ASTM D1676-17

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: D1676 − 17
Standard Test Methods for
Film-Insulated Magnet Wire
This standard is issued under the fixed designation D1676; 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.
1. Scope* 1.5 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
1.1 These test methods cover procedures for testing film-
responsibility of the user of this standard to establish appro-
insulatedmagnetwirethatisusedinelectricalapparatus.These
priate safety, health, and environmental practices and deter-
test methods are intended primarily for the evaluation of the
mine the applicability of regulatory limitations prior to use.
electrical insulating materials used.The intent is that these test
Specific hazard statements are given in 9.5, 19.1, 19.3, 19.8,
methods be used, except where modified, by individual speci-
52.1, 58, 59.1, 74.1, 112.1, 135.4, and 182.3.
fications for particular applications.
NOTE 1—This test method is related to IEC 60851. Since both methods
1.2 These test methods present different procedures for
contain multiple test procedures, many procedures are technically equiva-
evaluating given properties of round, rectangular or square,
lent while others differ significantly.
copper or aluminum film-insulated magnet wire.
1.6 This international standard was developed in accor-
1.3 The values stated in inch-pound units are the standard. dance with internationally recognized principles on standard-
The SI units in parentheses are provided for information only. ization established in the Decision on Principles for the
Development of International Standards, Guides and Recom-
1.4 The test methods appear in the following sections:
mendations issued by the World Trade Organization Technical
Sections
Barriers to Trade (TBT) Committee.
Bond Strength 4–12
Burnout (AC Overload Resistance) 13–21
2. Referenced Documents
Chemical Resistance 22–28
Coefficient of Friction 29–37
2.1 ASTM Standards:
Continuity, DC High Voltage 38–45
Continuity, DC Low Voltage 46–53 A228/A228MSpecification for Steel Wire, Music Spring
Completeness of Cure 54–60
Quality
Cut-Through Temperature (Thermoplastic Flow) 61–68
B3Specification for Soft or Annealed Copper Wire
Dielectric Breakdown AC Voltage 69–75
Dielectric Breakdown AC Voltage after Bending 76–82 B43Specification for Seamless Red Brass Pipe, Standard
Dielectric Breakdown AC Voltage at Elevated Temperatures 83–89
Sizes
Dielectric Breakdown AC Voltage after Conditioning in Refriger-
B193Test Method for Resistivity of Electrical Conductor
ant Atmosphere 90–99
Dimensional Measurement 100 – 106 Materials
Dissipation Factor Measurement 107 – 114
B279Test Method for Stiffness of Bare Soft Square and
Electrical Resistance 115 – 121
RectangularCopperandAluminumWireforMagnetWire
Elongation 122 – 129
Extractables, Refrigerant 130 – 140 Fabrication
Film Adherence and Flexibility 141 – 148
B324Specification for Aluminum Rectangular and Square
Formability:
Wire for Electrical Purposes
a) Elastic Ratio 152
b) Low Stress Elongation 153 B609/B609M Specification for Aluminum 1350 Round
c) Spring Back 154-155
Wire, Annealed and Intermediate Tempers, for Electrical
Heat Shock 156 – 162
Purposes
Oiliness 163 – 169
Scrape Resistance, Unidirectional 170 – 177
D149Test Method for Dielectric Breakdown Voltage and
Solderability 178 – 185
DielectricStrengthofSolidElectricalInsulatingMaterials
Resistance to Insulating Liquids and Hydrolytic Stability 186 – 195
at Commercial Power Frequencies
D150Test Methods forAC Loss Characteristics and Permit-
tivity (Dielectric Constant) of Solid Electrical Insulation
D374/D374MTest Methods for Thickness of Solid Electri-
These test methods are under the jurisdiction of ASTM Committee D09 on
Electrical and Electronic Insulating Materials and are the direct responsibility of
cal Insulation
Subcommittee D09.12 on Electrical Tests.
D877Test Method for Dielectric Breakdown Voltage of
Current edition approved Nov. 1, 2017. Published December 2017. Originally
Insulating Liquids Using Disk Electrodes
approved in 1959. Last previous edition approved in 2011 as D1676–03(2011).
DOI: 10.1520/D1676-17. D1533Test Method for Water in Insulating Liquids by
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D1676 − 17
Coulometric Karl Fischer Titration 5.1.1 bond strength, n—a measure of the force required to
D1711Terminology Relating to Electrical Insulation separate surfaces which have been bonded together.
D2475Specification for Felt 5.1.1.1 Discussion—For magnet wire which has been self
D2519Test Method for Bond Strength of Electrical Insulat- bonded or varnish treated, the bond strength is reported as the
ing Varnishes by the Helical Coil Test force required to break a test specimen in flexure.
D5423Specification for Forced-Convection Laboratory Ov-
6. Summary of Test Method
ens for Evaluation of Electrical Insulation
E4Practices for Force Verification of Testing Machines
6.1 Flexural strength tests are made on bonded helical coils
E6Terminology Relating to Methods of Mechanical Testing
todeterminetheforcerequiredtobreakthecoilunderspecified
E8Test Methods for Tension Testing of Metallic Materials
conditions.
E220Test Method for Calibration of Thermocouples By
Comparison Techniques
7. Significance and Use
E1356Test Method for Assignment of the Glass Transition
7.1 Bond strength values obtained by flexural tests provide
Temperatures by Differential Scanning Calorimetry
information with regard to the bond strength of a particular
E1545Test Method for Assignment of the Glass Transition
self-bonding outer coating in combination with a particular
Temperature by Thermomechanical Analysis
round film-insulated magnet wire when measured under con-
2.2 Other Documents:
ditions described in this test method.
