Magnet Wire General Engineering Data Bare and Film Insulated Copper and Aluminum
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1 Magnet Wire General Engineering Data Bare and Film Insulated Copper and Aluminum CABLE
2 Magnet Wire General Engineering Data Bare and Film Insulated Copper and Aluminum Forward This booklet contains engineering data for bare and film insulated conductors (copper and aluminum). It is to be used in conjunction with the individual product sheets. has combined established abilities in magnet wire engineering and production with large scale manufacturing facilities to provide a source of outstanding copper and aluminum magnet wires. The data presented in this booklet is consistent with NEMA MW 1000 specifications and is applicable for all film and insulation types. The data is given to help in the application and design choices of copper and aluminum magnet wire. All information contained herein is believed to be reliable and accurate. Note that it may not be all inclusive nor entirely suitable to all local codes and practices; and therefore they should first be confirmed by the user. The information found is this guide is given and accepted at the user s risk and assumes no responsibility for results obtained or damage inherent from use of the information in whole or in part. It should also be noted that metric units, given in this catalogue, are approximate equivalents to those of the English system of measures, and thus are given as information only. Table of Contents Forward/Table of Contents 1 Bare Wire Data Comparison, AWG and IEC R-40 2, 3 Annealed Copper 4, 5 Annealed Aluminum 6, 7 Film Insulated Dimensions AWG Sizes, Copper 8, 9 Half AWG Sizes, Copper 10,11 AWG Sizes, Aluminum 12,13 Half AWG Sizes, Aluminum 14,15 Recommended Winding Tensions Copper and Aluminum 16 Winding Space Factor Chart 17 Physical Constants at 20 C 18 Formula for Calculating Weights and Resistance at 20 C 19 Square Wire Data Annealed Copper 20 Annealed Aluminum 21 Square and Rectangular Wire Data Copper and Aluminum 22 Resistance Variation with Temperature 23 Factors for Converting Copper Resistance to 20 C 24 Aluminum Resistance to 20 C 25 Variations in Conductor Resistance due to Diameter Tolerance 26 Conversion Chart by Printed in Canada. 1
3 Comparison between AWG and IEC R-40 Series Bare Wire Diameters AWG AWG BARE WIRE NOM. DIA. NOM.** NOM. R-40 % AWG NOMINAL DIAMETER R-40 SERIES AWG AREA SERIES AREA NOM. DIA. NOM. AREA inches millimeters* millimeters millimeters 2 millimeters 2 R-40 to AWG R-40 to AWG
4 Comparison between AWG and IEC R-40 Series Bare Wire Diameters (cont d) AWG AWG BARE WIRE NOM. DIA. NOM.** NOM. R-40 % AWG NOMINAL DIAMETER R-40 SERIES AWG AREA SERIES AREA NOM. DIA. NOM. AREA inches millimeters* millimeters millimeters 2 millimeters 2 R-40 to AWG R-40 to AWG * These diameters are rounded numbers calculated from the inch value. ** The nominal areas of AWG wires have been calculated in square inches and then converted to square millimeters. The differences in diameter and area have been calculated from values more precise than those shown in the table. 3
5 Bare Wire Data/Annealed Copper AWG Sizes AWG BARE WIRE DIAMETER NOMINAL AREA RESISTANCE AT 20 C PHYSICAL DATA FOR NOMINAL DIAMETER AWG Minimum Nominal Maximum Min. Dia. Nom. Dia. Max. Dia. cir. sq. sq. ohms/ ohms/ ohms/ ohms/ ohms/ ohms/ in mm in mm in mm mils mils mm 1000ft km 1000ft km 1000ft /km 1000 ft kg/km ft/lb m/kg
