High performance materials for a wide range of applications
Aerumtec’s Histral®H – high-strength alloys have been specially developed for demanding applications where both high tensile strength and excellent electrical conductivity are required. Often used in the aerospace, automotive, radio frequency and other high-tech industries, these alloys offer an impressive combination of mechanical strength and electrical efficiency.
Small but powerful: our alloys ensure high performance
The special properties of Histral®H alloys such as Histral® H65 and Histral® H72 include higher tensile strength, improved flexlife behaviour and a reduction in cross-section without losing conductivity. These properties make them an ideal choice for applications that require minimised size and weight while maintaining high performance standards.
Environmentally friendly and versatile
Aerumtec Histral®H alloys are also free from harmful substances and therefore offer an environmentally friendly alternative to conventional materials. With a variety of alloy options to meet specific requirements, such as Histral® H95, which is known for its high electrical conductivity and excellent mechanical properties, our Histral®H – high strength alloys enables engineers to push the boundaries of their products’ performance.
- increased tensile strength
- smaller corss-section
- increased heat resistance
- higher flexlife behaviour
- free form harmful substances
Histral®H – high strength alloys can be used for the following applications:
- Aerospace
- Automotive
- High frequency technology
- Industry
- Medical & healthcare
- Military & defence
- Miniaturisation
- Railway
- Robotics
| Histral® | Composition | Density (g/m³) | Resistivity* (Ohm mm²/m) | Conductivity* (% IACS) | Temperature coefficient of resistance (1/°C) |
Tensile strength* (N/mm²) tempered |
Elongation* | Tensile strength* (N/mm²) hard |
|---|---|---|---|---|---|---|---|---|
| H16 | CCA15 | 3.63 | 0.0268 | 64 | 0.00404 | <172 | >5 | >207 |
| H18 | CCS40 | 8.24 | 0.0439 | 40 | 0.00387 | >350 | >10 | >760 |
| H26 | CuZn37 | 8.44 | 0.0663 | 26 | 0.00170 | >360 | >30 | >800 |
| H64 | CuMg0.4 | 8.9 | 0.0254 | 68 | 0.00185 | >270 | >20 | >510 |
| H65 | CuAg10 | 9.1 | 0.0216 | 80 | 0.00255 | >300 | >30 | >750 |
| H69 | CuSn0.3 | 8.9 | 0.0239 | 72 | 0.00290 | >250 | >20 | >530 |
| H72 | CuSn0.3 | 8.9 | 0.0216 | 80 | 0.00290 | >250 | >20 | >600 |
| H77 | CuMg0.2 | 8.9 | 0.0203 | 85 | 0.00320 | >230 | >20 | >650 |
| H79 | CuAg0.1 | 8.9 | 0.0171 | 99 | 0.00381 | >220 | >20 | >520 |
| H85 | CuMg0.15 | 8.9 | 0.0203 | 85 | 0.00320 | >350 | >6 | >650 |
| H88 | CuCrFeTiAgSi | 8.9 | 0.0203 | 85 | 0.00300 | >414 | >8 | >600 |
| H95 | CuCrFeTiAgSi | 8.9 | 0.0203 | >85 (bare, silver) >79 (nickel) |
0.00300 | 414 | 8 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Aerumtec’s product portfolio of Histral® H – high strength alloys
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0268 | 0.0268 |
| Electrical conductivity* (%IACS) | 64 | 64 |
| Tensile strength* (N/mm²) | < 172 | >207 |
| Elongation* (%) | 5 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00404 | 0.00404 |
| Density (g/cm³) | 3.63 | 3.36 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- ASTM B566
- ABS 0949
- ABS 0957
- ABS 1354
Availability**
- Coating: Bare, Silver, Nickel, Tin, Gold
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.10 mm (AWG 38)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H16:
- Low weight: Aerumtec’s Histral® H16 is a composite material, made up of an aluminum core, which has a copper coating, also known as copper-clad aluminum. This allows for the positive mechanical properties of copper to be combined with the very low net weight of aluminum. Histral® H16 lends itself extremely well to applications for which weight plays a crucial role while good electrical properties are also required. Histral® H16 boasts a material length per kilogram produced that exceeds that of copper by a factor of about 2.4, while it still attains 64 % of the conductivity provided by bare copper.