CCCM-911Federal Specification for Bleached Muslin
IEC 60851Methods of Test for Winding Wire
8. Apparatus
8.1 Testing Machine—Tensile testing machines used for
3. Terminology
bond strength test shall conform to the requirements of
3.1 Definitions:
Practices E4.
3.1.1 conductor, n—a wire or combination of wires not
8.2 Test Fixture—The test fixture shall conform to the test
insulatedfromeachother,suitableforcarryingelectriccurrent.
fixture for bond strength tests required byTest Method D2519.
3.1.2 magnet wire, n—a metal electrical conductor, covered
8.3 Mandrel Holder—The mandrel holder shall be a metal
with electrical insulation, for use in the assembly of electrical
block of sufficient size and thickness with a hole capable of
inductive apparatus such as coils for motors, transformers,
supporting the winding mandrel in a vertical position during
generators, relays, magnets, and so forth.
the bonding cycle of the helical coil.
3.1.3 For definition of other terms used in this test method
8.4 Winding Tensions—The winding tensions are listed in
refer to Terminology D1711.
Table 1.
3.2 Definitions of Terms Specific to This Standard:
3.2.1 film coating, n—cured enamel coating.
8.5 Bonding Weights—Bonding weights (listed in Table 1)
are made with a hole through the center to allow the weight to
3.2.2 film insulated wire, n—a conductor insulated with a
slip freely over the winding mandrel and load a helical coil
film coating.
during bonding of coil.
BOND STRENGTH OF ROUND FILM-INSULATED
8.6 Forced-Air Oven—See Specification D5423.
SELF-BONDING MAGNET WIRE BY THE HELICAL
COIL TEST
9. Test Specimen Preparation
9.1 Select the appropriate mandrel from Table 1, spray it
4. Scope
with a suitable release agent (fluorocarbon or silicone spray is
4.1 This test method covers the determination of the bond
adequate),andallowittodry.Carefullywindontotheprepared
strengthofaself-bondingoutercoatingonroundfilm-insulated
mandrel a length of wire, long enough to wind a helical coil at
magnet wires (AWG 14 through 44). Both thermal and solvent
least 3 in. (76 mm) long. The winding tension shall be as
bonding methods are defined.
prescribed in Table 1. Ensure that the coil is wound without
4.2 This international standard was developed in accor-
space between turns.
dance with internationally recognized principles on standard-
9.2 Prepare six or more coils from each wire sample.
ization established in the Decision on Principles for the
9.3 Thermal Bonding—Mount the mandrel supporting the
Development of International Standards, Guides and Recom-
coil vertically in the mandrel holder and loaded with the
mendations issued by the World Trade Organization Technical
bonding weight specified in Table 1. Place the mandrel holder
Barriers to Trade (TBT) Committee.
and coil into a forced-air oven at a specified temperature for a
specified time, after which the assembly is removed from the
5. Terminology
oven and cooled to room temperature. Remove the coil from
5.1 Definitions of Terms Specific to This Standard:
the mandrel and inspect the coil for breaks or physical damage
prior to testing.
9.4 Solvent Bonding—After winding, immerse the coil and
AvailablefromStandardizationDocumentsOrderDesk,Bldg.4SectionD,700
Robbins Ave., Philadelphia, PA 19111-5094, Attn: NPODS. mandrel into the specified solvent for 5 s. Immediately
D1676 − 17
TABLE 1 Helical Coil Bond Parameters
Design test equipment, test chambers, and test specimens so as
Recommended tominimizethepossibilityofsuchoccurrencesandtoeliminate
A A
Mandrel Diameter Bond Weights
Wire Size,
Winding Tension
the possibility of personal injury. If the potential for fire exists,
AWG
in. mm g N g N
have fire suppression equipment available.)
44 0.011 0.28 2.5 0.025 0.80 0.008
43 0.011 0.28 2.5 0.025 0.80 0.008
10. Procedure
42 0.016 0.41 5.0 0.50 1.60 0.016
41 0.016 0.41 5.0 0.50 1.60 0.016
10.1 Use a rate of loading such that the duration of the test
40 0.022 0.56 10.0 0.098 3.15 0.031
shall be greater than the full-scale response time of the load
39 0.022 0.56 10.0 0.098 3.15 0.031
recording instrument.
38 0.022 0.56 10.0 0.098 3.15 0.031
37 0.032 0.81 20.0 0.196 6.30 0.062
10.2 Prepare sufficient specimens to obtain six data points
36 0.032 0.81 20.0 0.196 6.30 0.062
35 0.032 0.81 20.0 0.196 6.30 0.062
for each wire sample. One or more of the specimens are
34 0.044 1.12 40.0 0.392 12.5 0.123
potentially going to be destroyed in adjusting the rate of
33 0.044 1.12 40.0 0.392 12.5 0.123
loading.
32 0.044 1.12 40.0 0.392 12.5 0.123
31 0.063 1.60 80.0 0.785 25.0 0.245
10.3 Break specimens according to the test procedures
30 0.063 1.60 80.0 0.785 25.0 0.245
described in Test Method D2519.
