This series encompasses a group of wires and cables used in aerospace applications due to their superior flammability and arc propagation performance, as well as their high corona resistance. In addition, due to their flexibility and easy installation, the products are a great fit for industrial applications. These constructions can operate continuously at 260°C for voltages meeting the SAE standard, AIR7502, Level 3 and Level 4 (300 to 1000 VDC).

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High-Voltage Composite Wire

These 1,000-volt wires offer lighter weight and smaller diameters compared to similar extruded constructions in applications up to 260°C. They offer exceptional installation characteristics like Seamless™ Wrap PTFE jacket technology and a high-strand-count, nickel-plated copper conductor.

High-Voltage Extruded Wire

Our high-voltage extruded wires are capable of 1,000-volt performance while maintaining excellent flammability and arc-propagation resistance. They are ideal for applications, such as aerospace, that require a cable with excellent safety factors.

Ultra-Flexible High-Voltage Shielded Composite Wire

These 1,000-volt wires offer exceptional flexibility in smaller-diameter, lightweight construction for applications requiring temperatures up to 260 °C. They feature a nickel-plated copper shield, Seamless™ Wrap PTFE jacket technology, and highly flexible conductor strands.

LTE high-performance expanded PTFE dielectric

Ultra-high-temperature, non-asbestos wire

Mil-Spec M22759 wire is designed for severe environment aerospace applications, such as engine controls and SWAMP (Severe Weather and Moisture Prone) areas.

AS22759/5, /6 wire

Mineral-filled PTFE insulation – medium wall.

AS22759/5 and /6 wires have mineral-filled PTFE insulation for high-temperature applications such as aircraft engines, SWAMP zones, and other applications where increased abrasion resistance is required.

For reduced-weight versions of these wires, see AS22759/7 and /8.

See M27500 shield and jackets cable incorporating these wires.

Construction Details

Insulation Extruded PTFE with abrasion-resistant mineral fillers.
Conductor /5: Silver-plated copper
/6: Nickel-plated copper
Colors White preferred.
All 10 basic colors and stripes available to MIL-STD-104.
Identification to AS22759
Performance
Voltage Rating
to 600V
Temperature
Rating
/5: -55 to 200°C
/5: -55 to 260°C

Products Manufactured to this specification are ROHS COMPLIANT.

Dimensions, Resistance, and Weights – M22759/5 (Silver-Plated Conductor)

M22759 P/N AWG Size Stranding Conductor Diameter Insulation Diameter Maximum Weight Maximum Resistance Thermax P/N
Min Max
M22759/5-10-* 10 37/26 0.109   (2.77) 0.172   (4.37) 0.186   (4.72) 48.0 (71.4) 1.19 (3.90) 10-AF3XT-3726
M22759/5-12-* 12 19/25 0.086   (2.18) 0.153   (3.89) 0.167   (4.24) 34.5 (51.3) 1.81 (5.94) 12-AF3XT-1925
M22759/5-14-* 14 19/27 0.068   (1.74) 0.136   (3.45) 0.150   (3.81) 25.0 (37.2) 2.88 (9.45) 14-AF3XT-1927
M22759/5-16-* 16 19/29 0.054   (1.38) 0.120   (3.05) 0.130   (3.30) 18.0 (26.8) 4.52 (14.8) 16-AF3XT-1929
M22759/5-18-* 18 19/30 0.048   (1.22) 0.105   (2.67) 0.115   (2.92) 14.0 (20.8) 5.79 (19.0) 18-AF3XT-1930
M22759/5-20-* 20 19/32 0.038   (0.98) 0.090   (2.29) 0.100   (2.54) 10.0 (14.9) 9.19 (30.1) 20-AF3XT-1932
M22759/5-22-* 22 19/34 0.030   (0.77) 0.080   (2.03) 0.090   (2.29) 8.0 (12.0) 15.1 (49.5) 22-AF3XT-1934
M22759/5-24-* 24 19/36 0.024   (0.61) 0.070   (1.78) 0.080   (2.03) 6.0 (9.0) 24.3 (79.7) 24-AF3XT-1936

Dimensions in inches (mm). Weights in pounds/1000 feet (Kg/1,000 M). Resistance in Ω/1,000 feet (Ω/Km), @20° C.
All values are nominal unless otherwise indicated.
* Add color coding per MIL-STD-104.