- Good resistivity (specific resistance): Copper ranks second to silver as an electrical conductor. The copper cladding of Aerumtec’s Histral® H16 ensures a good electrical conductivity whenever mechanical properties do not play a primary role.
Histral® H16 can be used for the following applications:
- Aviation and automotive industry: Weight is of major importance for the construction of airplanes and automobiles. Histral® H16 is particularly suited for larger cross-sections here that can be employed for the transmission of power, where there is a significant weight reduction potential.
- High-frequency (HF) technology / coaxial cables: In HF technology the so-called “skin effect“ ensures that the current flow is restricted to a very thin layer situated on the surface of the conductor and that the overall resistance in the conductor is reduced. Histral® H16 has copper, which features good electrical, in the cladding only. The additional galvanic plating of the surface causes the skin effect to be optimized.
- Shielding braids: Histral® H16 features a resistivity lending itself well to shielding braids because high coverage can be achieved at a comparatively low weight. The fact that aluminum suffers from the drawback of having a poor contact resistance is largely offset by the copper cladding.
- Heating conductors: The combination of a relatively good resistance value with a rather low mechanical resilience suggest that Histral® H16 may well be used in all kinds of heating applications that are not exposed to a permanently varying level of stress.
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0439 | 0.0439 |
| Electrical conductivity* (%IACS) | 40 | 40 |
| Tensile strength* (N/mm²) | 350 | 760 |
| Elongation* (%) | 10 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00387 | 0.00387 |
| Density (g/cm³) | 8.24 | 8.24 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- ASTM B193
- ASTM B452
- ASTM B501
- ASTM B520
- ASTM B559
- ASTM B910
Availability**
- Coating: Bare, Silver, Nickel, Tin, Gold
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.05 mm (AWG 44)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H18:
- Exceptional mechanical strength: Histral® H18 stands for a composite material consisting of a copper-clad steel core. It allows for the excellent mechanical qualities of steel and the very good electrical properties of copper to be combined. In an environment characterised by marked vibrations or significant mechanical stress Histral® H18 is a good choice.
- Good resistivity: Copper ranks second to silver as an electrical conductor. The copper coating in Histral® H18 makes for a good electrical conductivity without hampering the outstanding mechanical resilience. The resistivity Histral® H18 provides lends itself well to heating applications, too. Even at relatively low cross-sections the required heating power can be achieved.
Histral® H18 can be used for the following applications:
- Automotive: Histral® H18 is particularly suitable for seat heating as well as for signal or data cables.
- Heating conductors: The high mechanical strength of Histral® H18, in combination with a good resistance value, renders it particularly suitable for heating applications. Its steel core prevents the material from getting soft in such applications.
- High-frequency (HF) technology / coaxial cables: In HF technology the so-called “skin effect“ ensures that the current flow is restricted to a very thin layer situated on the surface of the conductor and that the overall resistance in the conductor is reduced. Histral® H18 has copper, which features good electrical, in the cladding only. The additional galvanic plating of the surface causes the skin effect to be optimized.
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0663 | 0.0718 |
| Electrical conductivity* (%IACS) | 26 | 24 |
| Tensile strength* (N/mm²) | 360 | 800 |
| Elongation* (%) | 30 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00170 | 0.00170 |
| Density (g/cm³) | 8.44 | 8.44 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- EN 12166
- DIN CEN/TS 13388
Availability**
- Coating: Bare, Silver, Nickel, Tin
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.05 mm (AWG 44)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H26:
- Medium conductivity: Signals are usually transmitted at fairly low amperage. The resistance level of Aerumtec’s Histral® H26 does therefore not lead to losses that might hamper the application.
- High mechanical strength: Histral® H26 is an extraordinarily strong copper alloy that clearly outperforms the mechanical properties of pure copper.
- High Flex Life: Aerumtec’s Histral® H26 gives excellent performance levels in situations where vibration or constant flexing are present.
- Low weight: The high mechanical strength of Histral® H26 allows for its individual wires to be drawn down to much smaller diameters than copper, which results in a substantial weight reduction.
- Contact properties: The crimp qualities of Aerumtec’s Histral® H26 correspond to those of pure copper in hard condition. However, the tools applied have to be adapted to the lower cross-sections.
