ASTM B566-04a(2021)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation:B566 −04a (Reapproved 2021)
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 Wires Used as Electrical Conductors
2.3 NIST Standard:
1.1 This specification covers bare round copper-clad alumi-
NBS Handbook 100— Copper Wire Tables
num wire for electrical applications.
1.2 Four classes of copper-clad aluminum wire are covered
3. Terminology
as follows:
3.1 Definitions of Terms Specific to This Standard:
Class 10A—Nominal 10 volume % copper, annealed,
3.1.1 lot—a lot is any amount of wire of one class and size
Class 15A—Nominal 15 volume % copper, annealed,
presented for acceptance at one time; such amount, however,
Class 10H—Nominal 10 volume % copper, hard-drawn,
not to exceed 100 production units.
Class 15H—Nominal 15 volume % copper, hard-drawn.
3.1.2 sample—a quantity of production units (coils, reels,
1.3 The values stated in inch-pound units are to be regarded
andsoforth)selectedatrandomfromthelotforthepurposeof
as standard. The values given in parentheses are mathematical
determining conformance of the lot to the requirements of this
conversions to SI units that are provided for information only
specification.
and are not considered standard.
3.1.3 specimen—a length of wire removed for test purposes
1.3.1 Exception—ThevaluesstatedinSIunitsforresistivity
from any individual production unit of the sample.
and density are to be regarded as standard.
1.4 This international standard was developed in accor-
4. Ordering Information
dance with internationally recognized principles on standard-
4.1 Ordersformaterialunderthisspecificationshallinclude
ization established in the Decision on Principles for the
the following information:
Development of International Standards, Guides and Recom-
4.1.1 Quantity of each size and class;
mendations issued by the World Trade Organization Technical
4.1.2 Wire size, diameter in inches (see Section 7 and Table
Barriers to Trade (TBT) Committee.
1);
4.1.3 Class of wire (see 1.2 and Table 1);
2. Referenced Documents
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
B258Specification for Standard Nominal Diameters and
core throughout and shall be of such quality as to meet the
Cross-Sectional Areas of AWG Sizes of Solid Round
requirements of this specification.
6. General Requirements
This specification is under the jurisdiction of ASTM Committee B01 on
6.1 Tensile Strength and Elongation—The copper-clad alu-
Electrical Conductors and is the direct responsibility of Subcommittee B01.06 on
minum wire shall conform to the tensile strength and elonga-
Bi-Metallic Conductors.
Current edition approved Oct. 1, 2021. Published October 2021. Originally
tion requirements of Table 1. For intermediate diameters not
approved in 1972. Last previous edition approved in 2016 as B566–04a (2016).
listed in Table 1, the elongation requirements of the next
DOI: 10.1520/B0566-04AR21.
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’s Document Summary page on Available from National Institute of Standards and Technology (NIST), 100
the ASTM website. 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 (2021)
TABLE 1 Tensile and Elongation Requirements for Copper-Clad value of 0.15328 Ω·g/m at 20°C are, respectively, the international
Aluminum Wire
equivalent of volume and weight resistivity of annealed copper equal to
100%conductivity.Thelatertermmeansthatacopperwire1minlength
Elongation, min,
Nominal
andweighing1gwouldhavearesistanceof0.15328Ω.Thisisequivalent
Tensile Strength %in10in.
Diameter 2
toaresistivityvalueof875.20Ω·lb/mile ,whichsignifiestheresistanceof
(or 250 mm)
a copper wire 1 mile in length weighing 1 lb. It is also equivalent, for
Minimum All Maximum All
All H All A example,to1.7241µΩ/cmoflengthofacopperbar1cm incrosssection.
H Classes A Classes
in. (mm)
Classes Classes
Acomplete discussion of this subject is contained in NBS Handbook 100.
ksi (MPa) ksi (MPa)
The use of five significant figures in expressing resistivity does not imply
0.3249 8.252 16 110 20 138 1.5 15
the need for greater accuracy of measurement than that specified in Test
0.2893 7.348 16 110 20 138 1.5 15
Method B193. The use of five significant figures is required for complete
0.2576 6.543 18 124 20 138 1.5 15
reversible conversion from one set of resistivity units to another.
0.2294 5.827 20 138 20 138 1.5 15
6.3 Cohesion—The copper-clad aluminum wire, when
0.2043 5.189 22 152 20 138 1.5 15
tested in accordance with 10.4, shall be free from seams or
0.1819 4.620 23 159 20 138 1.5 15
0.1620 4.115 24 166 20 138 1.5 15 splits.Examinationofthewireshallbemadeatamagnification
0.1443 3.665 25 172 20 138 1.5 15
not to exceed 10×.
