The M22759/41-22-9 is a SAE AS22759/41 compliant electrical wire designed for aerospace and helicopter wiring systems operating in high-temperature, high-stress environments. It features stranded nickel-plated copper conductors with cross-linked modified ETFE dual-wall insulation, delivering 600 V rating at 200°C continuous operation. The dual-layer construction provides superior cut-through and abrasion resistance while enabling quick visual identification of damage through distinct color contrasts. This 22 AWG wire maintains tensile strength ≥34.5 MPa and elongation ≥100%, with high residual properties after thermal aging (≥85% tensile strength and ≥75% elongation following 180°C exposure for 168 hours). Dielectric withstand voltage reaches 2.5 kV AC at 60 seconds without breakdown. Finished wire diameter (insulation O.D.) ranges 0.048–0.052 inches with approximate weight of 3.20 pounds per 1000 feet. The wire resists flame, chemical attack, radiation, and soldering iron contact, making it suitable for critical airframe, avionics, and military defense applications where reliability is non-negotiable.
Technical Specifications
• Specification: SAE AS22759/41 (formerly MIL-W-22759/41)
• Conductor Material: Stranded nickel-plated copper
• Insulation Material: Cross-linked modified ETFE, dual-wall construction
• Wire Gauge: 22 AWG
• Temperature Rating: 200°C continuous
• Voltage Rating: 600 V
• Resistance (20°C, max): 16.0 Ohms/1000 ft
• Dielectric Withstand Voltage: 2.5 kV AC, 60 seconds
• Finished Wire Diameter (Insulation O.D.): 0.048–0.052 inches
• Weight: 3.20 pounds/1000 ft (approximate)
– Key Features
• Dual-wall insulation with color-coded identification per MIL-STD-681
• High tensile strength ≥34.5 MPa and elongation ≥100%
• Residual tensile strength ≥85% and elongation ≥75% after 168-hour aging at 180°C
• Superior resistance to flame, chemicals, radiation, and soldering iron contact
• Cut-through and abrasion protection via dual-layer construction
– Typical Applications
• Helicopter and fixed-wing airframe wiring
• Avionics systems in high-temperature zones
• Military and aerospace defense installations
• Weight and space-constrained installations
– Compatibility & Integration
• Color coding compliant with MIL-STD-681 standards (10-color system with stripe combinations available)