29 0.063 1.60 80.0 0.785 25.0 0.245
28 0.088 2.24 160.0 1.569 50.0 0.490
10.4 Tests at other than room temperature are able to be
27 0.088 2.24 160.0 1.569 50.0 0.490
26 0.088 2.24 160.0 1.569 50.0 0.490
performed, if desired, using an insulated heat-resistant
25 0.124 3.15 315.0 3.089 100.0 0.981
enclosure, designed to fit around the test fixture and in the
24 0.124 3.15 315.0 3.089 100.0 0.981
stress strain analyzer. Place the specimens in the fixture in the
23 0.124 3.15 315.0 3.089 100.0 0.981
22 0.177 4.50 630.0 6.178 200.0 1.961 oven for 15 min but not more than 30 min after the oven has
21 0.177 4.50 630.0 6.178 200.0 1.961
recovered to the set temperature 62°C. Break the specimens
20 0.177 4.50 630.0 6.178 200.0 1.961
according to the test procedures described in Test Method
19 0.248 6.30 1250.0 12.258 400.0 3.923
18 0.248 6.30 1250.0 12.258 400.0 3.923
D2519. The specified test temperature and minimum bond
17 0.248 6.30 1250.0 12.258 400.0 3.923
strength shall be agreement upon between the manufacturer
16 0.354 8.99 2500.0 24.517 800.0 7.845
and the user.
15 0.354 8.99 2500.0 24.517 800.0 7.845
14 0.354 8.99 2500.0 24.517 800.0 7.845
A
11. Report
±2 % on all mandrels and bond weights.
11.1 Report the following:
11.1.1 Identification of size, build and type of insulation
used,
thereafter, secure the mandrel supporting the coil in the
11.1.2 Heat or solvent bonding (including temperature or
mandrel holder and load the coil with the bonding weight
type of solvent, or both),
specified in Table 1. Dry the coils for1hat room temperature.
11.1.3 Test temperature, and
Carefully remove the coils from the mandrels and further dry
11.1.4 Atablelistingtheindividualvaluesinpounds,grams
in a forced air oven for 15 6 2 min at 100 6 3°C (unless
or newtons of bond strength and their averages.
otherwisespecified).Coolthecoiltoroomtemperature,inspect
for breaks or physical damage, and test.
9.5 Resistance Bonding—Mountthemandrelsupportingthe
TABLE 2 Critical Differences, Percent of Average Pounds to
A
coilverticallyinamandrelholderandloadedwiththebonding
Break
weight specified in Table 1. Energize the coil with enough
Number of Single- Within- Between-
Observations in Operator Laboratory Laboratory
current and time to allow bonding. Remove the coil from the
each Average Precision Precision Precision
mandrel and inspect for breaks or physical damage, and test.
610 11 12
Specific bonding conditions shall be agreed upon between the
A
The critical differences were calculated using t = 1.960, which is based on infinite
manufacturer and the user. (Warning—Lethal voltages are a
degrees of freedom
potential hazard during the performance of this test. It is
essential that the test apparatus, and all associated equipment
electrically connected to it, be properly designed and installed
for safe operation. Solidly ground all electrically conductive
12. Precision and Bias
parts which it is possible for a person to contact during the
12.1 In comparing two averages of six observations, the
test. Provide means for use at the completion of any test to
differences are not expected to exceed the critical difference in
ground any parts which were at high voltage during the test or
Table2,in95outof100caseswhenalloftheobservationsare
have the potential for acquiring an induced charge during the
takenbythesamewell-trainedoperatorusingthesamepieceof
test or retaining a charge even after disconnection of the
test equipment and specimens randomly drawn from the same
voltage source. Thoroughly instruct all operators as to the
sample of material.
correct procedures for performing tests safely. When making
high voltage tests, particularly in compressed gas or in oil, it
is possible for the energy released at breakdown to be suffıcient
Supporting data are available fromASTM International Headquarters. Request
to result in fire, explosion, or rupture of the test chamber. RR:D09-1007.
D1676 − 17
FIG. 1 Twist Fabricator
12.2 Precision—Two averages of observed values are con- 14.1.2 one twist (dielectric twist specimen), n—one 360°
sidered significantly different at the 95% probability level if revolution of the head of the dielectric twist maker.
thedifferenceequalsorexceedsthecriticaldifferenceslistedin
15. Summary of Test Method
Table 2.
15.1 Acontrolled current (I) is passed through both strands
12.3 Bias—This test method has no bias because the value
of a film-insulated magnet wire twisted pair. The resistance
of bond strength is determined solely in terms of this test
heating of this specimen due to the current (I) will result in
method.
thermal degradation of the film.When the level of degradation
BURNOUT (AC OVERLOAD RESISTANCE)
is sufficient for a 50-mA current at 130 6 10 Vac to pass
through the film, burnout occurs. The burnout is reported in
13. Scope
seconds (t).
13.1 This test method and equipment described herein is
16. Significance and Use
usedtodeterminetheacoverloadresistanceof18AWGheavy
build film-insulated round copper magnet wire by measuring
16.1 The film-insulated magnet wire current burnout tester
the time to obtain a dielectric failure when subjected to a
is designed to rate the performance of various wire insulation
step-wise increase in AC overload current.
underhigherthannormaloperatingtemperaturesbroughtabout
13.2 This international standard was developed in accor- by current overloads. The seconds (t) to burnout relates to the
dance with internationally recognized principles on standard- performance of the film coating under overload conditions in
ization established in the Decision on Principles for the actual field operations.
Development of International Standards, Guides and Recom-
16.2 Test results will allow the film-insulated magnet-wire
mendations issued by the World Trade Organization Technical
user to analyze the relative performance of various magnet-
Barriers to Trade (TBT) Committee.
wire products.
14. Terminology 16.3 Test condition #1 was developed for faster and more
reproducible testing results, especially for product confor-
14.1 Definitions of Terms Specific to This Standard:
mance testing.