Histral® H26 can be used for the following applications:
- Signal cables: Aerumtec’s Histral® H26 is particularly suitable for signal cables in robotics facing very high mechanical demands.
Brass wires can be found in a most diverse range of applications:
- spark erosion wire (conductive materials are vaporized by applying sparks allowing for the conductor to be cut in this state)
- brushes made from brass wire (high mechanical strength and malleability, particularly suited for processing soft metals such as gold, brass or copper)
- decoration (e.g. the color of Histral® H26 looks very much like gold)
- grids and sieves made from brass wire
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0254 | 0.0269 |
| Electrical conductivity* (%IACS) | 68 | 64 |
| Tensile strength* (N/mm²) | 270 | 510 |
| Elongation* (%) | 20 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00185 | 0.00185 |
| Density (g/cm³) | 8.9 | 8.9 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- DIN 48200 T2
- DIN 48203 T2
- DIN CEN/TS 13388
Availability**
- Coating: Bare, Silver, Nickel, Tin, Gold
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.025 mm (AWG 50)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H64:
- High electrical conductivity
- Good mechanical properties
- Temperature resistance
Histral® H64 can be used for the following applications:
- Automotive industry
- Railway industry
- Heating elements
- Enamelled wires
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0216 | 0.0246 |
| Electrical conductivity* (%IACS) | 80 | 70 |
| Tensile strength* (N/mm²) | 300 | 750 |
| Elongation* (%) | 30 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00255 | 0.00255 |
| Density (g/cm³) | 9.1 | 9.1 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Availability**
- Coating: Bare, Silver, Nickel, Tin, Gold
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.025 mm (AWG 50)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H65:
- High electrical conductivity: The 10 % silver portion of the Histral® H65 alloy ensures very good electrical conductivity without relinquishing any of its excellent mechanical resilience. Hence, the material lends itself exceptionally well to strands consisting of very fine wires made into small cross-sections.
- High mechanical strength: Aerumtec’s Histral® H65 is an alloy composed of copper at 90 % and silver at 10 %. Having been drawn down cold, this material preserves its outstanding mechanical properties coupled with good electrical qualities. Therefore, it is particularly suited for any environment characterized by significant mechanical stress.
- Flex Life: Histral® H65 gives excellent performance levels in situations where vibration or constant flexing are present.
- Very good high temperature performance: The high tensile strength is maintained even at high temperatures.
Histral® H65 can be used for the following applications:
- High-frequency micro cables: Histral® H65 material lends itself exceptionally well to conductors with small cross-sections. Wires as thin as 0.03 mm (AWG48) and strands up to 7 ends using single wire this thin (AWG 40) have already been produced successfully. It might be advisable to use silver-plated wire in coaxial cables.
- Medical technology: Since Histral® H65 is extremely suitable for miniaturisation, it can be made good use of in medical technology. Cables employed in that field may be subjected to heavy tensile stress in the wake of conductors being yanked or bent. This calls for perfect precision, reliability, and an extraordinary resilience, for the patients’ safety has to be considered as the top priority at all times.
- Miniaturisation: Because of its excellent mechanical properties, Histral® H65 can be smoothly processed into wires featuring a diameter as low as 0.025 mm (AWG 50) while maintaining all its relevant qualities.
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0239 | 0.0253 |
| Electrical conductivity* (%IACS) | 72 | 68 |
| Tensile strength* (N/mm²) | 250 | 530 |
| Elongation* (%) | 20 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00290 | 0.00290 |
| Density (g/cm³) | 8.9 | 8.9 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- DIN CEN/TS 13388
Availability**
- Coating: Bare, Silver, Nickel, Tin, Gold
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.025 mm (AWG 50)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H69:
- High electrical conductivity: Due to the alloy portion in Histral® H69 being very low, there is just a slight decrease in resistance if compared with pure copper. Thus, the material preserves its high electrical conductivity while also featuring a great mechanical strength. Therefore, the material lends itself perfectly to strands where the very low diameter or cross-section must not lead to inadequate tensile strength.
