What Is M22759 Wire?
M22759 wire is a high-temperature, single-conductor wire originally specified for military use and manufactured under the Mil-W-22759 specification. Most wires of this type can handle temperatures between 200 degrees Celsius and 260 C and retain their properties at very low temperatures. Common insulation materials include fluoropolymers like polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), and ethylene tetrafluoroethylene (ETFE). All M22759 wires use tin-, silver-, or nickel-plated copper wire or high-strength copper alloy that resists corrosion and oxidation at high temperatures as well as chemicals, alkalis, hydraulic fluids, and fuel.
MIL-spec M22759 and SAE AS22759
MIL-spec wires have a long history and were initially developed to standardize wires and cables used in military equipment. Military standards, such as Mil-W-22759, have onerous testing and verification requirements to ensure wires perform correctly under arduous conditions. The M22759 standard transitioned to SAE AS22759 in 2004 and the original military standards were canceled. However, these two standards are essentially identical, and it is common practice to still refer to them as M22759 standards.
M22759 Wire Construction
This specification covers a wide range of wire types, although with many similarities.
Conductors
Available in a range of sizes, M22759 use stranded conductors made from plated copper or plated high-strength copper alloys. Types of plating include:
- Tin plating: Commonly used because of its lower cost, tin plating improves solderability and corrosion resistance.
- Silver plating: Silver plating has better high-temperature properties than tin-plating, and silver reduces wire resistance, improves high-frequency skin effect, and has good solderability.
- Nickel plating: Nickel plating has good high-temperature properties and excellent corrosion resistance, but you can't join it except by using a special solder flux or crimped joints.
- Copper alloys: Alloyed copper wires have a higher tensile strength, good conductivity, and resist softening at higher temperatures than copper.
Insulation
Common insulation materials include:
- PTFE: Polytetrafluoroethylene is a fluoropolymer with good high-temperature properties (up to 260 C), excellent chemical resistance, and a low coefficient of friction.
- FEP: Fluorinated ethylene propylene is a transparent fluoropolymer with excellent low friction properties and a maximum usable temperature of 200 C.
- ETFE: Ethylene tetrafluoroethylene is a strong and lightweight fluorine-based plastic with a maximum temperature rating of 150 C.
- XL-ETFE: A cross-linked version of ETFE that has thermoset properties and slightly improved high-temperature characteristics.
- FP/PI tape: A high-temperature insulating tape made from a fluoropolymer, such as Tefzel™ and polyamide insulation.
Jacket and Braid
Some M22759 wires have an external jacket or braid for improved abrasion resistance and protection. Jacket materials include PTFE, XL-ETFE, polyvinylidene fluoride (PVDF), and polyamide (PI). Braid materials used are PTFE coated fiberglass.
M22759 Applications
Common applications for M22759 wires are in aerospace applications and for military and civilian aircraft. They're especially useful in harsh aircraft engine environments and for control surfaces. You can use M22759 wires in areas subject to severe weather and moisture-prone (SWAMP) applications.
M22759 Wires Quick Reference Table
| Mil-Specification | Conductor | Insulation | Jacket | Shield | Temperature Rating (°C) |
Voltage |
|---|---|---|---|---|---|---|
| M22759/1 | Silver-Plated Copper | FEP | PTFE | Braided PTFE coated fiberglass | 200 | 600 |