14.1.1 burnout (of magnet wire), n—the time required for
dielectric failure to occur between wires of a twisted pair as a 16.4 Test condition #2 was developed to provide the great-
result of heating due to controlled ac overload current. est relative product performance differentiation. Calculation of
D1676 − 17
FIG. 2 Burnout Tester
an Overload Figure of Merit (OFM) is possible using this 17.3 A means of mechanically stripping the legs of the
procedure and is described in 19.9. twisted-pair specimen to a clean bright copper finish.
17.4 Small Vise or Pair of Needle-Nose Pliers, for stabiliz-
17. Apparatus
ing the specimen during the stripping operation, and removal
17.1 Twist Fabricator, that duplicates in function the one
of the test specimen from the tester.
pictured in Fig. 1.
17.5 Burnout Tester, see Fig. 2.
17.2 Three-Pound Load Weight, necessary for use in con-
18. Test Specimen Preparation
junction with the twist fabricator.
18.1 Using the twist fabricator and a 3-lb load weight, form
a 30-in. (76-cm) length of 18AWG heavy-build film-insulated
Suitable testers are available from A/Z Tech, Inc., 2701 South Coliseum
Boulevard,Suite1228,FortWayne,IN46803;AmpacInternational,1118CedarSt,
th 5 th
Fort Wayne, IN 46803; or Byrne Harnessed Electronics, Inc., 16726 150 Ave., Test equipment available from Byrne Harnessed Electronics, Inc., 16726 150
Spring Lake, MI 49456. Ave., Spring Lake, MI 49456.
D1676 − 17
round copper magnet wire into a U-shape and twist the two test specimen, and proceed with 19.4 – 19.6. This condition is
legstogether.Atotalof8or16twistsarerequired.Cuttheloop often the result of poor electrical contact; clean the contacts as
and carefully hand-form the ends for easy placement in the necessary.
burnout tester.
19.3 Secure the specimen in the burnout tester using the
18.2 There shall be no sharp bends in the specimen or
clamps, and close the lid. (Warning—Provide adequate ven-
damage to the insulation. After ensuring that the legs are the tilation during burnout testing of film-insulated magnet wire to
proper length to fit the burnout tester, the excess shall be
remove products of decomposition.)
trimmed and each leg carefully stripped bare. Maintain a
19.4 Turn on the main power switch and wait for comple-
minimum of 0.5 in. (13 mm) of insulated wire between the
tion of reset indicated by lamp.
twisted portion of the twisted pair and the stripped bare ends.
19.5 Push the start button and after the current indicated on
18.3 Test a minimum of five specimens for each type of
onemeterhasstabilizedatfirstAmpsetting,adjustthebalance
film-insulated magnet wire being evaluated.
so that the second meter also reads the same.
19. Procedure 19.6 Uponcompletionofthetestindicatedbythelamp,note
the time in seconds on the meter.
19.1 Warning—Lethal voltages are a potential hazard
during the performance of this test. It is essential that the test 19.7 Push the reset button and wait until reset is complete.
apparatus, and all associated equipment electrically connected
19.8 Carefully remove test specimen with needle-nose pli-
to it, be properly designed and installed for safe operation.
ers and repeat 19.4 – 19.8 for the next specimen. (Warning—
Solidly ground all electrically conductive parts which it is
The twisted-pair specimen remains hot for some time after the
possible for a person to contact during the test. Provide means
test is completed.)
for use at the completion of any test to ground any parts which
19.9 Calculation of Overload Figure of Merit (OFM) When
were at high voltage during the test or have the potential for
Using Condition #2:
acquiring an induced charge during the test or retaining a
charge even after disconnection of the voltage source. Thor- 2 5
OFM 5 I t/10 (1)
~ !
(
oughly instruct all operators as to the correct procedures for
where:
performing tests safely. When making high voltage tests,
particularly in compressed gas or in oil, it is possible for the I = the applied current in each step of the test, and
t = time in seconds for each step.
energy released at breakdown to be suffıcient to result in fire,
explosion, or rupture of the test chamber. Design test
20. Report
equipment, test chambers, and test specimens so as to minimize
the possibility of such occurrences and to eliminate the
20.1 Report the following information:
possibility of personal injury. If the potential for fire exists,
20.1.1 Nominal conductor size,
have fire suppression equipment available. Referring to Fig. 2,
20.1.2 Build,
use the tensiometer to adjust the load weight so that 300 6
20.1.3 Type of insulation,
6.0g of tension will be applied to the twisted-pair specimen.
20.1.4 Test condition used (1 or 2),
Adjust the current step controls to the settings indicated in
20.1.5 Time to failure of each individual specimen,
Table 3.
20.1.6 Average time to failure, and
19.2 Special Considerations:
20.1.7 OFM if using Condition #2.
19.2.1 A warm-up is recommended prior to using the
burnout tester for an actual test. This is accomplished by
21. Precision and Bias
replacing the twisted-pair specimen (see Section 18) with two
21.1 Precision—This test method has been in use for many
straight lengths of AWG 18 round copper bare wire and
years, but no information has been presented to ASTM upon
proceed with 19.3 – 19.5. When the timer reaches 900 s, push
which to base a statement of precision. No activity is planned
reset. The tester is warmed up and ready for use.
to develop such information.
19.2.2 Iftheover/underdrivelampenergizesduringnormal
testing, the results obtained are invalid. Push reset, replace the
21.2 Bias—This test method has no bias because the value
for burnout (AC overload resistance) is determined solely in
terms of this test method.