6 Bare Wire Data/Annealed Copper Half AWG Sizes AWG BARE WIRE DIAMETER NOMINAL AREA RESISTANCE AT 20 C PHYSICAL DATA FOR NOMINAL DIAMETER AWG Minimum Nominal Maximum Min. Dia. Nom. Dia. Max. Dia. cir. sq. sq. ohms/ ohms/ ohms/ ohms/ ohms/ ohms/ in mm in mm in mm mils mils mm 1000ft km 1000ft km 1000ft /km 1000 ft kg/km ft/lb m/kg
7 Bare Wire Data/Annealed Aluminum AWG Sizes AWG BARE WIRE DIAMETER NOMINAL AREA RESISTANCE AT 20 C PHYSICAL DATA FOR NOMINAL DIAMETER AWG Minimum Nominal Maximum Min. Dia. Nom. Dia. Max. Dia. cir. sq. sq. ohms/ ohms/ ohms/ ohms/ ohms/ ohms/ in mm in mm in mm mils mils mm 1000ft km 1000ft km 1000ft /km 1000 ft kg/km ft/lb m/kg 1/ /
8 Bare Wire Data/Annealed Aluminum Half AWG Sizes AWG BARE WIRE DIAMETER NOMINAL AREA RESISTANCE AT 20 C PHYSICAL DATA FOR NOMINAL DIAMETER AWG Minimum Nominal Maximum Min. Dia. Nom. Dia. Max. Dia. cir. sq. sq. ohms/ ohms/ ohms/ ohms/ ohms/ ohms/ in mm in mm in mm mils mils mm 1000ft km 1000ft km 1000ft /km 1000 ft kg/km ft/lb m/kg 1/ /
9 Film Insulated Data Copper AWG Sizes AWG LIGHT BUILD SINGLE BUILD AWG OVERALL DIAMETER NOMINAL WEIGHT * OVERALL DIAMETER NOMINAL WEIGHT * Minimum Nominal Maximum Minimum Nominal Maximum in mm in mm in mm 1000 ft kg/km in mm in mm in mm 1000 ft kg/km * Nominal Weight, see page 19 8
10 Film Insulated Data Copper AWG Sizes AWG HEAVY BUILD TRIPLE BUILD AWG OVERALL DIAMETER NOMINAL WEIGHT * OVERALL DIAMETER NOMINAL WEIGHT * Minimum Nominal Maximum Minimum Nominal Maximum in mm in mm in mm 1000 ft kg/km in mm in mm in mm 1000 ft kg/km * Nominal Weight, see page 19 9
11 Film Insulated Data Copper Half AWG Sizes AWG LIGHT BUILD SINGLE BUILD AWG OVERALL DIAMETER NOMINAL WEIGHT * OVERALL DIAMETER NOMINAL WEIGHT * Minimum Nominal Maximum Minimum Nominal Maximum in mm in mm in mm 1000 ft kg/km in mm in mm in mm 1000 ft kg/km * Nominal Weight, see page 19 10
12 Film Insulated Data Copper Half AWG Sizes AWG HEAVY BUILD TRIPLE BUILD AWG OVERALL DIAMETER NOMINAL WEIGHT * OVERALL DIAMETER NOMINAL WEIGHT * Minimum Nominal Maximum Minimum Nominal Maximum in mm in mm in mm 1000 ft kg/km in mm in mm in mm 1000 ft kg/km * Nominal Weight, see page 19 11
13 Film Insulated Data Aluminum AWG Sizes AWG LIGHT BUILD SINGLE BUILD AWG OVERALL DIAMETER NOMINAL WEIGHT * OVERALL DIAMETER NOMINAL WEIGHT * Minimum Nominal Maximum Minimum Nominal Maximum in mm in mm in mm 1000 ft kg/km in mm in mm in mm 1000 ft kg/km * Nominal Weight, see page 19 12
14 Film Insulated Data Aluminum AWG Sizes AWG HEAVY BUILD TRIPLE BUILD AWG OVERALL DIAMETER NOMINAL WEIGHT * OVERALL DIAMETER NOMINAL WEIGHT * Minimum Nominal Maximum Minimum Nominal Maximum in mm in mm in mm 1000 ft kg/km in mm in mm in mm 1000 ft kg/km * Nominal Weight, see page 19 13
15 Film Insulated Data Aluminum Half AWG Sizes AWG LIGHT BUILD SINGLE BUILD AWG OVERALL DIAMETER NOMINAL WEIGHT * OVERALL DIAMETER NOMINAL WEIGHT * Minimum Nominal Maximum Minimum Nominal Maximum in mm in mm in mm 1000 ft kg/km in mm in mm in mm 1000 ft kg/km * Nominal Weight, see page 19 14
16 Film Insulated Data Aluminum Half AWG Sizes AWG HEAVY BUILD TRIPLE BUILD AWG OVERALL DIAMETER NOMINAL WEIGHT * OVERALL DIAMETER NOMINAL WEIGHT * Minimum Nominal Maximum Minimum Nominal Maximum in mm in mm in mm 1000 ft kg/km in mm in mm in mm 1000 ft kg/km * Nominal Weight, see page 19 15
