Introduction
The ASTM B800-05 (Reapproved 2015) standard is a critical specification that governs the production and quality assurance of 8000 series aluminum alloy wire for electrical purposes. These wires are widely used in electrical applications, particularly in the construction of conductors for power transmission and distribution. This comprehensive guide aims to provide an in-depth understanding of the ASTM B800-05 standard, its key sections, and its importance in the electrical industry.
Overview and Scope
ASTM B800-05 covers 8000 series aluminum alloys fabricated into round wires in annealed or intermediate tempers suitable for stranding into conductors or for solid single conductors, usually to be insulated. The standard specifies the chemical composition, mechanical properties, construction requirements, and quality assurance for these wires. It is issued under the jurisdiction of ASTM Committee B01 on Electrical Conductors and is the direct responsibility of Subcommittee B01.07 on Conductors of Light Metals.
Key Sections of ASTM B800-05
- Referenced Documents:
- The standard references several other ASTM standards and practices, ensuring comprehensive coverage of all aspects of wire manufacturing and testing. Key references include:
- ASTM B193: Test Method for Resistivity of Electrical Conductor Materials.
- ASTM B557: Test Methods for Tension Testing Wrought and Cast Aluminum- and Magnesium-Alloy Products.
- ASTM B830: Specification for Uniform Test Methods and Frequency.
- ASTM E29: Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications.
- ANSI H35.1: American National Standard Alloy and Temper Designation Systems for Aluminum.
- NIST Handbook 100: Copper Wire Tables.
- NIST Handbook 109: Aluminum Wire Tables.
- The standard references several other ASTM standards and practices, ensuring comprehensive coverage of all aspects of wire manufacturing and testing. Key references include:
- Chemical Composition:
- The aluminum alloys capable of meeting the requirements of this specification are listed in Table 1 of the standard. The chemical composition limits for these alloys ensure high conductivity and corrosion resistance. The alloy and temper designations conform to ANSI H35.1, and the Unified Numbering System (UNS) alloy designations are listed in accordance with Practice E527.
- Mechanical Properties:
- The mechanical properties of the aluminum wires, including tensile strength and elongation, are critical for determining their suitability for electrical applications. The standard specifies that the wire shall conform to the tensile strength and elongation requirements prescribed in Table 3. These properties are determined using tension tests conducted in accordance with ASTM B557.
- Construction Requirements:
- The standard specifies the construction requirements for aluminum alloy wires, including the diameter of the wires and the permissible variations in diameter. The diameter of the wire shall be specified in inches to the nearest 0.0001 inch or in millimeters to the nearest 0.001 mm for wires less than 1.000 mm in diameter, and to the nearest 0.01 mm for wires 1.00 mm in diameter or larger. The actual wire diameter shall not vary from the specified diameter by more than the values shown in Table 5.
- Quality Assurance:
- The producer is responsible for performing all inspection and test requirements unless otherwise specified in the contract. The standard defines lot sizes for inspection and the number of samples required for testing. Quality assurance ensures that the wires meet the specified requirements and are free from defects.
- Dimensional Tolerances:
- Variations from specified dimensions are not to exceed the permissible variations outlined in the standard. This ensures that the wires meet the required dimensional accuracy. For example, the diameter tolerance for wires is specified in Table 5.
- Electrical Properties:
- The electrical properties of the wires, including resistivity and conductivity, are critical for their performance in electrical applications. The standard specifies that the electrical resistivity shall not exceed the values shown in Table 4. The resistivity is measured at 20°C and corrected using the multiplying factors provided in the standard.
- Identification and Marking:
- When specified, wires must be marked according to the requirements outlined in the standard. This includes marking for identification and traceability, which is crucial for quality control and certification. Identification and marking ensure that the wires can be traced back to their production batch and verified for quality.
- Packaging and Shipping:
- The wires must be packaged to provide adequate protection during handling and transportation. Packaging requirements are detailed in the standard, ensuring safe delivery to the end user. Each package must contain only one size, alloy, and temper of material unless otherwise agreed. Proper packaging and shipping ensure that the wires arrive at their destination in good condition.
Detailed Exploration of Key Sections
Chemical Composition
The chemical composition of 8000 series aluminum alloys is a critical factor that determines their properties and suitability for electrical applications. The ASTM B800-05 standard specifies the chemical composition limits for a wide range of aluminum alloys. These limits ensure that the material meets the required purity and alloying element specifications.