Dimensions, Resistance, and Weights – M22759/6 (Nickel-Plated Conductor)

M22759 P/N AWG Size Stranding Conductor Diameter Insulation Diameter Maximum Weight Maximum Resistance Thermax P/N
Min Max
M22759/6-10-* 10 37/26 0.110   (2.79) 0.172   (4.37) 0.186   (4.72) 48.0 (71.4) 1.24 (4.07) 10-AF3XTN-3726
M22759/6-12-* 12 19/25 0.087   (2.21) 0.153   (3.89) 0.167   (4.24) 34.5 (51.3) 1.89 (6.20) 12-AF3XTN-1925
M22759/6-14-* 14 19/27 0.069   (1.75) 0.136   (3.45) 0.150   (3.81) 25.0 (37.2) 3.00 (9.84) 14-AF3XTN-1927
M22759/6-16-* 16 19/29 0.055   (1.40) 0.120   (3.05) 0.130   (3.30) 18.0 (26.8) 4.76 (15.6) 16-AF3XTN-1929
M22759/6-18-* 18 19/30 0.048   (1.23) 0.105   (2.67) 0.115   (2.92) 14.0 (20.8) 6.10 (20.0) 18-AF3XTN-1930
M22759/6-20-* 20 19/32 0.039   (0.99) 0.090   (2.29) 0.100   (2.54) 10.0 (14.9) 9.77 (32.1) 20-AF3XTN-1932
M22759/6-22-* 22 19/34 0.031   (0.79) 0.080   (2.03) 0.090   (2.29) 8.0 (12.0) 16.0 (52.5) 22-AF3XTN-1934
M22759/6-24-* 24 19/36 0.024   (0.62) 0.070   (1.78) 0.080   (2.03) 6.0 (9.0) 25.9 (85.0) 24-AF3XTN-1936

Dimensions in inches (mm). Weights in pounds/1000 feet (Kg/1,000 M). Resistance in Ω/1,000 feet (Ω/Km), @20° C.
All values are nominal unless otherwise indicated.
* Add color coding per MIL-STD-104.


AS22759/7, /8 wire

Mineral-filled PTFE insulation – medium wall.

AS22759/7 and /8 wires have reduced weight, mineral-filled PTFE insulation for high-temperature applications such as aircraft engines, SWAMP zones, and other applications where increased abrasion resistance is required.

These wires are reduced-weight versions of AS22759/5 and /6.

See M27500 shield and jackets cable incorporating these wires.

Construction Details

Insulation Extruded PTFE with abrasion-resistant mineral fillers.
Conductor /7: Silver-plated copper.
/8: Nickel-plated copper.
Colors White preferred.
All 10 basic colors and stripes available to MIL-STD-104.
Identification to AS22759
Performance
Voltage Rating
to 600V
Temperature
Rating
/7: -55 to 200°C
/8: -55 to 260°C

Products Manufactured to this specification are ROHS COMPLIANT.

Dimensions, Resistance, and Weights – M22759/7 (Silver-Plated Conductor)

M22759 P/N AWG Size Stranding Conductor Diameter Insulation Diameter Maximum Weight Maximum Resistance Thermax
P/N
Min Max
M22759/7-8-* 8 133/29 0.164   (4.15) 0.215   (5.46) 0.225   (5.72) 76.8 (114) 0.658 (2.16) 8-AF2XT-13329
M22759/7-10-* 10 37/26 0.109   (2.77) 0.154   (3.91) 0.162   (4.11) 41.8 (62.2) 1.19 (3.90) 10-AF2XT-3726
M22759/7-12-* 12 19/25 0.086   (2.18) 0.131   (3.33) 0.137   (3.48) 28.5 (42.4) 1.81 (5.94) 12-AF2XT-1925
M22759/7-14-* 14 19/27 0.068   (1.74) 0.112   (2.84) 0.118   (3.00) 18.6 (27.7) 2.88 (9.45) 14-AF2XT-1927
M22759/7-16-* 16 19/29 0.054   (1.38) 0.099   (2.51) 0.105   (2.67) 13.8 (20.5) 4.52 (14.8) 16-AF2XT-1929
M22759/7-18-* 18 19/30 0.048   (1.22) 0.090   (2.29) 0.094   (2.39) 11.0 (16.4) 5.79 (19.0) 18-AF2XT-1930
M22759/7-20-* 20 19/32 0.038   (0.98) 0.080   (2.03) 0.084  (2.13) 8.1 (12.1) 9.19 (30.1) 20-AF2XT-1932
M22759/7-22-* 22 19/34 0.030   (0.77) 0.071   (1.80) 0.075   (1.91) 6.0 (8.93) 15.1 (49.5) 22-AF2XT-1934
M22759/7-24-* 24 19/36 0.024   (0.61) 0.060   (1.52) 0.064   (1.63) 4.3 (6.40) 24.3 (79.7) 24-AF2XT-1936

Dimensions in inches (mm). Weights in pounds/1000 feet (Kg/1,000 M). Resistance in Ω/1,000 feet (Ω/Km), @20° C.
All values are nominal unless otherwise indicated.
* Add color coding per MIL-STD-104.

