M22759

M22759 Wire

Allied Wire & Cable offers a premium selection of M22759 wire, engineered for high-temperature applications in the military and aerospace sectors. This single-conductor wire can withstand temperatures ranging from -65°C to 260°C, ensuring reliable performance in extreme conditions. Our M22759 wire features insulation options such as PTFE, FEP, and ETFE, providing excellent resistance to chemicals, alkalis, hydraulic fluids, and fuels. The conductors, available in tin, silver, or nickel-plated copper, or high-strength copper alloy, offer exceptional resistance to corrosion and oxidation. Choose Allied Wire & Cable for unmatched durability and performance in demanding environments.

Additional Information

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.

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 like 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 identical, and it is common practice to refer to them as M22759 standards.

How is M22759 Wire Constructed?

M22759 wire is constructed with high-strength, lightweight materials designed to withstand harsh conditions. It features stranded conductors made from plated copper or plated high-strength copper alloys. Tin plating improves solderability and corrosion resistance and is commonly used for its lower cost. Silver plating provides better high-temperature properties, reduces wire resistance, and improves high-frequency skin effect. Nickel plating offers excellent high-temperature properties and corrosion resistance but requires special solder flux or crimped joints for joining. Copper alloys provide higher tensile strength, good conductivity, and resist softening at higher temperatures than pure copper.

The insulation materials used in M22759 wire are chosen for their high-performance characteristics. PTFE (Polytetrafluoroethylene) offers excellent high-temperature properties (up to 260°C), chemical resistance, and a low coefficient of friction. FEP (Fluorinated Ethylene Propylene) is transparent, with excellent low friction properties and a maximum usable temperature of 200°C. ETFE (Ethylene Tetrafluoroethylene) is strong and lightweight, with a maximum temperature rating of 150°C. XL-ETFE (Cross-linked ETFE) has thermoset properties with slightly improved high-temperature characteristics. FP/PI tape, made from fluoropolymer (e.g., Tefzel™) and polyamide insulation, provides high-temperature insulating capabilities.

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), while braid materials often consist of PTFE-coated fiberglass.

What are Common Applications of M22759 Wire?

M22759 wire is widely used in the aerospace and defense industries due to its exceptional high-temperature performance and resistance to chemicals, radiation, and abrasion. It is ideal for aircraft, spacecraft, and military vehicles, ensuring reliable performance in critical systems. Additionally, M22759 wire is utilized in high-stress environments such as industrial machinery and medical devices, where durability and reliability are paramount. This wire is also suitable for use in commercial aviation and marine applications, where it provides robust and dependable electrical connections.

Are There Alternatives to M22759 Wire?

M22759 wire, with its stringent military specifications and high-temperature resilience, stands out as a specialized option in the wiring industry, making it difficult to find an exact alternative that matches its unique combination of properties. While there are wires with similar high-temperature capabilities, such as Tefzel and Kynar insulated wires, they typically do not offer the same comprehensive resistance to chemicals, abrasion, and extreme environmental conditions. These alternatives might suffice in less demanding applications but often fall short in military or aerospace environments where maximum durability and reliability are crucial. Thus, for applications requiring the highest standards of performance, particularly in harsh or critical settings, there is no true substitute for M22759 wire.

M22759 Wires Quick Reference Table

Additional M22759 Wire Reading

For more information, you can visit:

• M22759 Wire Informatic
• M22759/16-19 vs. M22759/32-35

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