MIL-DTL-16878H
be sufficiently translucent so as not to impair the visibility of any underlying color code of the braid
materials when stripes are specified. Color carriers used in braids shall be one carrier (minimum)
revolving in the same direction and shall be composed of synthetic textile or glass yarn (see 3.4.3). The
braid shall not increase the outside diameter of the finished wire by more than the maximum amount
specified in table II.
TABLE II. Outside diameter thickness increase after application of braid.
Diameter over insulation before
Diameter increase
application of braid (inch)
(inch, maximum)
.125 or less
.015
.126 .250
.020
Greater than .250
.035
3.5.4 Jacket. When specified by the applicable specification sheet, a jacket shall be extruded over
the insulation.
3.5.5 Insulation colors. Insulation colors shall conform to MIL-STD-104, class I, except that pastel
colors shall be acceptable when cross-linking is done by irradiation. When insulation surfaces have been
color-coded with inks or dyes, the insulation surfaces shall be nonconductive, permanently fast, and shall
not change, fade, run, or bleed when used in direct sunlight and within the specific temperature rating of
the insulation used.
3.5.5.1 Lay of stripes. When stripes are specified (see 6.2b and 1.2.6), the length of lay of colored
stripes shall be as specified in table III.
TABLE III. Length of lay of stripes.
Finished wire outside diameter
Length of lay
(inch)
(inches, maximum)
.000 to .083
1.00
.084 to .110
1.50
.111 and larger
2.00
3.5.6 Splices. Splices shall not be made in a stranded conductor as a whole; however, individual
strands and solid conductors may be spliced. Splices shall be made by electro-welding or brazing, using
silver composition solder conforming to J-STD-006.
3.6 Performance. Unless otherwise specified herein, all requirements shall be met on finished wire.
3.6.1 Insulation flaws. After application of the primary insulation, the wire shall withstand the spark or
impulse dielectric voltage specified in the applicable specification sheet without breakdown. After
applications of braid or jacket, the finished wire shall withstand the spark or impulse dielectric voltage
specified in the applicable specification sheet without breakdown.
3.6.2 Dielectric withstanding voltage. The wire shall withstand the specified voltage of the applicable
specification sheet for 1 minute (minimum) without breakdown.
3.6.3 Insulation resistance. The insulation resistance shall not be less than the value specified on
the applicable specification sheet.
3.6.4 Conductor resistance. The resistance of the wire conductor shall be not greater than the value
specified in table I.
3.6.5 Cold bend. The wire shall reveal no readily visible cracks in the insulation when subjected to
the cold bending conditions specified on the applicable specification sheet.
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