0.1285 3.264 26 179 20 138 1.0 15
6.4 Adhesion—The copper-clad aluminum wire, when
0.1144 2.906 27 186 20 138 1.0 15
tested in accordance with 10.5, shall be free from cladding
0.1019 2.588 28 193 20 138 1.0 15
delamination. Examination of the wire shall be made at a
0.0907 2.30 29 200 20 138 1.0 15
magnification not to exceed 10×.
0.0808 2.05 30 207 20 138 1.0 15
0.0720 1.83 30 207 20 138 1.0 15 6.5 Joints—The finished wire shall contain no joints or
0.0641 1.63 30 207 20 138 1.0 15
splices.
0.0571 1.45 30 207 20 138 1.0 15
6.6 Copper Thickness—The minimum copper thickness,
0.0508 1.29 30 207 20 138 1.0 15
when tested in accordance with 10.6, shall be not less than the
0.0453 1.15 30 207 20 138 1.0 15
following:
0.0403 1.02 30 207 20 138 1.0 15
0.0359 0.912 30 207 20 138 1.0 15
6.6.1 Class 10A and 10H wire shall have a minimum
thickness of not less than 3.5% of the wire radius.
0.0320 0.813 30 207 20 138 1.0 15
6.6.2 Class 15A and 15H wire shall have a minimum
0.0285 0.724 30 207 20 138 1.0 15
0.0253 0.643 30 207 20 138 1.0 15
thickness of not less than 5.0% of the wire radius.
0.0226 0.574 30 207 25 172 1.0 10
6.7 Copper Volume (Area)—The copper volume (area) per
0.0201 0.511 30 207 25 172 1.0 10
class, when tested in accordance with 10.6, shall meet the
0.0179 0.455 30 207 25 172 1.0 10
following tolerances:
0.0159 0.404 30 207 25 172 1.0 10
0.0142 0.361 30 207 25 172 1.0 10 6.7.1 Class 10A and 10H wire shall contain not less than
8% and not more than 12% copper by volume (area).
0.0126 0.320 30 207 25 172 1.0 5
6.7.2 Class 15A and 15H wire shall contain not less than
0.0113 0.287 30 207 25 172 1.0 5
0.0100 0.254 30 207 25 172 1.0 5 13% and not more than 17% copper by volume (area).
0.0089 0.226 30 207 25 172 1.0 5
7. Dimensions, Mass and Permissible Variations
0.0080 0.203 30 207 25 172 1.0 5
0.0071 0.180 30 207 25 172 1.0 5
7.1 The wire size shall be expressed as the diameter of the
0.0063 0.160 30 207 25 172 1.0 5
wire in decimal fractions of an inch to the nearest 0.0001 in.
0.0056 0.142 30 207 25 172 1.0 5
(0.003 mm) (Note 2). For diameters under 0.0100 in.
0.0050 0.127 30 207 25 172 1.0 5
(0.254mm),thewireshallnotvaryfromthespecifieddiameter
by more than 60.0001 in. (60.003 mm) and for diameters of
smaller size shall apply; in the case of tensile strength the 0.0100 in. (0.254 mm) and over, the wire shall not vary from
the specified diameter by more than 61%, expressed to the
requirements of the next larger size shall apply.
nearest 0.0001 in. (0.003 mm).
6.2 Resistivity—The electrical resistivity at a temperature of
20°C shall not exceed the values prescribed in Table 2. See 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
Note 1 for calculating electrical resistance.
inSpecificationB258.Theuseofgagenumberstospecifywiresizesisnot
NOTE 1—Relationships which may be useful in connection with the
recognized in this specification because of the possibility of confusion.A
values of electrical resistivity prescribed in this specification are shown in
discussionofwiregagesandrelatedsubjectsiscontainedin“CopperWire
Table 3. Resistivity units are based on the InternationalAnnealed Copper
Tables,” NBS Handbook 100.
Standard (IACS) adopted by IEC in 1913, which is ⁄58Ω·mm /m and the
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
8.2 For wire diameters of 0.0720 in. (1.829 mm) and larger,
15A and 15H 0.02676
surface finish inspection shall be made with the unaided eye
B566−04a (2021)
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 5 Sample for Surface Finish and Packaging Inspection
(normal spectacles excepted), and for wire diameters smaller
than 0.0720 in., surface finish inspection shall be made at a Allowable Number of
Number of Units Number of Units
Defects in Sample
magnification not to exceed 10×.
in Lot in Sample, n
to Accept Lot, c
1–3 all 0
9. Sampling
4–8 4 0
9.1 The number of production units in a sample shall be as 9–15 9 0
16–25 14 0
follows:
26–40 20 0
9.1.1 For tensile strength, elongation, resistivity, adhesion,
41–65 30 0
66–100 42 0
cohesion, and dimensional measurements, the sample
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