- Good mechanical strength: Aerumtec’s Histral® H69 is counted among the so-called “low-alloyed copper products“, the copper portion of which is 99.7 % of copper, with no more than the remaining 0.3 % covered by alloy additives (mainly tin in this case). Having been hard drawn, its mechanical properties even improve, without the very good electrical qualities being impaired. This phenomenon allows for a significant reduction of cross-sections. Consequentially, Histral® H69 lends itself well to applications in which reduced weight plays a primary role. A prime example for this is signal cables, but also shielding braids, both of which require an above-average mechanical strength in order for the actual conductor to be sufficiently protected.
- Flex Life properties: Alloys are usually employed in hard condition. Histral® H69 boasts excellent Flexlife properties, which ensure highest stability in any environment that is exposed to a lot of vibration and motion.
- Contact properties: The crimp qualities of Histral® H69 correspond to those of pure copper in hard condition. However, the tools applied must be adapted to the lower cross-sections.
- Reduced weight: The outstanding properties of Histral® H69 translate into much lower cross-sections supporting the same breaking load if compared to pure copper. For a breaking load of 70 N a pure copper strand must have a cross-section of 0.35 mm2, whereas the comparable value for a strand made from Histral® H69 is 70 N at a cross-section of only 0.132 mm2, by means of which a weight reduction by 62 % can be achieved! Using weight as a reference value, a copper strand requires 0.0445 (g/m) per each 1 N of breaking load, with Histral® H69 attaining the same breaking load at a weight of just 0.0168 (g/m).
- Thermal stability: Pure copper in hard condition is susceptible to re-crystallization even at room temperature, at which it already begins to soften again resulting in a loss of mechanical strength. Adding on small quantities of alloys will suffice to vastly increase the point of re-crystallization of hard-drawn materials so that the greater strength is maintained in the event of higher ambient temperature, too. Histral® H69 has a much better thermal stability than pure copper. Hence, it is also suited for those applications that are subjected to elevated temperatures.
- Resistance: Histral® H69 has a slightly higher resistance than pure copper, while still boasting a conductivity of 72 % IACS (in soft condition).
Histral® H69 can be used for the following applications:
- Automotive industry: Histral® H69 is frequently employed for ABS sensor cables in vehicles.
- Data cables / Signal cables: Its small alloy portion reduces the resistance value of Histral® H69 no more than a little, as compared with pure copper. Thus, the very good electrical conductivity of the material remains unaffected whilst its excellent mechanical strength persists. This makes it a perfect fit for data cables and signal cables featuring very low diameters and cross-sections, but also a sufficient tensile strength.
- Shielding braids: Histral® H69 features a resistivity lending itself well to shielding braids because high coverage can be achieved at a comparatively low weight.
- Automation technology / Industrial applications: Histral® H69 boasts excellent Flexlife properties, which ensure highest stability in any environment that is exposed to a lot of vibration and motion.
- Loudspeakers: The connection cables of loudspeaker membranes are exposed to extremely strong vibrations. Histral® H69 lends itself well to this application owing to its great mechanical strength in combination with a very good conductivity, in particular as a substitute for cadmium-containing alloys used in the past.
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0216 | 0.0240 |
| Electrical conductivity* (%IACS) | 80 | 74 |
| Tensile strength* (N/mm²) | 250 | 600 |
| Elongation* (%) | 20 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00290 | 0.00290 |
| Density (g/cm³) | 8.9 | 8.9 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- LV112-4 DRAFT
- DIN CEN/TS 13388
Availability**
- Coating: Bare, Silver, Nickel, Tin, Gold
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.025 mm (AWG 50)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H72:
- High electrical conductivity: Due to the alloy portion in Histral® H72 being very low, there is just a slight decrease in resistance if compared with pure copper. Thus, the material preserves its high electrical conductivity while also featuring a great mechanical strength. Therefore, the material lends itself perfectly to strands where the very low diameter or cross-section must not lead to inadequate tensile strength.
- Good mechanical strength: Histral® H72 is counted among the so-called „low-alloyed copper products“, the copper portion of which is 99.7 % of copper, with no more than the remaining 0.3 % covered by alloy additives (mainly tin in this case). Having been hard drawn, its mechanical properties even improve, without the very good electrical qualities being impaired. This phenomenon allows for a significant reduction of cross-sections. Consequentially, Histral® H72 lends itself well to applications in which reduced weight plays a primary role. A prime example for this is signal cables, but also shielding braids, both of which require an above-average mechanical strength in order for the actual conductor to be sufficiently protected.
