Resistant Mineral Filled TFE|
|M22759/28||JB||Silver||600V||200ºC||Extruded TFE with Polyimide Coating|
|M22759/29||JC||Nickel||600V||260ºC||Extruded TFE with Polyimide Coating|
|M22759/30||JD||SPHSCA||600V||200ºC||Extruded TFE with Polyimide Coating|
|M22759/31||JE||NPHSCA||600V||260ºC||Extruded TFE with Polyimide Coating|
|M22759/32||SB||Tin||600V||150ºC||Crosslinked Modified ETFE|
|M22759/33||SC||SPHSCA||600V||200ºC||Crosslinked Modified ETFE|
|M22759/34||SD||Tin||600V||150ºC||Crosslinked Modified ETFE|
|M22759/35||SE||SPHSCA||600V||200ºC||Crosslinked Modified ETFE|
|M22759/41||SM||Nickel||600V||200ºC||Crosslinked Modified ETFE|
|M22759/42||SN||NPHSCA||600V||200ºC||Crosslinked Modified ETFE|
|M22759/43||SP||Silver||600V||200ºC||Crosslinked Modified ETFE|
|M22759/44||SR||Silver||600V||200ºC||Crosslinked Modified ETFE|
|M22759/45||SS||Nickel||600V||200ºC||Crosslinked Modified ETFE|
|M22759/46||ST||NPHSCA||600V||200ºC||Crosslinked Modified ETFE|
MIL-W-22759 (M22759) or SAE AS22759 is constantly relied on for military, aerospace and defence agency applications. The MIL-W-22759 (M22759) is designed for high-performance and meets the requirements for low weight, high-temperature resistance, low flame and for small dimension installations. Being a single conductor electrical wire the MIL-W-22759 (M22759) variations are manufactured with tin, nickel or silver-plated copper conductors. The different conductor constructions enable the MIL-W-22759 (M22759) wire to be used in varying temperatures and environments. The final major difference between the varying MIL-W-22759 (M22759) models is the different insulations such as: polyvinylidene fluoride (PVF2), polytetrafluoroethylene (TFE), fluorinated ethylene propylene (FEP) and ethylene-tetrafluoroethylene copolymer (ETFE). Each insulation provides various strengths towards the intended applications and in some cases are combined to create up to 4 layers of insulation protection, which has excellent durability and shelf life for any application this powerful wire could be subject to.
Military wire and cable must be built in accordance with military specification. The MIL-W-22759 (M22759) specification is important to note because these wires are consistently subject to extreme conditions, where weaker cables would fail consistently. The MIL-W-22759 (M22759) is a strong reliable wire and is perfect for government or commercial applications requiring extreme resistance.
The MIL-W-16878 (M16878) specification identifies the temperature range as -65°C to +250°C. MIL-W-16878 (M16878) is also a designated hook-up wire that is used for high-performance applications that require small dimensions, low weight, high-temperature resistance and low flame. MIL-W-16878 (M16878) similar to its MIL-W-22759 (M22759) counterpart comes in various constructions each of which gives different strengths to the intended applications. With a voltage rating ranging from 300 Volts to 5000 Volts, the MIL-W-16878 (M16878) cable is rated for low and high voltage applications. Typically the MIL-W-16878 (M16878) is used for military, government, and aerospace applications, but can be used for some commercial applications when required. NEMA HP3 – HP8 is a MIL-W-16878 (M16878) designation and is used to identify different constructions, but most industries still use the traditional “16878”. The last unique aspect that the MIL-W-16878 (M16878) cable has is how the conductor plating, gauge and stranding is identified. While most organizations use the last numbers at the end of the product code to identify these attributes, this unique product uses 3 different letters to identify those previously mentioned cable attributes. This is helpful for purchasing personnel and engineers to find their exact product fast and efficiently.
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