17 Recommended Winding Tensions Copper and Aluminum AWG NOMINAL DIAMETER COPPER ALUMINUM AWG inches millimeters 8500 PSI 598 kg/cm PSI 387 kg/cm lbs 126 kg 180 lbs 81.6 kg lbs 100 kg 143 lbs 64.8 kg lbs 79.4 kg 113 lbs 5.12 kg lbs 63.0 kg 90.0 lbs 40.8 kg lbs 49.9 kg 71.4 lbs 32.4 kg lbs 39.5 kg 56.4 lbs 25.6 kg lbs 33.4 kg 44.8 lbs 20.3 kg lbs 24.9 kg 35.5 lbs 16.1 kg lbs 19.9 kg 28.3 lbs 12.8 kg lbs 15.6 kg 22.3 lbs 10.1 kg lbs 12.5 kg 17.8 lbs 8.07 kg lbs 9.99 kg 14.1 lbs 6.53 kg lbs 7.85 kg 11.2 lbs 5.08 kg lbs 6.26 kg 8.90 lbs 4.04 kg lbs 4.94 kg 7.05 lbs 3.20 kg lbs 3.89 kg 5.55 lbs 2.52 kg lbs 3.10 kg 4.42 lbs 2.00 kg lbs 2.46 kg 3.51 lbs 1.59 kg lbs 1.94 kg 2.77 lbs 1.26 kg lbs 1.54 kg 2.20 lbs.998 kg lbs 1.23 kg 1.75 lbs.794 kg lbs.975 kg 1.39 lbs.630 kg lbs.771 kg 1.10 lbs.499 kg lbs.612 kg 13.9 oz.394 kg lbs.485 kg 11.0 oz.312 kg oz.385 kg 6.88 oz.195 kg oz.303 kg oz.240 kg oz.194 kg oz.152 kg oz.120 kg oz 95.0 g oz 75.7 g oz 61.2 g oz 48.5 g oz 36.9 g oz 29.2 g oz 23.7 g oz 18.9 g oz 14.7 g oz 12.1 g 44 16
18 Winding Space Factor Chart Winding Space Factors (basis square lay) Chart expresses percentage of cross sectional area occupied by bare conductor. 17
19 Physical Constants at 20 C Property Annealed Copper Annealed Aluminum Volume electrical conductivity minumum percent I.A.C.S Density lb/in kg/m Weight resistivity ohm-circular mil/ft ohm-mm 2 /m x x10-3 Volume resistivity micro-ohm-inch micro-ohm-mm Temperature coefficient of resistance ohm/ C Specific heat cal/gm/ C Coefficient of thermal conductivity cal/sec/cm 2 /cm/ C Coefficient of linear expansion/ C
20 Formula for Calculating Weights and Resistances at 20 C Copper Aluminum Weight lb/1000 ft 3854 A 1172 A kg/km a a Length ft/lb A A m/kg a a Resistance ohm/1000 ft A A ohm/km a a ohm/lb A 2 A 2 ohm/kg a 2 a 2 A = nominal cross sectional area of wire in square inches. a = nominal cross sectional area of wire in square millimeters. 19
21 Square Wire Data Annealed Copper Square AWG Sizes AWG DIMENSIONS NOMINAL AREA NOMINAL RESISTANCE AT 20 C PHYSICAL DATA FOR AWG NOMINAL DIMENSIONS Minimum Nominal Maximum cir sq. sq. ohms/ ohms/ ohms/ ohms/ kg/ ft/ m/ in mm in mm in mm mils in mm 1000 ft km lb kg 1000 ft km lb kg Bare Wire Characteristics for all Square and Rectangular Copper Products (corner radii) SPECIFIED THICKNESS CORNER RADIUS AREA REDUCTION WEIGHT REDUCTION Inches Millimeters sq. mils sq. millimeters 1000 ft kg/km Width.189" Width 4.801mm Width.189" Width 4.801mm Width.189" Width 4.801mm under to under to under to under to under to under to Inches Millimeters.189" 751" 4.801mm mm.189".751" 4.801mm mm.189".751" 4.801mm mm Under.061 Under Round Round Round Round (a) (a) (b) (b) Edge Edge Edge Edge Based on ASTM Specification B48-68 (a) = Rounded edge area reduction in square mils is T 2, where T is wire thickness in inches. (b) = Rounded edge area reduction in square millimeters is.2146 t 2, where t is wire thickness in millimeters. 20
22 Square Wire Data Annealed Aluminum Square AWG Sizes AWG DIMENSIONS NOMINAL AREA NOMINAL RESISTANCE AT 20 C PHYSICAL DATA FOR AWG NOMINAL DIMENSIONS Minimum Nominal Maximum cir sq. sq. ohms/ ohms/ ohms/ ohms/ kg/ ft/ m/ in mm in mm in mm mils in mm 1000 ft km lb kg 1000 ft km lb kg 1/ / Bare Wire Characteristics for all Square and Rectangular Aluminum Products (corner radii) SPECIFIED THICKNESS CORNER RADIUS AREA REDUCTION WEIGHT REDUCTION Inches Millimeters sq. mils sq. millimeters 1000 ft kg/km Width.189" Width 4.801mm Width.189" Width 4.801mm Width.189" Width 4.801mm under to under to under to under to under to under to Inches Millimeters.189" 751" 4.801mm mm.189".751" 4.801mm mm.189".751" 4.801mm mm Under.061 Under Round Round Round Round (a) (a) (b) (b) Edge Edge Edge Edge Based on ASTM Specification B (a) = Rounded edge area reduction in square mils is T 2, where T is wire thickness in inches. (b) = Rounded edge area reduction in square millimeters is.2146 t 2, where t is wire thickness in millimeters. 21
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