TABLE 3 Current Step Controls
CHEMICAL RESISTANCE
Current Time t in Condition 1 Condition 1 Condition 2 Condition 2
A A
Steps seconds No. of Twists I, Amps No. of Twists I, Amps
22. Scope
A-1 0 to 180 16 34 8 36
A-2 181 to 360 16 36 8 38
22.1 This test method determines the effects of ambient
A-3 361 to 540 16 39 8 40
A-4 541 to 720 16 43 8 42 chemical conditions on film-insulated magnet wire.
A-5 721 to 900 16 48 8 44
22.2 This international standard was developed in accor-
A-6 901 + . . 8 46
A dance with internationally recognized principles on standard-
Amps ± 2 %.
ization established in the Decision on Principles for the
D1676 − 17
Development of International Standards, Guides and Recom- drynesswithacleancheesecloth.Cutoffanddiscardthelower
mendations issued by the World Trade Organization Technical 1 in. (25 mm) of the specimen.
Barriers to Trade (TBT) Committee.
NOTE 2—Immerse each specimen in only one liquid.
23. Significance and Use 26.2 WireDiameter0.10to0.010in.(2.5to0.25mm)(AWG
10 to 30)—Test each specimen using the scraper device, after
23.1 The retention of the integrity of the film insulation is
1 but before 2 min after removal from the liquid. Apply the
desirable when film-insulated magnet wire is exposed to
specifiedforcetotheneedleandthespecimen.Use580 612g
environments that contain chemical liquids (or vapors). This
whentesting18AWGcopperwire,and340 67gwhentesting
testprovidesinformationusefulforpredictingthesuitabilityof
18 AWG aluminum wire. The force used to test other magnet
thefilm-insulatedmagnetwirewhenexposedtotheseenviron-
wire sizes shall be based on agreement between user and
ments.
supplier.Scrapethespecimenforalengthofnotlessthan6in.
23.2 Since the test is normally conducted at room
(150 mm) of the portion previously immersed. Draw the
temperature, the results are not necessarily indicative of
specimen between the needle and anvil at a uniform speed of
performance at other temperatures.
approximately2in.⁄s(50mm/s).Exposureoftheconductor,as
detected by visual inspection, shall constitute failure.
24. Apparatus
26.3 Wire Diameter 0.20 to 0.114 in. (5.2 to 2.9 mm) (AWG
24.1 Containers for Liquids—Test tubes 10 in. (250 mm) in
4 to 9) and 0.009 to 0.002 in. (0.24 to 0.05 mm) (AWG 31 to
length by 1 in. (25 mm) in diameter or equivalent.
44)—Testeachspecimenafter1butbefore2minafterremoval
24.2 Scraper—A device that will position a steel needle or
from the liquid, by drawing once, without stretching, between
musicwire(SpecificationA228/A228M)0.016in.(0.4mm)in
four folds of cheesecloth held firmly between the thumb and
diameter in a horizontal plane and perpendicular to the axis of
theforefinger.Exposureoftheconductor,asdetectedbyvisual
the wire specimen. The force applied between the needle or
inspection, shall constitute failure.
music wire and the anvil is adjusted by adding weights to the
spindle as shown in Fig. 3.
27. Report
24.3 Cheesecloth, Grade A, bleached, unsized cheesecloth
27.1 Report the following information:
shall be used.
27.1.1 Nominal conductor size,
27.1.2 Conductor composition,
24.4 Forced-Air Oven, (see Specification D5423).
27.1.3 Build and type of insulation,
25. Test Specimen Preparation 27.1.4 Time of immersion,
27.1.5 Temperature of liquid,
25.1 Select 12 6 1 in. (300 6 25 mm) long specimens of
27.1.6 Liquid used,
unbent, unstretched film-insulated magnet wire. Stress anneal
27.1.7 Scraping force if used, and
specimens for 10 6 1 min at 150 6 3°C (302 6 5°F).
27.1.8 Visual observations, pass or fail.
26. Procedure
28. Precision and Bias
26.1 Exposure—Immerse specimens in approximately 8 in.
28.1 No information is presented about either precision or
(200mm)ofapplicableliquidat23 62°C(73 64°F)for24h
bias of this test method as the determination of chemical
or as specified. Remove each specimen and carefully blot to
resistance of magnet wire is nonquantitative.
DYNAMIC COEFFICIENT OF FRICTION TEST
METHOD
29. Scope
29.1 Thistestmethoddeterminesthedynamiccoefficientof
friction between a wire moving at constant speed and a lead
contact surface.
29.2 This international standard was developed in accor-
dance with internationally recognized principles on standard-
ization established in the Decision on Principles for the
Development of International Standards, Guides and Recom-
mendations issued by the World Trade Organization Technical
Barriers to Trade (TBT) Committee.
30. Terminology
30.1 The dynamic coefficient of friction is the ratio of the
force developed between a moving wire surface and the load
FIG. 3 Scrape Fixture for Chemical Resistance Tester contact surface, described by the following equation:
D1676 − 17
µ 5 F/L (2)
d
where:
µ = dynamic coefficient of friction,
d
F = forcedevelopedbetweenamovingwiresurfaceandthe
load contact surface, gf (N), and
L = test load, gf (N).
31. Summary of Test Method
31.1 The wire specimen is pulled at a constant speed over a
loadcontactsurfaceunderatestload(L).Africtionalforce(F)
is developed between the wire surface and the load contact
surface and transferred to an appropriate measuring device.
The reading (F) is divided by the test load (L) to obtain the
dynamic coefficient of friction (µ ).
d
32. Significance and Use
32.1 The dynamic coefficient of friction (µ ) of film-
d
insulated magnet wire is primarily a measure of lubricity and
the smoothness of the insulation surface. The combination of
these factors represented by the coefficient of friction value
affectswindability,layofwire,fillfactorofelectricalcoils,and
the spooling quality during manufacture of film-insulated
magnet wire.
