M22759

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.

Additional Information

What are the MIL-spec M22759 and SAE AS22759 standards?

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.

What are the differences between Mil-Spec 22759 and Mil-Spec 16878?

Both Mil-Spec 22759 and Mil-Spec 16878 are high-performance electrical wires used in military, aerospace, and other applications where high reliability is vital. Although both wire specifications are typically used in military environments, Mil-Spec 22759 wire is more commonly used in avionics, while Mil-Spec 16878 wire is more commonly used in high-temperature applications such as engines and other mechanical components. Choosing between Mil-Spec 22759 and Mil-Spec 16878 wire is dependent on the specific requirements of the intended application. Mil-Spec 22759 typically has a wider rated temperature range, along with a higher voltage rating than Mil-Spec 16878 wire. Another different between Mil-Spec 22759 and Mil-Spec 16878 are the common insulation types used. Mil-Spec 22759 typically utilizes cross-linked ETFE insultation, while Mil-Spec 16878 commonly used PTFE insulation.

M22759 Wires Quick Reference Table

Contact us for further information on selecting and using M22759 wires.

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