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51-448: The AWG originated in the number of drawing operations used to produce a given gauge of wire. Very fine wire (for example, 30 gauge) required more passes through the drawing dies than 0 gauge wire did. Manufacturers of wire formerly had proprietary wire gauge systems; the development of standardized wire gauges rationalized selection of wire for a particular purpose. While the AWG

102-451: A cold working process, but it may be performed at elevated temperatures for large wires to reduce forces. Of the elemental metals, copper , silver , gold , and platinum are the most ductile and immune from many of the problems associated with cold working . The wire drawing process is quite simple in concept. The wire is prepared by shrinking the beginning of it, by hammering, filing, rolling or swaging , so that it will fit through

153-543: A DC circuit. However, most such circuits have a DC solution. This solution gives the circuit voltages and currents when the circuit is in DC steady state . Such a circuit is represented by a system of differential equations . The solution to these equations usually contain a time varying or transient part as well as constant or steady state part. It is this steady state part that is the DC solution. There are some circuits that do not have

204-407: A DC solution. Two simple examples are a constant current source connected to a capacitor and a constant voltage source connected to an inductor. In electronics, it is common to refer to a circuit that is powered by a DC voltage source such as a battery or the output of a DC power supply as a DC circuit even though what is meant is that the circuit is DC powered. In a DC circuit, a power source (e.g.

255-453: A battery system to ensure power is maintained for subscriber lines during power interruptions. Other devices may be powered from the telecommunications DC system using a DC-DC converter to provide any convenient voltage. Many telephones connect to a twisted pair of wires, and use a bias tee to internally separate the AC component of the voltage between the two wires (the audio signal) from

306-423: A battery, capacitor, etc.) has a positive and negative terminal, and likewise, the load also has a positive and negative terminal. To complete the circuit, positive charges need to flow from the power source to the load. The charges will then return to the negative terminal of the load, which will then flow back to the negative terminal of the battery, completing the circuit. If either the positive or negative terminal

357-434: A block or Turk's-head machine are used. Lubrication in the drawing process is essential for maintaining good surface finish and long die life. The following are different methods of lubrication: Various lubricants, such as oil , are employed. Another lubrication method is to immerse the wire in a copper(II) sulfate solution, such that a film of copper is deposited which forms a kind of lubricant. In some classes of wire

408-490: A different rotation speed for each block. One of these machines may contain 3 to 12 dies. The operation of threading the wire through all the dies and around the blocks is termed "stringing-up". The arrangements for lubrication include a pump which floods the dies, and in many cases also the bottom portions of the blocks run in lubricant. Often intermediate anneals are required to counter the effects of cold working, and to allow further drawing. A final anneal may also be used on

459-524: A direct current source . The DC solution of an electric circuit is the solution where all voltages and currents are constant. Any stationary voltage or current waveform can be decomposed into a sum of a DC component and a zero-mean time-varying component; the DC component is defined to be the expected value, or the average value of the voltage or current over all time. Although DC stands for "direct current", DC often refers to "constant polarity". Under this definition, DC voltages can vary in time, as seen in

510-498: A slightly larger overall diameter than a solid wire with the same AWG. By definition, 36 AWG is 0.005 inches in diameter, and 0000 AWG is 0.46 inches in diameter. The ratio of these diameters is 1:92, and there are 40 gauge sizes from 36 to 0000, or 39 steps. Because each successive gauge number increases cross sectional area by a constant multiple, diameters vary geometrically . Any two successive gauges (e.g., A and B ) have diameters whose ratio (dia. B ÷ dia. A )

561-421: Is 92 39 {\displaystyle {\sqrt[{39}]{92}}} (approximately 1.12293), while for gauges two steps apart (e.g., A , B , and C ), the ratio of the C to A is about 1.12293 ≈ 1.26098. Similarly for gauges n steps apart the ratio of the first to last gauges is about 1.12293. The diameter of an AWG wire is determined according to the following formula: (where n

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612-482: Is an AC device which uses a rectifier to produce DC for battery charging. Most highway passenger vehicles use nominally 12  V systems. Many heavy trucks, farm equipment, or earth moving equipment with Diesel engines use 24 volt systems. In some older vehicles, 6 V was used, such as in the original classic Volkswagen Beetle . At one point a 42 V electrical system was considered for automobiles, but this found little use. To save weight and wire, often

663-435: Is commonly found in many extra-low voltage applications and some low-voltage applications, especially where these are powered by batteries or solar power systems (since both can produce only DC). Most electronic circuits or devices require a DC power supply . Domestic DC installations usually have different types of sockets , connectors , switches , and fixtures from those suitable for alternating current. This