33. Apparatus
33.1 The tester shown in Fig. 4 is an example of an
acceptable design.
NOTE 1—Calibrated Adjustment for parallelism between the test load
and test bed surfaces.
33.2 Amotor shall pull the wire specimen at 50 6 5 ft/min
NOTE 2—Test Bed Guides
(15 61.5m/min)acrossasmoothsurfaceusingamotor-driven
NOTE 3—Test Weight
take-up.
NOTE 4—Load Block — See Figures 2-4 and 2-5
33.3 Various load weights shall be available, which will
NOTE 5—Test Bed
provide100to1000gf(0.98to9.81N).Theloadsurfaceshall NOTE 6—Dampening System
FIG. 5 Detail Drawing of Friction Head Assembly
besyntheticsapphireandhaveasurfaceroughnessofnotmore
than 0.5 µm (20 µin.).The sapphires are described and shall be
mounted in accordance with Fig. 6.
33.4 There shall be a means to guide the wire and a means
andachartrecorderwitha0to5Vrangeanda0.5-sfull-scale
to maintain a slight tension, if needed.
response time is satisfactory.
33.5 Electronic force-measuring devices or transducers in-
33.6 Itissuitabletouseamechanicaldynamometerinplace
corporated with a chart recorder measure the force due to
of an electronic force transducer and chart recorder. Two
friction. The electronic force-measuring device provides a
dynamometer ranges, 0 to 50 gf (0 to 0.5 N) and 0 to 200 gf (0
record indicating the peak variation along the surface of the
to 2.0 N), are satisfactory.
wire.Aforcetransducerwitharangeof0to500gf(0to5.0N)
33.7 Another part of the measuring device is a mechanical
dampeningsystemconsistingofapaddleandacontainerfilled
toadepthof2 60.2in.(5 61mm)withoilhavingaviscosity
of 10000 6 500 cps (10 6 0.5 Pa·s) at 25°C. Dampening is
alsoaccomplishedbyelectronicmeanseliminatingtheneedfor
this mechanical dampening system.
33.8 A cleaning solvent appropriate for the lubricant being
tested shall be used.
34. Test Specimen
34.1 Remove the wire test specimen from the shipping
package by dereeling over the end flange or pulling from the
pail or drum. Remove all contaminated wire before selecting
FIG. 4 Coefficient of Friction Tester test specimens.
D1676 − 17
TABLE 5 Test Loads for Coefficient of Friction Testing
Wire Size Range Test Load in Test Load
(AWG) Grams-Force ±2 % in Newtons
14–24 1000 9.9
25–35 600 5.9
36–40 200 2.0
41–44 100 1.0
TABLE 6 Threshold Fault Current
DC Test Voltage, V ±5 % Threshold Fault Current ±10 %, µA
3000 16
2500 14
2000 12
1500 10
1000 8
750 7
500 6
350 5
35.7 Position the test load on the test bed where no reading
is indicated on the force transducer or dynamometer.
35.8 Zero the mechanical dynamometer if used. Adjust the
calibrated dial to make the test load parallel with the test bed
surface.
NOTE 1—Top number denotes millimetres: lower number denotes
35.9 Turn on the tester to pull the test wire through the
decimals of an inch.
apparatus.
FIG. 6 Load Contact Surface – Sapphire (Synthetic)
35.10 Apply slight tension to keep the wire traveling
smoothly.
35. Procedure
35.11 Allow time (15 s) for start-up variations to cease.
35.1 Level off a smooth surface using the leveling leg
Record the average dynamometer reading to the nearest grams
screws and the float level. Adjust the sensitivity of the
force (newton).
electronicforcetransducertotheappropriaterange,andsetthe
chart recorder at full-scale for the wire size being tested using
36. Calculation
a calibrating weight. Remove the calibrating weight after the
transducer and chart recorder have been adjusted.
36.1 Calculate the average dynamic coefficient of friction
(µ ) as follows:
d
35.2 If a mechanical dynamometer is used, install one
having the correct range for the size wire being tested µ 5 F/L (3)
d
according to Table 4.
where:
35.3 Clean the sapphire surfaces located on the load block,
F = average dynamometer force reading, gf (N), and
that are in contact with the wire, with an appropriate cleaning
L = test load, gf (N).
solvent and dry thoroughly.
35.3.1 Although the wear resistance of the sapphire contact
37. Report
blocks exceeds that of steel, inspect the surfaces of the blocks
37.1 Report the following information:
at periodic intervals (for example, every three months) under
37.1.1 Nominal conductor size,
100× magnification for evidence of wear.
37.1.2 Build,
35.4 Lower the dampening paddle into the oil: immerse
37.1.3 Insulation type,
completelyforAWG14-30;immerseone-halfpaddleforAWG
37.1.4 Lubricant,
31-44.
37.1.5 Test load used,
37.1.6 Average coefficient of friction value (µ ),
d
35.5 Thread the wire over appropriate guide pulleys so the
37.1.7 Maximum reading, and
wire is in contact with the two sapphires.
37.1.8 Standard deviation of the readings.
35.6 Apply the appropriate test load according to Table 5.
38. Precision and Bias
TABLE 4 Dynamometer Parameters
38.1 Thistestmethodhasbeeninuseformanyyears,butno
Wire Size Range (AWG) Grams - Force Newtons
information has been presented to ASTM upon which to base
14–35 0–200 0 to 2.0
astatementofprecision.Noactivityisplannedtodevelopsuch
36–44 0–50 0 to 0.5
information.
