KD500 winding wires with ceramic insulation ( 500°C )

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This ceramic wire was developed to produce windings with high functional reliability, i.e. windings that retain their functionality even under thermal overload (peaks of up to 1000°C).

The ever-increasing success of this wire has led to it being used in numerous high-tech applications, often as a preventative measure in safety elements.

Applications:

Special windings for transformers, chokes, coils or sensors that have to function continuously at elevated temperatures of up to 500°C (peaks up to 1000°C) in the low-voltage range.
Various safety applications that must withstand a fire of up to 600°C without destruction (mechanical heating, short circuit, heat risks, etc.).

Art.-Nr.

Structure:

Conductor: Copper/nickel plating 27%
Other conductor materials on request.
Speciality materials can also be processed, which are provided by the customer.
Corresponding tests are carried out at the factory
Insulation: Ceramic in thicknesses of 5-20 µm
Color: gray
Dimensions: AWG 41 to AWG 18 or 0.07 mm to 1.0 mm
Linear density: Like that of copper = 8.92 kg/dm3 per km
Nickel migration: At temperatures > 315°C, the KD500 is subject to nickel penetration into the copper.
This effect is negligible with larger diameters but considerable with wire diameters < 0.15 mm (AWG 34) after 48 hours of operation, resulting in an increase in resistance.

 

Heat resistance:

Continuous -90°C to +500°C (2500 hours min.)

Short-term up to 800°C (tested for 10 days or 240 hours) and peaks up to 1000°C.

 

Electrical values:

Test voltage 150V AC, corresponding to 212V DC, test with rolled wire Bending radius = 20 x diameter.
For bending radius < 20 x diameter please enquire
Breakdown voltage > 150V AC
Resistance max. 3.10-6 Ω.cm at 20° C after ageing at 500°C

 

 

Further properties

Moisture resistance: The ceramic is sensitive to moisture.
It may need to be impregnated in the finished state.
Chemical resistance: The ceramic is highly resistant to solvents and organic oils
Radiation resistance: High resistance.
Flammability: Non-flammable.
At temperatures > 1000°C the wire can melt but not burn.
Bending radius: 5x outer diameter (see table)
Halogen-free: Yes
Outgassing: None

 

Verarbeitungshinweise

Keramik unterscheidet sich stark von herkömmlichen Drahtisolierungen. It is very hard and sensitive to moisture. It therefore requires special care during processing.

 

  • KD 500 must be stored and processed in a dry environment.
  • The winding must not be subjected to shocks or impacts.
  • No higher tensile forces than those specified in the table below may be used for winding.
  • The bending radius must not exceed
    5 x the outer diameter of the wire (see table).
  • The wire should not be unwound overhead but axially, preferably with a constant tensile force.
  • The wires must not be kinked under any circumstances. Visual inspection of the winding.
  • A bending radius that is too tight or a kink in the wire can generally be recognized by cracks in the ceramic insulation, which are visible as a white discoloration of the surface.

 

Stripping

The ceramic coating on the KD500 is very thin and adheres to the conductor. Conventional stripping tools can therefore not be used. Stripping can be carried out with fine sandpaper.

 

Please note: When mechanically stripping nickel-coated wires, this coating must not be removed, otherwise good welding is no longer guaranteed.

 

Connect

The ceramic wires are connected either by soldering with silver solder, crimping or wrapping.

 

Dimensions:

Item number Diameter [mm] AWG Size Outer diameter [mm] Weight [g/km] Length [m kg]
KD500/007RR 0,07 41 0,086 34 29 800
KD500/010RR 0,10 38 0,116 71 14 000
KD500/012RR 0,12 36 0,136 101 9 901
KD500/015RR 0,15 34 0,167 161 6 210
KD500/017RR 0,17 33 0,186 202 4 950
KD500/020RR 0,20 32 0,217 286 3 500
KD500/025RR 0,25 30 0,268 446 2 240
KD500/030RR 0,30 28 0,318 637 1 570
KD500/035RR 0,35 27 0,368 862 1 160
KD500/040RR 0,40 26 0,418 1 136 880
KD500/045RR 0,45 25 0,468 1 433 698
KD500/050RR 0,50 24 0,518 1 754 570
KD500/055RR 0,55 23 0,568 2 105 475
KD500/060RR 0,60 22 0,619 2 500 400
KD500/065RR 0,65 22 0,669 2 899 345
KD500/070RR 0,70 21 0,719 3 356 298
KD500/075RR 0,75 20 0,769 3 846 260
KD500/080RR 0,80 20 0,820 4 348 230
KD500/090RR 0,90 19 0,920 5 814 172
KD500/100RR 1,00 18 1,020 7 194 139

Diameter [mm] Max. permissible
Tractive force (N)

 Minim.
Bending radius [mm]		 Resistance at

20°C [Ω/m]
7/100 0,23 0,45 7,795
10/100 0,47 0,60 3,818
12/100 0,67 0,70 2,652
15/100 1,06 0,85 1,697
17/100 1,36 0,93 1,322
20/100 1,88 1,10 0,954
25/100 2,95 1,35 0,611
30/100 4,24 1,60 0,424
35/100 5,77 1,85 0,312
40/100 7,54 2,10 0,239
45/100 9,55 2,35 0,189
50/100 11,78 2,60 0,153
55/100 14,25 2,85 0,126
60/100 16,96 3,10 0,106
65/100 19,91 3,35 0,090
70/100 23,09 3,60 0,078
75/100 26,51 3,85 0,068
80/100 30,16 4,10 0,059
90/100 38,17 4,60 0,047
100/100 47,12 5,10 0,038

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