714-427: Is disconnected, the circuit will not be complete and the charges will not flow. In some DC circuit applications, polarity does not matter, which means you can connect positive and negative backwards and the circuit will still be complete and the load will still function normally. However, in most DC applications, polarity does matter, and connecting the circuit backwards will result in the load not working properly. DC

765-424: Is dissimilar to IEC 60228 , the metric wire-size standard used in most parts of the world, based directly on the wire cross-section area (in square millimetres, mm). The AWG tables are for a single, solid and round conductor. The AWG of a stranded wire is determined by the cross-sectional area of the equivalent solid conductor. Because there are also small gaps between the strands, a stranded wire will always have

816-412: Is distributed to a substation, which utilizes a rectifier to convert the power to direct current. The term DC is used to refer to power systems that use only one electrical polarity of voltage or current, and to refer to the constant, zero-frequency, or slowly varying local mean value of a voltage or current. For example, the voltage across a DC voltage source is constant as is the current through

867-606: Is essentially identical to the Brown & Sharpe (B&S) sheet metal gauge, the B&;S gauge was designed for use with sheet metals as its name suggests. These are functionally interchangeable but the use of B&S in relation to wire gauges, rather than sheet metal gauges, is technically improper. Increasing gauge numbers denote logarithmically decreasing wire diameters, which is similar to many other non-metric gauging systems such as British Standard Wire Gauge (SWG). However, AWG

918-426: Is generally 15–25% and in larger wires is 20–45%. The exact die sequence for a particular job is a function of area reduction, input wire size and output wire size. As the area reduction changes, so does the die sequence. Very fine wires are usually drawn in bundles. In a bundle, the wires are separated by a metal with similar properties, but with lower chemical resistance so that it can be removed after drawing. If

969-447: Is mostly due to the lower voltages used, resulting in higher currents to produce the same amount of power . It is usually important with a DC appliance to observe polarity, unless the device has a diode bridge to correct for this. Most automotive applications use DC. An automotive battery provides power for engine starting, lighting, the ignition system, the climate controls, and the infotainment system among others. The alternator

1020-435: Is often easier and more accurate than attempting to measure bundle diameter and packing ratio. Such measurement can be done with a wire gauge go-no-go tool or with a caliper or micrometer. Alternative ways are commonly used in the electrical industry to specify wire sizes as AWG. AWG is colloquially referred to as gauge and the zeros in thick wire sizes are referred to as aught / ˈ ɔː t / . Wire sized 1 AWG

1071-435: Is one-directional flow of electric charge . An electrochemical cell is a prime example of DC power. Direct current may flow through a conductor such as a wire, but can also flow through semiconductors , insulators , or even through a vacuum as in electron or ion beams . The electric current flows in a constant direction, distinguishing it from alternating current (AC). A term formerly used for this type of current

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1122-406: Is provided with means for rapidly coupling or uncoupling it to its vertical shaft, so that the motion of the wire may be stopped or started instantly. The block is also tapered, so that the coil of wire may be easily slipped off upwards when finished. Before the wire can be attached to the block, a sufficient length of it must be pulled through the die; this is effected by a pair of gripping pincers on

1173-418: Is referred to as "one gauge" or "No. 1" wire; similarly, thinner sizes are pronounced " x  gauge" or "No.  x " wire, where x is the positive-integer AWG number. Consecutive AWG wire sizes thicker than No. 1 wire are designated by the number of zeros: and so on. Wire drawing Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling

1224-430: Is the AWG size for gauges from 36 to 0, n = −1 for 00, n = −2 for 000, and n = −3 for 0000. See below for rule.) or equivalently: The gauge can be calculated from the diameter using  and the cross-section area is The standard ASTM B258-02 (2008), Standard Specification for Standard Nominal Diameters and Cross-Sectional Areas of AWG Sizes of Solid Round Wires Used as Electrical Conductors , defines

1275-463: Is the area of a wire one mil in diameter. One million circular mils is the area of a circle with 1,000 mil (1 inch) diameter. An older abbreviation for one thousand circular mils is MCM . AWG can also be used to describe stranded wire. The AWG of a stranded wire represents the sum of the cross-sectional diameter of the individual strands; the gaps between strands are not counted. When made with circular strands, these gaps occupy about 25% of

1326-448: The DC component of the voltage between the two wires (used to power the phone). High-voltage direct current (HVDC) electric power transmission systems use DC for the bulk transmission of electrical power, in contrast with the more common alternating current systems. For long-distance transmission, HVDC systems may be less expensive and suffer lower electrical losses. Applications using fuel cells (mixing hydrogen and oxygen together with

