MIL-DTL-28781E
2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict
between the text of this document and the references cited herein (except for related specification
sheets), the text of this document takes precedence. Nothing in this document, however, supersedes
applicable laws and regulations unless a specific exemption has been obtained.
3. REQUIREMENTS
3.1. First article. When specified (see 6.2 and 6.3), a sample shall be subjected to first article
inspection in accordance with 4.2.
3.2 Materials.
3.2.1 Conductors. The conductors shall utilize number 24 American Wire Gauge (AWG) (nominal
diameter .0201 inch (.511 mm)), tinned solid copper wire, in accordance with ASTM-B33.
3.2.1.1 Joining conductors. Joints made in conductors may be brazed using a silver alloy solder and
a non-acid flux, or welded. Joints shall be butted and shall be free from lumps and sharp projections.
The tensile strength of any section of a conductor joint that was brazed or welded shall be not less than
85 percent of the tensile strength of an adjacent section without a joint.
3.2.1.2 Conductor resistance. The direct current (dc) resistance of each conductor shall not exceed
30 ohms per 1,000-foot (304.8-meter) length, when measured at, or corrected for, 68° F.
3.2.2 Insulation material. The insulation material shall be .010±.002-inch (.254±.051 mm) thick
polyamide material .002±.001 inch (.508±.025 mm) thick shall be placed over the insulation. The outside
diameter of the conductor, including insulation and polyamide material, is to be not greater than .0502
inch (1.275 mm) to permit application of commercially available cable connector devices.
3.2.2.1 Insulation defects. The insulation shall be smooth and free from holes, splits, blisters, and
other imperfections.
3.2.2.2 Cold bend. The finished conductor insulation shall show no evidence of cracking or fracturing
when cold bend tested in accordance with 4.6.4.
3.2.2.3 Color coding of insulation. The color coding shall be as shown in table I to identify each pair
in the completed cable.
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