D1676 − 17
38.2 This test method has no bias because the values for possibility of personal injury. If the potential for fire exists,
dynamic coefficient of friction are determined solely in terms have fire suppression equipment available.
of this test method.
High Voltage Power Supply—The high voltage power sup-
ply must be regulated and provide to the electrode sheaves a
CONTINUITY, DC HIGH VOLTAGE
filtered direct current voltage free of transient over-voltage
spikes. Measure the voltage with a high impedance device,
39. Scope
such as an electrostatic voltmeter. Provide sufficient series
39.1 This test method covers the evaluation of the continu-
resistance so that rapid collapse of the voltage across the wire
ityoffilm-insulatedmagnetwire,insizesrangingfrom0.0641
occurs when a fault is detected. Rapid recovery of the voltage
to 0.0020 in. (1.628 to 0.051 mm) (AWG No. 14 to 44),
to the test level is also required.
inclusive by dc high voltage.
42.2 Steady-State Short-Circuit Current—The steady-state
39.2 This international standard was developed in accor-
short-circuit current shall be limited by the power supply to 25
dance with internationally recognized principles on standard-
6 5 mAat any test voltage setting. A50 MΩ fault resistance at
ization established in the Decision on Principles for the
the electrode sheaves shall not cause more than a 75% drop in
Development of International Standards, Guides and Recom-
voltage on the high-voltage electrode sheaves at any voltage
mendations issued by the World Trade Organization Technical
setting.
Barriers to Trade (TBT) Committee.
42.3 Fault Detection Circuit—The sensitivity of the fault
40. Terminology
detection circuit shall be such that the threshold fault current
will be as shown in Table 4, with a tolerance of 610%. The
40.1 Definitions of Terms Specific to This Standard:
speed of response of the fault circuit shall be 4 to 6 ms. The
40.1.1 continuity (of magnet-wire insulation), n—thedegree
fault circuit shall be designed to repeat at the rate of 450 6 45
of freedom from defects in the film coating as indicated by the
counts/min when bare wire is passed over the electrode
number of electrical faults per unit length.
sheaves.
40.1.2 fault (in magnet-wire insulation), n—a defect, or
group of defects, within a length of wire being exposed to a
42.4 Fault Counter—The fault counter shall be a digital
proofvoltage,suchthatcurrentthroughthedefect(s)willcause
readout device such as an electromechanical counter or its
the test equipment to indicate one fault.
electronic equivalent. Means of resetting the counter to zero
shall be included. Additional recorder equipment for making
40.1.3 fault detection current, n—the current required to
records of fault patterns is optional.
indicate a fault under specified conditions.
40.1.4 sensitivity (of fault detector circuit), n—theminimum
42.5 Electrode Sheaves:
current required to indicate a fault.
42.5.1 For sizes AWG 14–24 (see 42.8), dual high-voltage
40.1.5 test voltage, n—the open-circuit voltage applied be-
electrodesheavesshallbeconstructedofstainlesssteelwithan
tween the contact sheave and the grounded conductor.
outside diameter of 1.69 in. (43 mm), with a “V” groove such
that the included angle will be 90 6 3°C and the root diameter
41. Significance and Use
will be 1.50 +0, −0.011 in. (38 +0, −0.25 mm). The electrode
sheavecentershallbeseparatedby1.81 60.005in.(46 60.13
41.1 This test provides a method of nondestructive testing
mm).
for continuity of film-insulated magnet wire. Excessive faults
in film insulation could result in failure of wound coils. 42.5.2 The electrode sheaves shall have a contact length of
1.0 +0, −0.1 in. (25.4 +0, −2.5 mm).The electrode sheaves are
42. Apparatus
placed between two grounded guide sheaves and on a line
offset 42 6 3° from a line intersecting the center of the guide
42.1 Warning—Lethal voltages are a potential hazard
sheaves. The two grounded guide sheaves are of the same
during the performance of this test. It is essential that the test
material and their centers are spaced 5.50 in. (140 mm) apart
apparatus, and all associated equipment electrically connected
on a horizontal line. These grounded sheaves are constructed
to it, be properly designed and installed for safe operation.
with an outside diameter of 2 in. (51 mm), with a “V” groove
Solidly ground all electrically conductive parts which it is
such that the included angle will be 45 6 3° and the root
possible for a person to contact during the test. Provide means
diameter will be 1.50 6 0.1 in. (38 6 2.5 mm). (See Fig. 7.)
for use at the completion of any test to ground any parts which
were at high voltage during the test or have the potential for 42.5.3 For sizes AWG 31 to 44, (see 42.8) install the 1-in.
acquiring an induced charge during the test or retaining a diameter dual electrode sheaves. These electrode sheaves are
charge even after disconnection of the voltage source. Thor- madeofstainlesssteelwithanoutsidediameterof1.13 60.01
oughly instruct all operators as to the correct procedures for in. (28.7 6 0.25 mm) and a “V” shaped groove such that the
performing tests safely. When making high voltage tests, included angle will be 90 6 3° and the root diameter will be
particularly in compressed gas or in oil, it is possible for the 1.00+0,−0.01in.(25.4+0,−0.25mm).Thecentersofthedual
energy released at breakdown to be suffıcient to result in fire, electrode sheaves are separated by 1.25 6 0.005 in. (32 6
explosion, or rupture of the test chamber. Design test 0.13mm). The dual electrode sheaves are adjusted to an angle
equipment, test chambers, and test specimens so as to minimize resulting in 1.0 +0, −0.1 in. (25.4 +0, −2.5 mm) length of wire
the possibility of such occurrences and to eliminate the making contact with each electrode sheave. (See Fig. 8.)