1377-558: The Formulas and Rules of Thumb sections above, differences in AWG translate directly into ratios of diameter or area. This property can be employed to easily find the AWG of a stranded bundle by measuring the diameter and count of its strands. (This only applies to bundles with circular strands of identical size.) To find the AWG of 7-strand wire with equal strands, subtract 8.4 from the AWG of a strand. Similarly, for 19-strand subtract 12.7, and for 37 subtract 15.6. Measuring strand diameter

1428-471: The above formulas. For instance, for 0000 AWG or 4/0 AWG, use n = −3 . The sixth power of √ 92 is very close to 2, which leads to the following rules of thumb: Convenient coincidences result in the following rules of thumb for resistances: The table below shows various data including both the resistance of the various wire gauges and the allowable current ( ampacity ) based on a copper conductor with plastic insulation. The diameter information in

1479-474: The charging of batteries to large power supplies for electronic systems, motors, and more. Very large quantities of electrical energy provided via direct-current are used in smelting of aluminum and other electrochemical processes. It is also used for some railways , especially in urban areas . High-voltage direct current is used to transmit large amounts of power from remote generation sites or to interconnect alternating current power grids. Direct current

1530-407: The circuit voltages and currents are independent of time. A particular circuit voltage or current does not depend on the past value of any circuit voltage or current. This implies that the system of equations that represent a DC circuit do not involve integrals or derivatives with respect to time. If a capacitor or inductor is added to a DC circuit, the resulting circuit is not, strictly speaking,

1581-493: The conductor diameter; it is therefore an upper limit for wire wound in the form of a helix (see solenoid ), based on uninsulated wire. In the North American electrical industry, conductors thicker than 4/0   AWG are generally identified by the area in thousands of circular mils (kcmil), where 1 kcmil = 0.5067 mm. The next wire size thicker than 4/0 has a cross section of 250 kcmil. A circular mil

American wire gauge - Misplaced Pages Continue

1632-557: The copper is left after the final drawing to serve as a preventive of rust or to allow easy soldering . The best example of copper coated wire is in MIG wire used in welding. The strength-enhancing effect of wire drawing can be substantial. The highest strengths available on any steel have been recorded on small-diameter cold-drawn austenitic stainless wire. Drawing dies are typically made of tool steel , tungsten carbide , or diamond , with tungsten carbide and manufactured diamond being

1683-560: The die; the wire is then pulled through the die. As the wire is pulled through the die, its volume remains the same, so as the diameter decreases, the length increases. Usually the wire will require more than one draw, through successively smaller dies, to reach the desired size. The American wire gauge scale is based on this. This can be done on a small scale with a draw plate , or on a large commercial scale using automated machinery. The process of wire drawing changes material properties due to cold working. The area reduction in small wires

1734-443: The dies accurately in position and for drawing the wire steadily through the holes. The usual design consists of a cast-iron bench or table having a bracket standing up to hold the die, and a vertical drum which rotates and by coiling the wire around its surface pulls it through the die, the coil of wire being stored upon another drum or "swift" which lies behind the die and reels off the wire as fast as required. The wire drum or "block"

1785-471: The end of a chain which is wound around a revolving drum, so drawing the wire until enough can be coiled two or three times on the block, where the end is secured by a small screw clamp or vice. When the wire is on the block, it is set in motion and the wire is drawn steadily through the die; it is very important that the block rotates evenly and that it runs true and pulls the wire at a constant velocity, otherwise "snatching" occurs which will weaken or even break

1836-445: The finished product to maximize ductility and electrical conductivity . An example of product produced in a continuous wire drawing machine is telephone wire. It is drawn 20 to 30 times from hot rolled rod stock. While round cross-sections dominate most drawing processes, non-circular cross-sections are drawn. They are usually drawn when the cross-section is small and quantities are too low to justify rolling . In these processes,

1887-567: The loops of wire each half turn, it caused the flow of electricity to reverse, generating an alternating current . At Ampère's suggestion, Pixii later added a commutator , a type of "switch" where contacts on the shaft work with "brush" contacts to produce direct current. The late 1870s and early 1880s saw electricity starting to be generated at power stations . These were initially set up to power arc lighting (a popular type of street lighting) running on very high voltage (usually higher than 3,000 volts) direct current or alternating current. This

1938-512: The metal frame of the vehicle is connected to one pole of the battery and used as the return conductor in a circuit. Often the negative pole is the chassis "ground" connection, but positive ground may be used in some wheeled or marine vehicles. In a battery electric vehicle , there are usually two separate DC systems. The "low voltage" DC system typically operates at 12V, and serves the same purpose as in an internal combustion engine vehicle. The "high voltage" system operates at 300-400V (depending on

