High temperature wire insulation plays a great importance in industrial, automotive and aerospace applications. High temperature wire is manufactured using better materials and utilizes improved grade insulating materials capable of withstanding high temperatures. Come along with us and learn more about the types of high temperature wire insulation today!
High-Temperature Wire Define
High-temperature cable is usually referred to as high-temp wire and is made of special materials with both strength and heat resistance, after special processing. It refers to the operating temperature of 150°C or higher, some manufacturers will also be working temperature of 125 ° C and above the cable called high temperature wire.
What are high temperature wire insulation types?
Depending on the material as well as the insulation we look at what are the high temp wire types that are used frequently:
Cross-linked Polyethylene (XLPE): Cross-linked polyethylene (XLPE) insulation is produced by a process in which polyethylene molecules are chemically linked to form a three-dimensional network. This cross-linking process enhances its thermal and mechanical properties. It can operate effectively over a wide temperature range up to 125°C (257°F). Because of these versatile properties, XLPE is often used in automotive wiring to ensure the safety and efficiency of automotive electrical systems.
Teflon: Polytetrafluoroethylene (PTFE)and fluorinated ethylene propylene (FEP) materials have very high heat resistance. PTFE can work at a high temperature of 250 ℃ for a long time. It has excellent chemical stability, electrical properties and non-flammability, and is widely used in extreme high temperature environments and chemically corrosive environments. PFA insulation temperature rating of 250 ℃ and maintains electrical stability. It can be installed and operated more flexibly and can be used in narrow space wiring.
Silicone rubber: Silicone rubber insulated wire maintains good flexibility and electrical properties in temperatures ranging from -60℃ to 200℃. Silicone high temperature resistant wire, on the other hand, has excellent high temperature resistance, low temperature resistance and corrosion resistance. It is widely used in aerospace, automotive industry.
Fiberglass: While ceramic or glass filaments are not commonly used for wire insulation, they are very important in extreme high temperature environments. In some industrial heating systems, it can be used as insulation to achieve higher heat ratings.
Mica: Mica tape is a kind of high performance mica insulation products, with excellent high temperature resistance and combustion resistance. Mica insulated wires can protect cables at temperatures up to 450ºC. Common applications such as machine tools, electrical appliances, electric furnaces, electrical instrumentation, etc.;
Types Of Conductors For High Temp Wire
- Nickel-Nickel is one of the most commonly used materials for high temperature conductors. It can withstand temperatures up to 600°C or higher and is commonly used in aerospace, power and industrial applications.
- Nickel-plated copper-With a temperature range of 400°C to 800°C, this alloy is resistant to high temperatures and corrosion, making it suitable for wires exposed to high temperatures for long periods of time. High-temperature wires for heating elements often use these materials to ensure reliable performance.
- Silver Plated Copper-Typically used in the 200°C to 250°C temperature range, silver-plated copper wire has good electrical conductivity and high temperature resistance. It is commonly used in aerospace and military applications.
- Copper-Although copper has a relatively low melting point (about 1083°C), it is still used as a conductor for high-temperature wires in the lower temperature ranges (typically between 105°C and 200°C). It is commonly used for high-temperature conductors in general industry and household appliances.
- Tinned copper-Tin plating on copper wire enhances its corrosion and heat resistance, making it suitable for use in lower temperature applications (typically below 150°C).
Precautions for using high-temperature wire
- Selection of suitable materials
High temperature wires should use insulation and conductor materials that can withstand high temperatures. For example, FEP Wire、PFA Wire、PTFE Hook Up Wire are some of the quality high temperature wire types offered by ZW Cable. At the same time, avoid using materials that may cause damage to the cable. Choosing compatible materials reduces the likelihood of damage caused by external factors.
- Minimize bending and stretching
In the process of installation and use, high temp insulated wires should be avoided excessive bending and stretching, which may damage the insulation and conductor structure.
- Regular inspection and maintenance
In order to ensure the normal operation of high temperature wiring, they should be regularly inspected and maintained. This includes measuring the temperature, checking the insulation and conductors for damage, etc. Also keep track of the temperature level during operation. This helps to assess whether the cable is operating within safe limits.
- Ensure good sealing
In high temperature environments, the risk of gas or moisture intrusion can pose a serious threat to cable performance. High temperature cables should therefore be well sealed to prevent the ingress of these harmful substances from causing damage to the cable.
High temperature wire is critical for dependable performance under harsh environmental conditions. ZW Cable offers a variety of options such as high temperature wire 10 AWG and high temperature wire 12 AWG. For more customized professional cable consulting we welcome your inquiries!
