MIL-DTL-25038J
3.7.2 High temperature endurance. The resistance of the conductor shall not increase more than
15 percent during conditioning at 650 °F.
3.7.3 Bend. A wire shall show no visible cracks when bent around a mandrel with the diameter
specified in the applicable specification sheet.
3.7.4 Wet dielectric. A wire shall show no evidence of electrical breakdown (arcing or flashing)
between the conductor and salt water after being immersed for 5 hours at room temperature and having a
potential of 1,500 V rms at 60Hz applied after the immersion period.
3.7.5 Conductor resistance. The conductor resistance of the finished wire shall be as specified in the
applicable specification sheet.
3.7.6 Fluid immersion. The wire shall meet the bend and wet dielectric requirements of 3.7.3 and
3.7.4 after being immersed for 8 hours at the temperatures and in the types of fluids specified in 4.6.7.
3.7.7 Cold bend. The wire shall show no evidence of cracking of the outer surface of the insulation
and shall meet the wet dielectric requirements of 3.7.4 after being exposed to a cold temperature of -65°F
for 4 hours and bent as specified in the applicable specification sheet.
3.7.8 Flame resistance. The insulation shall be flame resistant. No insulation shall flake or fall off
during exposure to flame up to 2,000°F. At no time shall the insulation resistance be less than 50Ω, and
the flame travel shall not extend beyond the outer marking bands required in the test (see 4.6.10.1).
3.7.9 Wicking. The indicator ink solution shall not wick a distance of more than .250 inch (6.35 mm)
beyond a 2-inch (50.8 mm) immersion depth between any layers or components in the insulation.
3.7.10 Thermal shock. The wire insulation layer, or layers, shall not exhibit shrinkage or expansion
greater than that specified in the applicable specification sheet, when exposed to and stabilized at 500°F
followed by immediate exposure to -67°F and stabilized at that temperature.
3.7.11 Insulation flaws. The finished wire shall withstand a spark-test voltage of 2,500 V rms at 60Hz
or 3kHz, or an impulse dielectric voltage of 5,000V (peak), without breakdown.
3.8 Marking. The finished wire shall be identified by a printed marking applied to the outer surface or
visible through the outer surface. The printed identification shall consist of the following, at intervals of
6 inches (152 mm) to 60 inches (1520 mm), as measured from the end of one complete marking to the
beginning of the succeeding complete marking:
a. PIN (see 1.2).
b. Manufacturer's Commercial and Government Entity (CAGE) code.
The printing shall be green in color in accordance with MIL-STD-104, class 1, except that when the
wire is solid green or any other color against which green is difficult to distinguish, the printing shall be
white. Identification printing shall be applied with the vertical axis of the printed characters lengthwise of
the wire when the nominal diameter of the finished wire is .050 inch (1.27 mm) or smaller. The vertical
axis of the printed characters may be either crosswise or lengthwise of the wire when the nominal
diameter of the wire exceeds .050 inch (1.27 mm). All printed characters shall be complete and legible.
3.8.1 Marking durability. Identification printing shall be capable of withstanding repeated abrasion.
Marking durability is not applicable when printing is under a clear jacket, if used.
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