- Flex Life properties: Alloys are usually employed in hard condition. Histral® H72 boasts excellent Flexlife properties, which ensure highest stability in any environment that is exposed to a lot of vibration and motion.
- Contact properties: The crimp qualities of Histral® H72 correspond to those of pure copper in hard condition. However, the tools applied have to be adapted to the lower cross-sections.
- Reduced weight: The outstanding properties of Histral® H72 translate into much lower cross-sections supporting the same breaking load if compared to pure copper. For a breaking load of 70 N a pure copper strand must have a cross-section of 0.35 mm2, whereas the comparable value for a strand made out of Histral® H72 is 84 N at a cross-section of only 0.13 mm2, by means of which a weight reduction by 63 % can be achieved! Using weight as a reference value, a copper strand requires 0.0445 (g/m) per each 1 N of breaking load, with Histral® H72 attaining the same breaking load at a weight of just 0.0136 (g/m).
- Thermal stability: Pure copper in hard condition is susceptible to re-crystallization even at room temperature, at which it already begins to soften again resulting in a loss of mechanical strength. Adding on small quantities of alloys will suffice to vastly increase the point of re-crystallization of hard-drawn materials so that the greater strength is maintained in the event of higher ambient temperature, too. Histral® H72 has a much better thermal stability than pure copper. Hence, it is also suited for those applications that are subjected to elevated temperatures.
- Resistance: Histral® H72 has a slightly higher resistance than pure copper, while still boasting a conductivity of 80 % IACS (in soft condition).
Histral® H72 can be used for the following applications:
- Automotive industry: The emphasis is more and more shifting towards environmental protection and husbanding of resources, with the focus revolving around the minimization of weight and consumption accompanied by heightened standards of safety and comfort. The growing use of electronic assistance systems constitutes a major step in this direction, which entails an increasing demand for signal cables. At the same time, the space accorded to cable harnesses is declining because of optimized safety systems. Signal cables made from Histral® H72 have the potential to render an important contribution to overcoming this predicament.
- Data cables / Signal cables: Its small alloy portion reduces the resistance value of Histral® H72 no more than a little, as compared with pure copper. Thus, the very good electrical conductivity of the material remains unaffected whilst its excellent mechanical strength persists. This makes it a perfect fit for data cables and signal cables featuring very low diameters and cross-sections, but also a sufficient tensile strength.
- Automation technology / Industrial applications: Histral® H72 boasts excellent Flexlife properties, which ensure highest stability in any environment that is exposed to a lot of vibration and motion.
- Loudspeakers: The connection cables of loudspeaker membranes are exposed to extremely strong vibrations. Histral® H72 lends itself well to this application owing to its great mechanical strength in combination with a very good conductivity, in particular as a substitute for cadmium-containing alloys used in the past.
- Miniaturisation: On account of its outstanding mechanical properties, Histral® H72 will not pose any problems when processed downstream into wires as fine as 0.025 mm (AWG 50). It keeps its conductivity level and remains an alloy that is highly suitable for being electro-plated.
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0216 | 0.0240 |
| Electrical conductivity* (%IACS) | 80 | 74 |
| Tensile strength* (N/mm²) | 250 | 600 |
| Elongation* (%) | 20 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00290 | 0.00290 |
| Density (g/cm³) | 8.9 | 8.9 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- LV112-4 DRAFT
- DIN CEN/TS 13388
Availability**
- Coating: Bare, Silver, Nickel, Tin, Gold
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.025 mm (AWG 50)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H77:
- Very high electrical conductivity: Due to the alloy portion in Histral® H77 being very low, there is just a slight decrease in resistance if compared with pure copper. Thus, the material preserves its high electrical conductivity while also featuring a great mechanical strength. Therefore, the material lends itself perfectly to strands where the very low diameter or cross-section must not lead to inadequate tensile strength.
