MIL-DTL-16878H
3.4.1.4 Silver-coated, copper-clad steel conductors. Silver-coated copper-clad steel conductors shall
conform to class 40A of ASTM B501 with a 40 microinches (minimum) thickness of silver.
3.4.1.5 Nickel-coated copper-clad steel conductors. Nickel-coated copper-clad steel conductors
shall conform to ASTM B559 with a 50 microinches minimum thickness of commercially pure nickel.
3.4.1.6 High-strength copper alloy conductors. High-strength copper alloy conductors shall conform
to ASTM B624. The strands shall be silver- or nickel-coated in accordance with 3.4.1.2 or 3.4.1.3, as
applicable.
3.4.1.7 Tin-coated, copper-clad steel conductors. Tin-coated copper-clad steel conductors shall
conform to ASTM B520.
3.4.2 Insulation and jacket materials. Materials shall be as specified in 3.4.2.1 through 3.4.2.6, as
designated in the applicable specification sheet.
3.4.2.1 Polyvinyl chloride (PVC). PVC or its copolymer polyvinyl acetate shall meet the requirements
of the applicable specification sheet. Note: PVC-insulated wire is not to be used in aerospace
applications or aboard Navy ships.
3.4.2.2 Polyamide (nylon). Polyamide shall conform to ASTM D4066 or, when used in braid, shall
conform to type P of MIL-C-572.
3.4.2.3 Polyethylene (PE). PE shall conform to type II of ASTM D1248, except that colored material
may be used.
3.4.2.4 Silicone rubber. Silicone rubber shall meet the requirements of the applicable specification
sheet.
3.4.2.5 Ethylene-propylene diene elastomer (EPDM). EPDM shall conform to SAE AMS 3249.
3.4.2.6 Cross-linked material. Other materials are acceptable as substitutes for the above materials
provided the cross-linked final product meets the requirements of the applicable specification sheet.
3.4.3 Braid material. The braid, when required by the applicable specification sheet, shall be
synthetic textile conforming to type P of MIL-C-572 or glass yarn conforming to MIL-Y-1140.
3.5 Construction.
3.5.1 Conductors. Conductor construction shall be as specified in table I. Stranding shall be as
specified in table I before insulation. The conductors shall be round in shape, uniform in cross section,
and free from flaws, scales, and other imperfections. Unless otherwise specified (see 6.2), the method of
stranding for AWG sizes 32 (single conductor) through 10 (105 stranding) inclusive, shall be at the option
of the contractor. Rope lay stranding shall be used for AWG sizes 8 (133 stranding) and larger. Length
of lay of finished, stranded conductors shall conform to ASTM B286 or ASTM B173, as applicable.
3.5.2 Insulation. A tight-fitting, continuous coating of insulation shall be added over the conductor
and shall be cured, processed, or maintained to provide for accurate centering of the conductor
(see 3.6.6). The insulation shall be free from splinters, blisters, and other non-homogeneities visible to
the unaided eye. The insulation shall be constructed to be readily stripped from the conductor so that the
conductor is clean for soldering or crimping. A clean conductor shall have no particles of insulation visible
to the unaided eye.
3.5.3 Braid. When specified on the applicable specification sheet, a closely woven braid shall be
applied over the insulation. Braid shall be saturated (or filled and coated) with fungus-, heat-, flame-, and
moisture-resistant lacquers to a smooth finish that shall minimize fraying at the cut ends. Coatings shall
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