| M22759/2 | Nickel-Plated Copper | PTFE | PTFE | Braided PTFE coated fiberglass | 260 | 600 |
| M22759/3 | Silver-Plated Copper | FEP | PTFE | Braided PTFE coated fiberglass | 260 | 600 |
| M22759/4 | Silver-Plated Copper | FEP | PTFE | Braided PTFE coated fiberglass | 200 | 600 |
| M22759/5 | Silver-Plated Copper | Mineral Filled PTFE | 200 | 600 | ||
| M22759/6 | Nickel-Plated Copper | Mineral Filled PTFE | 260 | 600 | ||
| M22759/7 | Silver-Plated Copper | Mineral Filled PTFE | 200 | 600 | ||
| M22759/8 | Nickel-Plated Copper | Mineral Filled PTFE | 260 | 600 | ||
| M22759/9 | Silver-Plated Copper | PTFE | 200 | 1000 | ||
| M22759/10 | Nickel-Plated Copper | PTFE | 260 | 1000 | ||
| M22759/11 | Silver-Plated Copper | PTFE | 200 | 600 | ||
| M22759/12 | Nickel-Plated Copper | PTFE | 260 | 600 | ||
| M22759/13 | Tin-Coated Copper | FEP | PVDF | 135 | 600 | |
| M22759/14 | Tin-Coated Copper | FEP | PVDF | 135 | 600 | |
| M22759/15 | High-Strength Copper Alloy | FEP | PVDF | 135 | 600 | |
| M22759/16 | Tin-Coated Copper | ETFE | 150 | 600 | ||
| M22759/17 | Silver-Plated High-Strength Copper Alloy | ETFE | 150 | 600 | ||
| M22759/18 | Tin-Coated Copper | ETFE | 150 | 600 | ||
| M22759/19 | Silver-Plated Copper | ETFE | 150 | 600 | ||
| M22759/20 | Silver-Plated High-Strength Copper Alloy | PTFE | 200 | 1000 | ||
| M22759/21 | Silver-Plated High-Strength Copper Alloy | PTFE | 260 | 1000 | ||
| M22759/22 | Nickel-Plated High-Strength Copper Alloy | PTFE | 200 | 600 | ||
| M22759/23 | Silver-Plated High-Strength Copper Alloy | PTFE | 260 | 600 | ||
| M22759/28 | Silver-Plated Copper | PTFE | PI | 260 | 600 | |
| M22759/29 | Nickel-Plated Copper | PTFE | PI | 260 | 600 | |
| M22759/30 | Silver-Plated High-Strength Copper Alloy | PTFE | PI | 200 | 600 | |
| M22759/31 | Nickel-Plated High-Strength Copper Alloy | PTFE | PI | 260 | 600 | |
| M22759/32 | Tin-Coated Copper | XL-ETFE | 160 | 600 | ||
| M22759/33 | Silver-Plated High-Strength Copper Alloy | XL-ETFE | 200 | 600 | ||
| M22759/34 | Tin-Coated Copper | XL-ETFE | XL-ETFE | 160 | 600 | |
| M22759/35 | Silver-Plated High-Strength Copper Alloy | XL-ETFE | XL-ETFE | 260 | 600 | |
| M22759/41 | Nickel-Plated Copper | XL-ETFE | XL-ETFE | 200 | 600 | |
| M22759/42 | Nickel-Plated High-Strength Copper Alloy | XL-ETFE | XL-ETFE | 200 | 600 | |
| M22759/43 | Silver-Plated Copper | XL-ETFE | XL-ETFE | 200 | 600 | |
| M22759/44 | Silver-Plated Copper | XL-ETFE | 200 | 600 | ||
| M22759/45 | Nickel-Plated Copper | XL-ETFE | 200 | 600 | ||
| M22759/46 | Nickel-Plated High-Strength Copper Alloy | XL-ETFE | 200 | 600 | ||
| M22759/80 | Tin-Coated Copper | FP/PI Tape | 150 | 600 | ||
| M22759/81 | Silver-Plated High-Strength Copper Alloy | FP/PI Tape | 200 | 600 | ||
| M22759/82 | Nickel-Plated High-Strength Copper Alloy | FP/PI Tape | 260 | 600 | ||
| M22759/83 | Silver-Plated Copper | FP/PI Tape | 200 | 600 | ||
| M22759/84 | Nickel-Plated Copper | FP/PI Tape | 260 | 600 | ||
| M22759/85 | Tin-Coated Copper | FP/PI Tape | 150 | 600 | ||
| M22759/86 | Silver-Plated Copper | FP/PI Tape | 260 | 600 | ||
| M22759/87 | Nickel-Plated Copper | FP/PI Tape | 260 | 600 | ||
| M22759/88 | Tin-Coated Copper | FP/PI Tape | 150 | 600 | ||
| M22759/89 | Silver-Plated High-Strength Copper Alloy | FP/PI Tape | 200 | 600 | ||
| M22759/90 | Nickel-Plated High-Strength Copper Alloy | FP/PI Tape | 260 | 600 | ||
| M22759/91 | Silver-Plated Copper | FP/PI Tape | 200 | 600 | ||
| M22759/92 | Nickel-Plated Copper | FP/PI Tape | 260 | 600 |
Contact us for further information on selecting and using M22759 wires.
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