- Good mechanical strength: Histral® H77 is counted among the so-called “low-alloyed copper products“, the copper portion of which is 99.8 % of copper, with no more than the remaining 0.2 % covered by alloy additives (mainly magnesium in this case). Having been hard drawn, its mechanical properties even improve, without the very good electrical qualities being impaired. This phenomenon allows for a significant reduction of cross-sections. Consequentially, Histral® H77 lends itself well to applications in which reduced weight plays a primary role. A prime example for this is signal cables, but also shielding braids, both of which require an above-average mechanical strength in order for the actual conductor to be sufficiently protected.
- Flex Life properties: Alloys are usually employed in hard condition. Histral® H77 boasts excellent Flexlife properties, which ensure highest stability in any environment that is exposed to a lot of vibration and motion.
- Contact properties: The crimp qualities of Histral® H77 correspond to those of pure copper in hard condition. However, the tools applied must be adapted to the lower cross-sections.
- Reduced weight: The outstanding properties of Histral® H77 translate into much lower cross-sections supporting the same breaking load if compared to pure copper. For a breaking load of 70 N a pure copper strand must have a cross-section of 0.35 mm2, whereas the comparable value for a strand made from Histral® H77 is 84 N at a cross-section of only 0.13 mm2, by means of which a weight reduction by 63 % can be achieved! Using weight as a reference value, a copper strand requires 0.0445 (g/m) per each 1 N of breaking load, with Histral® H77 attaining the same breaking load at a weight of just 0.0136 (g/m).
- Thermal stability: Pure copper in hard condition is susceptible to re-crystallization even at room temperature, at which it already begins to soften again resulting in a loss of mechanical strength. Adding on small quantities of alloys will suffice to vastly increase the point of re-crystallization of hard-drawn materials so that the greater strength is maintained in the event of higher ambient temperature, too. Histral® H77 has a much better thermal stability than pure copper. Hence, it is also suited for those applications that are subjected to elevated temperatures.
- Resistance: Histral® H77 has a slightly higher resistance than pure copper, while still boasting a conductivity of 85 % IACS (in soft condition).
Histral® H77 can be used for the following applications:
- Automotive industry: The emphasis is more and more shifting towards environmental protection and husbanding of resources, with the focus revolving around the minimization of weight and consumption accompanied by heightened standards of safety and comfort. The growing use of electronic assistance systems constitutes a major step in this direction, which entails an increasing demand for signal cables. At the same time, the space accorded to cable harnesses is declining because of optimized safety systems. Signal cables made from Histral® H77 have the potential to render an important contribution to overcoming this predicament.
- Data cables / Signal cables: Its small alloy portion reduces the resistance value of Histral® H77 no more than a little, as compared with pure copper. Thus, the very good electrical conductivity of the material remains unaffected whilst its excellent mechanical strength persists. This makes it a perfect fit for data cables and signal cables featuring very low diameters and cross-sections, but also a sufficient tensile strength.
- Automation technology / Industrial applications: Histral® H77 boasts excellent Flexlife properties, which ensure highest stability in any environment that is exposed to a lot of vibration and motion.
- Loudspeakers: The connection cables of loudspeaker membranes are exposed to extremely strong vibrations. Histral® H77 lends itself well to this application owing to its great mechanical strength in combination with a very good conductivity, in particular as a substitute for cadmium-containing alloys used in the past.
- Miniaturisation: On account of its outstanding mechanical properties, Histral® H77 will not pose any problems when processed downstream into wires as fine as 0.025 mm (AWG 50). It keeps its conductivity level and remains an alloy that is highly suitable for being electro-plated.
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0171 | 0.0178 |
| Electrical conductivity* (%IACS) | 99 | 95 |
| Tensile strength* (N/mm²) | 220 | 520 |
| Elongation* (%) | 20 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00381 | 0.00381 |
| Density (g/cm³) | 8.9 | 8.9 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- LV112-4 DRAFT
- DIN CEN/TS 13388
Availability**
- Coating: Bare, Silver, Nickel, Tin, Gold
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.025 mm (AWG 50)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H79:
- Very high electrical conductivity: Due to the alloy portion in Histral® H79 being very low, there is just a slight decrease in resistance if compared with pure copper. Thus, the material preserves its high electrical conductivity while also featuring a great mechanical strength. Therefore, the material lends itself perfectly to strands where the very low diameter or cross-section must not lead to inadequate tensile strength.