Table: Chemical Composition of 8000 Series Aluminum Alloys
| Alloy | UNS | Aluminum (Al) (wt%) | Silicon (Si) (wt%) | Iron (Fe) (wt%) | Copper (Cu) (wt%) | Magnesium (Mg) (wt%) | Zinc (Zn) (wt%) | Boron (B) (wt%) | Other (each) (wt%) | Other (total) (wt%) |
|---|---|---|---|---|---|---|---|---|---|---|
| 8017 | A98017 | 98.52 – 99.12 | 0.10 | 0.55 to 0.8 | 0.10 to 0.20 | 0.01 to 0.05 | 0.05 | 0.04 | 0.03 | 0.10 |
| 8030 | A98030 | 98.65 – 99.54 | 0.10 | 0.30 to 0.8 | 0.15 to 0.30 | 0.05 | 0.05 | 0.001 to 0.04 | 0.03 | 0.10 |
| 8076 | A98076 | 98.36 – 99.26 | 0.10 | 0.6 to 0.9 | 0.04 | 0.08 to 0.22 | 0.05 | 0.04 | 0.03 | 0.10 |
| 8130 | A98130 | 98.42 – 99.27 | 0.15 | 0.40 to 1.0 | 0.05 to 0.15 | – | 0.10 | – | 0.03 | 0.10 |
| 8176 | A98176 | 98.35 – 99.52 | 0.03 to 0.15 | 0.40 to 1.0 | – | – | 0.10 | – | 0.05 | 0.15 |
| 8177 | A98177 | 98.76 – 99.56 | 0.10 | 0.25 to 0.45 | 0.04 | 0.04 to 0.12 | 0.05 | 0.04 | 0.03 | 0.10 |
The chemical composition is determined using suitable chemical or spectrochemical methods, such as those outlined in ASTM E34, E607, and E1251. These methods ensure accurate determination of the alloying elements and impurities.
Mechanical Properties
The mechanical properties of aluminum alloy wires, including tensile strength and elongation, are critical for determining their suitability for electrical applications. The ASTM B800-05 standard specifies the mechanical properties for various tempers of aluminum alloys.
Table: Mechanical Properties of 8000 Series Aluminum Alloy Wires
| Temper | Tensile Strength (ksi) | Tensile Strength (MPa) | Elongation (%) |
|---|---|---|---|
| -O | 8.5 to 16.0 | 59 to 111 | 8.5 |
| -H1X or -H2X | 15.0 to 22.0 | 103 to 152 | 11.0 |
These properties are determined using tension tests conducted in accordance with ASTM B557. The tests involve applying a uniaxial load to a specimen until it fractures, and measuring the resulting stress and strain. The mechanical properties ensure that the wires can withstand the required loads and stresses in their intended application.
Construction Requirements
The construction requirements for aluminum alloy wires are critical for ensuring their mechanical strength and flexibility. The ASTM B800-05 standard specifies the construction requirements for various classes of wires.
For example, the diameter tolerance for wires is specified in Table 5. The tolerances ensure that the wires meet the required dimensional accuracy and can be used in precision applications.
The standard also specifies the requirements for joints in the wires. Joints may be made in drawing stock and in the wire prior to final drawing in accordance with good commercial practice. If agreed upon between the manufacturer and the purchaser, joints may be made during final drawing or in the finished wire by electrical-butt welding, by cold-pressure welding, or by electric-butt, cold-upset welding with specific provisions.
Quality Assurance
Quality assurance is a critical aspect of the ASTM B800-05 standard. The producer is responsible for performing all inspection and test requirements unless otherwise specified in the contract. The standard defines lot sizes for inspection and the number of samples required for testing.
The quality assurance process involves:
- Sampling and testing the material to ensure it meets the specified requirements
- Inspecting the material for defects such as cracks, inclusions, and porosity
- Verifying the chemical composition and mechanical properties
Quality assurance ensures that the wires meet the specified requirements and are free from defects.
Dimensional Tolerances
Dimensional tolerances are critical for ensuring that the wires fit and function correctly in their intended application. The ASTM B800-05 standard specifies the permissible variations from specified dimensions.
Table: Permissible Variations in Diameter
| Specified Diameter (in.) | Permissible Variation (in.) |
|---|---|
| 0.0100 to under 0.0360 | ±0.0005 |
| 0.0360 to under 0.1000 | ±0.0010 |
| 0.1000 to 0.7071 incl. | ±1% |
The tolerances ensure that the wires meet the required dimensional accuracy and can be used in precision applications.
Electrical Properties
The electrical properties of the wires, including resistivity and conductivity, are critical for their performance in electrical applications. The ASTM B800-05 standard specifies the electrical properties for various classes of wires.
