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AIRCRAFT WIRE/CABLE
•

Is defined as sheath (covered) wire

Purpose as a medium for current flow &
complete the circuit (source → load →
ground).
Are design to withstand extreme
vibration, abrasion & adverse weather
condition especially for high altitude flying

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• Wire sizes
• Wire Guage
• American Wire Gage (AWG)
• Standard Wire Gage (SWG)
• To determine wire size, use Wire
• Gage Tool - insert stripped portion.
• Gauge size related to cross sectional area of wire
• Cross sectional is expressed in circular mils
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• 2 types of cable used:

Copper strand
Aluminum strand
Stranded for protection against breakage from
vibration

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• Copper
Used on almost all aircraft‟s wiring.
Better conductor than aluminum.
Coated with tin, silver or nickel to prevent oxidation.
Size 22 – 4/0 (0000) AWG.
Copper has relatively high tensile strength (the
greatest stress a substance can bear along its
length without tearing apart).
Copper can also be easily soldered.
However, copper is more expensive and heavier
than aluminum.

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Aluminum
• sed for carrying large amount of current in long
distance.
Can replace copper due to copper‟s high cost & limited
in market.
More susceptible than copper – save weight.
Disadvantages:-
Greater resistance.
Can carry 2/3 current of the same size copper wire.
Easily broken by vibration ( crystallize).

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• Aluminum wire that is 2 gauge number smaller ( 2

size larger) than copper, carries the same amount of
current.
E.g. – replace 12 gauge of copper wire with at 10 gauge
wire of aluminum.
Aluminum wire that is 2 gauge number smaller( 2 size
larger) than copper, carries the same amount of current.
Ex Copper size 6 – 100 A
Aluminum size 4 – 100 A

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• Aluminum is best for large current for long

distance.
Save weight, allow lighter aircraft
Wire size must be derated if routed in bundle
Heat generated in bundle

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• The smaller the AWG number, the larger the wire size

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