1989-447: The most common. For drawing very fine wire a single crystal diamond die is used. For hot drawing, cast-steel dies are used. For steel wire drawing, a tungsten carbide die is used. The dies are placed in a steel casing, which backs the die and allow for easy die changes. Die angles usually range from 6–15°, and each die has at least 2 different angles: the entering angle and approach angle. Direct current Direct current ( DC )

2040-593: The ratio between successive sizes to be the 39th root of 92, or approximately 1.1229322. ASTM B258-02 also dictates that wire diameters should be tabulated with no more than 4 significant figures, with a resolution of no more than 0.0001 inches (0.1 mils) for wires thicker than 44 AWG, and 0.00001 inches (0.01 mils) for wires 45 AWG and thinner. Sizes with multiple zeros are successively thicker than 0 AWG and can be denoted using " number of zeros /0", for example 4/0 AWG for 0000 AWG. For an m /0   AWG wire, use n = −( m − 1) = 1 − m in

2091-428: The raw output of a rectifier or the fluctuating voice signal on a telephone line. Some forms of DC (such as that produced by a voltage regulator ) have almost no variations in voltage , but may still have variations in output power and current. A direct current circuit is an electrical circuit that consists of any combination of constant voltage sources, constant current sources, and resistors . In this case,

American wire gauge - Misplaced Pages Continue

2142-435: The reduction in area is greater than 50%, the process may require an intermediate step of annealing before it can be redrawn. Commercial wire drawing usually starts with a coil of hot rolled 9 mm (0.35 in) diameter wire. The surface is first treated to remove scales. It is then fed into a wire drawing machine which may have one or more blocks in series. Single block wire drawing machines include means for holding

2193-416: The table applies to solid wires. Stranded wires are calculated by calculating the equivalent cross sectional copper area . Fusing current (melting wire) is estimated based on 25 °C (77 °F) ambient temperature. The table below assumes DC , or AC frequencies equal to or less than 60 Hz, and does not take skin effect into account. "Turns of wire per unit length" is the reciprocal of

2244-464: The vehicle), and provides the power for the traction motors . Increasing the voltage for the traction motors reduces the current flowing through them, increasing efficiency. Telephone exchange communication equipment uses standard −48 V DC power supply. The negative polarity is achieved by grounding the positive terminal of power supply system and the battery bank. This is done to prevent electrolysis depositions. Telephone installations have

2295-450: The wire area , thus requiring the overall bundle diameter to be about 13% larger than a solid wire of equal gauge. Stranded wires are specified with three numbers, the overall AWG size, the number of strands, and the AWG size of a strand. The number of strands and the AWG of a strand are separated by a slash. For example, a 22   AWG 7/30 stranded wire is a 22   AWG wire made from seven strands of 30   AWG wire. As indicated in

2346-447: The wire through one or more dies . There are many applications for wire drawing, including electrical wiring, cables, tension-loaded structural components, springs, paper clips, spokes for wheels, and stringed musical instruments. Although similar in process, drawing is different from extrusion , because in drawing the wire is pulled, rather than pushed, through the die. Drawing is usually performed at room temperature, thus classified as

2397-404: The wire. The speeds at which wire is drawn vary greatly, according to the material and the amount of reduction. Machines with continuous blocks differ from single block machines by having a series of dies through which the wire is drawn in a continuous fashion. Due to the elongation and slips, the speed of the wire changes after each successive redraw. This increased speed is accommodated by having

2448-515: Was galvanic current . The abbreviations AC and DC are often used to mean simply alternating and direct , as when they modify current or voltage . Direct current may be converted from an alternating current supply by use of a rectifier , which contains electronic elements (usually) or electromechanical elements (historically) that allow current to flow only in one direction. Direct current may be converted into alternating current via an inverter . Direct current has many uses, from

2499-406: Was followed by the widespread use of low voltage direct current for indoor electric lighting in business and homes after inventor Thomas Edison launched his incandescent bulb based electric " utility " in 1882. Because of the significant advantages of alternating current over direct current in using transformers to raise and lower voltages to allow much longer transmission distances, direct current

2550-407: Was produced in 1800 by Italian physicist Alessandro Volta 's battery, his Voltaic pile . The nature of how current flowed was not yet understood. French physicist André-Marie Ampère conjectured that current travelled in one direction from positive to negative. When French instrument maker Hippolyte Pixii built the first dynamo electric generator in 1832, he found that as the magnet used passed

2601-477: Was replaced over the next few decades by alternating current in power delivery. In the mid-1950s, high-voltage direct current transmission was developed, and is now an option instead of long-distance high voltage alternating current systems. For long distance undersea cables (e.g. between countries, such as NorNed ), this DC option is the only technically feasible option. For applications requiring direct current, such as third rail power systems, alternating current

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