D1676 − 17
44. Procedure
44.1 Thread the specimen through the equipment as de-
picted in Figs. 7 and 8. Connect the conductor to the grounded
terminal or to a grounded take-up drum. Payoff equipment
must be designed to prevent damage to the wire under test.
Maintain the open circuit test voltage between the energized
(positive polarity) electrode sheaves and the grounded conduc-
tor as indicated in Table 7.
44.2 When a referee test is required, dry a new wire
specimen at 60 6 3°C (140 6 5°F) for 20 6 5 min in a forced
airoven,cooltoroomtemperature,andtestinaccordancewith
the foregoing procedure.
FIG. 7 Direct-Current High Voltage Continuity Electrodes for
Wire Sizes 14 to 30 AWG 0.0641 to 0.010 in. (1.628 to 0.254 mm)
45. Report
45.1 Report the following information:
45.1.1 Nominal size of conductor,
45.1.2 Type of conductor,
45.1.3 Build,
45.1.4 Insulation type,
45.1.5 Test voltage used, and
45.1.6 Number of faults per 100 ft (30 m).
46. Precision and Bias
46.1 Thistestmethodhasbeeninuseformanyyears,butno
information has been presented to ASTM upon which to base
FIG. 8 Direct-Current High Voltage Continuity Electrodes for
astatementofprecision.Noactivityisplannedtodevelopsuch
Wire Sizes 25 to 44 AWG 0.0179 to 0.0020 in. (0.455 to 0.051 mm)
information.
46.2 Thistestmethodhasnobiasbecausethevalueforhigh
dc voltage continuity is determined solely in terms of this
42.5.4 For sizes AWG 25 to 30, either pair of high voltage
method.
dual electrode sheaves described above can be used.
CONTINUITY, DC LOW VOLTAGE
42.6 Ground Insulation for Electrode Sheaves—The ground
insulation for the electrode sheaves must be a high-resistivity
47. Scope
material, nonhygroscopic and easily cleaned, and dimensioned
so as to support a minimum of 3000 V direct current indefi-
47.1 This test method covers the evaluation of the continu-
nitely. All edges of the electrode sheaves must be rounded to
ity of insulation of film-insulated magnet wire 0.00176 in.
minimize corona.
(0.0447mm)(AWG45)andsmallerindiameter,asdetectedby
a dc voltage.
42.7 Damping Resistor—A 0.25-W surge damping resistor
of4.7MΩ 610%mustbeinstalledinthehighvoltagelineat
47.2 This international standard was developed in accor-
the electrode sheaves connection. No shielding is used on the
dance with internationally recognized principles on standard-
high voltage lead since a minimum capacitance to ground is
ization established in the Decision on Principles for the
sought during switching and counting events.
Development of International Standards, Guides and Recom-
mendations issued by the World Trade Organization Technical
42.8 Wire Handling Equipment —The test device includes
Barriers to Trade (TBT) Committee.
such wire handling equipment as will provide the wire speed
stipulated and is capable of handling wire sizes 14 through 44
AWG. A length indicator with a preset shutoff feature is
included so that exact lengths are monitored. The drive motor
TABLE 7 DC Volts ±5 %
must be of the brushless type and have sufficient power to
Heavy or Triple or
maintain a speed pf 60 63ft(18 6 1 m)/min under the
AWG Size Single Quadruple
Grade 1 Grade 2
heaviest load.
Copper
42.9 Forced-Air Oven, see Specification D5423. 14 to 24 1000 1500 2000 2500
25 to 30 750 1000 1500 2000
31 to 35 500 750 1000 . . .
43. Test Specimen
36 to 44 350 500 750 . . .
Aluminum
43.1 Ensure by visual inspection that the 100-ft (30-m)
14–24 750 1500 . . . . . .
specimenoffilm-insulatedmagnetwireisundamagedandfree
25–28 500 1000 . . . . . .
from contamination.
D1676 − 17
48. Terminology 52.2 Apply the test voltage of 20 Vdc between the conduc-
torandtheconductingbath.Thefaultcircuitryshallbelimited
48.1 Definitions of Terms Specific to This Standard:
to 20 mA. When testing wire for faults, the resistance of the
48.1.1 continuity (of magnet wire insulation), n—the degree
wire accumulated on the take-up spool shall not exceed 50%
of freedom from defects in the film coating as indicated by the
ofthelowervalueofthespecifiedresistancerange.Pass100ft
number of electrical faults per unit length.
(30 m) of insulated wire through the conducting bath, (without
elongating the wire) at a speed of 100 ft/min (30 m/min)
49. Significance and Use
610%.
49.1 This test method provides a low voltage test for
52.3 Calibrate the counting circuit for the specific range of
continuity of film-insulated magnet wire. Faults in the film
resistance with the conducting bath in the circuit and the
insulation could result in failure of wound coils.
conductor at ground potential.
50. Apparatus
53. Report
50.1 ElectrodeBath—Thebathshallbe1.0 60.06in.(25 6
2mm)longsothatnopointonthewirewillremaininthebath
53.1 Report the following information:
for more than 0.09 s. The electrode material is mercury, salt
53.1.1 Nominal conductor size,
water solution, or other conductive material as agreed upon
53.1.2 Conductor type,
between user and supplier.
53.1.3 Insulation type,
53.1.4 Build,
50.2 Counting Circuit, capable of recording 10 6 1 count/s
a
...