Dimensions, Resistance, and Weights – M22759/8 (Nickel-Plated Conductor)

M22759/8-10-*1037/260.110   (2.79)0.154   (3.91)0.162   (4.11)41.8(62.2)1.24(4.07)10-AF2XTN-3726

M22759 P/N AWG Size Stranding Conductor Diameter Insulation Diameter Maximum Weight Maximum Resistance Thermax
P/N
Min Max
M22759/8-12-* 12 19/25 0.087   (2.21) 0.131   (3.33) 0.137   (3.48) 28.5 (42.4) 1.89 (6.20) 12-AF2XTN-1925
M22759/8-14-* 14 19/27 0.069   (1.75) 0.112   (2.84) 0.118   (3.00) 18.6 (27.7) 3.00 (9.84) 14-AF2XTN-1927
M22759/8-16-* 16 19/29 0.055   (1.40) 0.099   (2.51) 0.105   (2.67) 13.8 (20.5) 4.76 (15.6) 16-AF2XTN-1929
M22759/8-18-* 18 19/30 0.048   (1.23) 0.090   (2.29) 0.094   (2.39) 11.0 (16.4) 6.10 (20.0) 18-AF2XTN-1930
M22759/8-20-* 20 19/32 0.039   (0.99) 0.080   (2.03) 0.084  (2.13) 8.1 (12.1) 9.77 (32.1) 20-AF2XTN-1932
M22759/8-22-* 22 19/34 0.031   (0.79) 0.071   (1.80) 0.075   (1.91) 6.0 (8.93) 16.0 (52.5) 22-AF2XTN-1934
M22759/8-24-* 24 19/36 0.024   (0.62) 0.060   (1.52) 0.064   (1.63) 4.3 (6.40) 25.9 (85.0) 24-AF2XTN-1936

Dimensions in inches (mm). Weights in pounds/1000 feet (Kg/1,000 M). Resistance in Ω/1,000 feet (Ω/Km), @20° C.
All values are nominal unless otherwise indicated.
* Add color coding per MIL-STD-104.

MIL-W-81822 (SAE AS81822) wires have solid conductors for wire-wrap termination, with extruded insulation of PTFE, PTFE with polyimide hardcoat, or ETFE. Each insulation type is available with a choice of three silver-plated conductor materials. All are rated at 300 volts.

Although these cables are designed primarily for use in aircraft and ground support equipment, their high performance and versatility makes them ideal in a wide variety of general-purpose electrical and electronic applications.

MIL-DTL-27500 (NEMA WC27500) cables incorporate from one to fifteen M22759, MIL-W-25038, or MIL-DTL-81381 wires, plus a single or double shield and a single or double jacket. MIL-DTL-27500 part numbering system provides for many combinations of cable construction characteristics.

Many of these cables are available with component wires and/or jackets with our unique Seamless Wrap PTFE tape.

Although designed for aerospace use, these wires are ideal for commercial applications which can benefit from their high temperature rating and resistance to abrasions and solvents.

Type E, EE and ET cables feature extruded PTFE insulation with medium (0.010″), heavy (0.015″) and thin (0.006″) wall thicknesses. PTFE insulation provides high reliability, with excellent thermal stability and chemical resistance.

Type E cables are shielded and jacketed cables with extruded FEP or PTFE tape jackets, incorporating MIL-W-16878/4 wires. These component wires are insulated with extruded PTFE, and have either silver-plated copper or nickel-plated copper conductors. Cables with PTFE jackets are available with our unique Seamless Wrap PTFE Insulation tape.

MIL-W-16878 wires (or NEMA HP3 and HP4 spec) are general-purpose, medium and high-temperature hookup wires, with PTFE or FEP insulation. Each insulation type is available in thin, medium, or heavy wall thickness, for voltage ratings from 250 to 1,000 volts. Conductor choices within MIL-W-16878 are solid or stranded copper, high-strength copper alloy, or copper-covered steel; with silver, nickel, or tin plating.

Performance Construction

MIL-W-16878 Slant Sheet Type Voltage Insulation Material Insulation Wall Thickness Conductor Plating Temperature Rating (Max)
MIL-W-16878/4 E 600 PTFE (Extruded) 0.01 Silver 200
MIL-W-16878/5 EE 1000 PTFE (Extruded) 0.015 Silver 200
MIL-W-16878/6 ET 250 PTFE (Extruded) 0.006 Silver 200
MIL-W-16878/11 K 600 FEP (Extruded) 0.01 Silver 200
MIL-W-16878/12 KK 1000 FEP (Extruded) 0.015 Silver 200
MIL-W-16878/13 KT 250 FEP (Extruded) 0.006 Silver 200
MIL-W-16878/20 250 PTFE (Tape) 0.006 Silver 200
MIL-W-16878/21 600 PTFE (Tape) 0.01 Silver 200
MIL-W-16878/22 1000 PTFE (Tape) 0.015 Silver 200
MIL-W-16878/23 ET 250 PTFE (Extruded) 0.006 Nickel 260
MIL-W-16878/24 250 PTFE (Tape) 0.006 Nickel 260
MIL-W-16878/25 E 600 PTFE (Extruded) 0.01 Nickel 260
MIL-W-16878/26 600 PTFE (Tape) 0.01 Nickel 260
MIL-W-16878/27 EE 1000 PTFE (Extruded) 0.015 Nickel 260
MIL-W-16878/28 1000 PTFE (Tape) 0.015 NIckel 260
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