Table: Electrical Properties of 8000 Series Aluminum Alloy Wires
| Property | Maximum Value |
|---|---|
| Electrical Resistivity (mm²/m) | 0.028264 |
| Volume Conductivity (% IACS) | 61.0 |
The resistivity is measured at 20°C and corrected using the multiplying factors provided in the standard. The electrical properties ensure that the wires have the necessary conductivity and resistivity for their intended applications.
Identification and Marking
Identification and marking are crucial for quality control and certification. The ASTM B800-05 standard specifies that wires must be marked according to the requirements outlined in the standard. This includes marking for identification and traceability.
Identification and marking ensure that the wires can be traced back to their production batch and verified for quality.
Packaging and Shipping
Proper packaging and shipping are essential for ensuring that the wires arrive at their destination in good condition. The ASTM B800-05 standard specifies the packaging requirements.
The wires must be packaged to provide adequate protection during handling and transportation. Each package must contain only one size, alloy, and temper of material unless otherwise agreed. Proper packaging and shipping ensure that the wires arrive at their destination in good condition.
Importance of ASTM B800-05
The ASTM B800-05 standard is essential for maintaining the quality and performance of 8000 series aluminum alloy wires. By adhering to this standard, manufacturers can ensure that their products meet the stringent requirements necessary for critical electrical applications. This standard also facilitates international trade by providing a common framework for specifying and testing aluminum wires.
Industry Applications
The ASTM B800-05 standard is widely used in various industries, particularly in electrical applications. The following sections explore the applications of the standard in these industries.
Electrical Industry
The electrical industry relies heavily on aluminum wires for their excellent conductivity, lightweight, and corrosion resistance. The ASTM B800-05 standard ensures that aluminum wires used in electrical applications meet the stringent quality and performance requirements.
For example, aluminum 8000 series wires are commonly used in overhead power lines due to their high conductivity and lightweight. The construction requirements specified in ASTM B800-05 ensure that the wires have the necessary mechanical strength and flexibility for overhead applications.
The electrical properties specified in the standard ensure that the wires have the necessary conductivity and resistivity for efficient power transmission.
Construction Industry
The construction industry uses aluminum wires for their lightweight, corrosion resistance, and ease of installation. The ASTM B800-05 standard ensures that aluminum wires used in construction applications meet the required quality and performance standards.
For example, aluminum 8000 series wires are commonly used in building wiring and electrical installations due to their high conductivity and corrosion resistance. The chemical composition and mechanical properties specified in ASTM B800-05 ensure that the wires meet the required performance standards.
The quality assurance and dimensional tolerances specified in the standard ensure that the wires are free from defects and meet the required dimensional accuracy.
Manufacturing Industry
The manufacturing industry uses aluminum wires for their excellent conductivity, corrosion resistance, and good mechanical properties. The ASTM B800-05 standard ensures that aluminum wires used in manufacturing applications meet the required quality and performance standards.
For example, aluminum 8000 series wires are commonly used in electrical equipment and machinery due to their high conductivity and good mechanical properties. The heat treatment and quality assurance requirements specified in ASTM B800-05 ensure that the wires meet the required mechanical properties and are free from defects.
The electrical properties specified in the standard ensure that the wires have the necessary conductivity and resistivity for efficient electrical performance.
Official ASTM B800-05:
PDF eBook of “ASTM B800-05(2021) Standard Specification for 8000 Series Aluminum Alloy Wire for Electrical Purposes—Annealed and Intermediate Tempers”
For more detailed information, refer to the full ASTM B800-05 document available here:
Validation and Verification
To ensure the accuracy and validity of the information provided, the following reputable sources were consulted:
- ASTM International: The primary source for the ASTM B800-05 standard and related documents. The official ASTM website (www.astm.org) provides access to the full text of the standard and other referenced documents.
- The Aluminum Association: Provides guidelines and standards for aluminum alloys, including chemical composition and mechanical properties. The Aluminum Association’s publications and resources were used to verify alloy specifications.
- ANSI H35.1: Provides alloy and temper designation systems for aluminum. This standard was referenced to validate the alloy and temper designations.
- AMS 2772: Aerospace Material Specification for heat treatment of aluminum alloy raw materials. This specification was referenced to validate heat treatment practices.
- ANSI H35.2M: Provides dimensional tolerances for aluminum mill products. This standard was used to verify dimensional tolerance requirements.
Conclusion
ASTM B800-05 is a vital standard for the electrical industry, providing detailed specifications for the chemical composition, mechanical properties, construction requirements, and quality assurance of 8000 series aluminum alloy wires. Understanding and adhering to this standard ensures that aluminum wires are reliable, high-quality, and suitable for their intended applications. By following the guidelines set forth in ASTM B800-05, manufacturers can produce aluminum wires that meet the highest standards of quality and performance, ensuring their suitability for critical electrical applications in various industries.
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