- Good mechanical strength: Histral® H79 is counted among the so-called “low-alloyed copper products“, the copper portion of which is 99.9 % of copper, with no more than the remaining 0.1 % covered by alloy additives (mainly silver in this case). Having been hard drawn, its mechanical properties even improve, without the very good electrical qualities being impaired. This phenomenon allows for a significant reduction of cross-sections. Consequentially, Histral® H79 lends itself well to applications in which reduced weight plays a primary role. A prime example for this is signal cables, but also shielding braids, both of which require an above-average mechanical strength in order for the actual conductor to be sufficiently protected.
- Reduced weight: The outstanding properties of Histral® H79 translate into much lower cross-sections supporting the same breaking load if compared to pure copper.
- Thermal stability: Pure copper in hard condition is susceptible to re-crystallization even at room temperature, at which it already begins to soften again resulting in a loss of mechanical strength. Adding on small quantities of alloys will suffice to vastly increase the point of re-crystallization of hard-drawn materials so that the greater strength is maintained in the event of higher ambient temperature, too. Histral® H79 has a much better thermal stability than pure copper. Hence, it is also suited for those applications that are subjected to elevated temperatures.
- Resistance: Histral® H79 has nearly the same resistance as pure copper, while still boasting a conductivity of 99 % IACS (in soft condition).
- Contact properties: The crimp qualities of Histral® H79 correspond to those of pure copper in hard condition. However, the tools applied have to be adapted to the lower cross-sections.
Histral® H79 can be used for the following applications:
- Automotive industry: The emphasis is more and more shifting towards environmental protection and husbanding of resources, with the focus revolving around the minimization of weight and consumption accompanied by heightened standards of safety and comfort. The growing use of electronic assistance systems constitutes a major step in this direction, which entails an increasing demand for signal cables. At the same time, the space accorded to cable harnesses is declining because of optimized safety systems. Signal cables made from Histral® H79 have the potential to render an important contribution to overcoming this predicament.
- Data cables / Signal cables: Its small alloy portion reduces the resistance value of Histral® H79 no more than a little, as compared with pure copper. Thus, the very good electrical conductivity of the material remains unaffected whilst its excellent mechanical strength persists. This makes it a perfect fit for data cables and signal cables featuring very low diameters and cross-sections, but also a sufficient tensile strength.
- Miniaturisation: On account of its outstanding mechanical properties, Histral® H79 will not pose any problems when processed downstream into wires as fine as 0.025 mm (AWG 50). It keeps its conductivity level and remains an alloy that is highly suitable for being electro-plated.
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0203 | 0.0216 |
| Electrical conductivity* (%IACS) | 85 | 80 |
| Tensile strength* (N/mm²) | 350 | >650 |
| Elongation* (%) | 6 | 1 |
| Temperature coefficient of resistance (1/°C) | 0.00320 | 0.00320 |
| Density (g/cm³) | 8.9 | 8.9 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- EN 2083
- EN 4434
- DIN CEN/TS 13388
Availability**
- Coating: Bare, Silver, Nickel, Tin, Gold
- Temper: Tempered or hard
- Single end conductors
- Stranded conductors
- Bunched conductors
- Concentric lay conductors
- Single end size ≥ 0.025 mm (AWG 50)
- Other diameters or special constructions are available
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H85:
- Excellent conductivity: The electrical conductivity of Histral® H85 can exceed 85 % IACS (International Annealed Copper Standard). This is extremely favourable compared to most alterative materials in its category and surpasses the requirements of the most exacting specifications within its applications.
- High mechanical strength: The tensile strength of Histral® H85 exceeds the highest expectations of the traditional “Copper-Cadmium” category of high strength / high conductivity copper alloys. This alloy is therefore ideally suited to applications where the finished product is exposed to a high degree of tension and drag – for example in automotive and aerospace environments where the finished cable is pulled through small openings. The high strength characteristic allows for smaller and lighter conductors, without performance loss.
- Flex Life properties: Histral® H85 gives above average performance levels in situations where vibration or constant flexing is present. It can be stranded or braided for optimum flexibility.
- Weight reduction: Histral® H85 conductors can be up to 25 % lighter compared to standard copper conductors. This appreciable weight saving is crucial in today’s commercial and military aviation market and is becoming increasingly important in the automotive industry – with continual innovations in new technologies such as performance monitoring, enhanced comfort and the ever-increasing electrification of vehicles.
