The commonly used metal conductor materials include copper, aluminum, silver, nickel-plated steel and tinned copper. Copper is most often used due to its high electrical conductivity and low cost. Aluminum is also widely used because it is lightweight and corrosion resistant. It also offers better thermal performance than copper or silver however it does have lower electrical conductivity which can make it less efficient as a conductor material in certain applications. Silver offers superior electrical conductivity but is much more expensive than other options. Nickel-plated steel provides increased mechanical strength which can be beneficial in certain applications while tinned copper offers improved corrosion resistance over plain copper wire or cable.
Coatings
Polyvinyl chloride (PVC) is one of the most common insulation materials used in cables due to its flexibility, low cost, fire retardant properties and ability to withstand moisture and chemicals. Ethylene Propylene Rubber (EPR) is another popular choice that provides higher dielectric strength than PVC as well as better resistance against ozone deterioration and temperature extremes. Other insulation materials include fluorinated ethylene propylene (FEP), cross-linked polyethylene (XLPE), silicone rubber (SR), chlorinated polyethylene (CPE) and kynar® PVDF among others each with their own unique set of properties that may make them suitable for specific applications or environments where other traditional insulation materials may not be suitable for use.
The type of conductor material chosen for an application depends on the required performance requirements such as current carrying capacity or mechanical strength while the choice of insulation coating should be based on factors such as operating temperature range or exposure to chemicals or moisture present in an environment which can have an effect on the longevity of the cable assembly over time if not properly specified during design phase. It’s important to factor all these considerations into account when selecting cables for your specific application so you can ensure you are getting the most out of your investment in terms of both performance and life expectancy of your cable assemblies. With careful consideration given to both conductor material selection as well as insulating coating type you will be able to get optimal performance with maximum longevity from your cable assemblies regardless of what kind of environment they are being used in!
During World War II, the US government recognized the need for increased standardization of military equipment, discovering that American screws, bolts and nuts did not fit British equipment properly, which meant they could not be interchanged. Cue a period of mass standardization, which was eventually followed by the cancelation of many standards that were considered to be restrictive and stifling innovation. What remains today is a range of US government defense standardizations, of which ‘MIL-SPEC’ is one. Others include MIL-STD (Defense Standard), MIL-PRF (Defense Perfomance), and MIL-DTL (Defense Detail) specifications.
Mil-Spec wire and cable has a broad range of applications, due to its high performance in extreme high and low temperatures, with high frequency tolerances and stable electrical characteristics to minimize power loss. The nature of these certified products makes them ideal for demanding military, marine and aerospace applications - such as military ground vehicles, aircraft cable, shielding and protective covering. Numerous companies worldwide manufacture Mil-Spec certified wire and cable, and all are subject to the same strict guidelines. This thankfully means that regardless of the manufacturer, you can trust these products to do the job effectively in the harshest of environments. The cost of Mil-Spec wire and cable however, can vary considerably by manufacturer, so unless you’re working to an unlimited budget (who is?), be sure to shop around for the most cost-efficient source. Here at WAVE, we have access to the whole of the market, which means we can source high quality functional equals from non-branded manufacturers, as well as from the major industry players. We can rapidly source Mil-Spec wire, cable and connectors in a variety of styles, sizes and conductors to suit your project requirements. Never march blindly into the arms of the large manufacturers first. It could be the costliest mistake you will NEVER know you made. Happy spec’ing Jeff
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