- High temperature resistance: High tensile strength is maintained even at high temperatures. Histral® H85 can be silver plated, where solderable connections are required, and can be nickel plated – up to 27 % nickel plate – for ultimate temperature resistance and for protection in harsh environments.
Histral® H85 can be used for the following applications:
- Aviation: Histral® H85 meets the requirements of EN 2083, EN 4434, ISO 2635 and BS 3G 231. The extremely high tensile strength of the alloy ensures that there are no installation issues. The weight saving of up to 25 % achieved by using smaller cross sections is a significant benefit. Strands of 19 x 0.12 mm and 19 x 0.10 mm have been successful and are widely used for signal transmission in cockpit, communication, and entertainment areas.
- Shielding braids: With its exceptional strength Histral® H85 is an ideal solution for shielding cables that undergo a wide range of mechanical stresses. The potential for miniaturisation offers an additional advantage – with many composite cables containing various cross sections, an excellent shielding braid that requires minimal space is extremely important.
- Industry: In particular the automation and robotics industry make extremely high demands on signal cables. Constantly changing tensions along with vibration and flexing require conductors with excellent strength and flexibility.
- Miniaturisation: The exceptionally high mechanical strength of Histral® H85 means that it can be drawn down to diameters as fine as AWG50 (0.025 mm) whilst still retaining its performance characteristics.
- Micro data cables: Electronic devices are constantly getting smaller and ever more powerful. Whether in folding mobile phones, laptops or other small communication devices ultra-thin cables are on the increase.
| Nominal values | Tempered | Hard |
|---|---|---|
| Resistivity* (Ohm mm²/m) | 0.0203 | 0.0216 |
| Electrical conductivity* (%IACS) | ≥85 | ≥80 |
| Tensile strength* (N/mm²) | ≥414 | ≥600 |
| Elongation* (%)≥414 | ≥8 | >1 |
| Temperature coefficient of resistance (1/°C) | 0.00300 | 0.00300 |
| Density (g/cm³) | 8.9 | 8.9 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- EN 2083 together with ASTM B8 and ASTM B298/ASTM B961
- DIN 48200 ff.
Availability**
- Coating: bare, silver, gold
- Temper: hard-drawn or thermal stress-relieved
- Single-end conductor (only in hard) 0.32 mm (AWG 28) > Ø ≥ 0.025 mm (AWG 50)
- Concentric lay conductors
- Stranded conductors
- Braided conductors
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H88:
- Environmentally friendly: As with the entire Histral® range of materials, H88 is environmentally friendly and fully RoHS compliant. Our product is therefore a sustainable alternative to the health hazards posed by copper-cadmium alloys. If you are thinking of switching to environmentally friendly materials, we will be happy to advise you and support you with any certified products you may require.
- Very good conductivity: In its tempered stated, the conductivity of Histral® H88 reaches approx. 85% IACS (International Annealed Copper Standard) and therefore outperforms most alternative materials in its category. In many application areas, the requirements from specifications are significantly exceeded.
- High flex life performance: The exceptionally good values achieved by Histral® H88 offer maximum stability in vibration- and motion-rich environments.
- Low weight: Opportunities for narrower diameters combined with the material’s excellent properties mean that Histral® H88 can be effectively deployed in order to achieve weight reductions. This is a key argument for its use, especially in the aviation industry.
- High mechanical strength: Histral® H88 is a high-strength and highly conductive copper alloy that significantly exceeds the properties of conventional copper-cadmium alloys. Thanks to its excellent tensile strength, the material is ideal for use in areas where cables are exposed to high loads during installation and operation. The material has proven to be a particularly good choice for drag chains in machinery manufacturing or for interconnecting loudspeaker membranes subject to constant vibration. In medical technology, wires are used with the very finest single-end conductor diameters down to 0.025 mm/AWG 50.
- High temperature resistance: Histral® H88 maintains its good mechanical and electrical properties even in high-temperature applications up to 260 °C. If cable production involves a sintering process, steps must be taken to avoid temperatures >380 °C. The sintering process itself must last only a few seconds. The subsequent cooling process should be gentle (no quenching).
Histral® H88 can be used for the following applications:
- Rail applications: Histral® H88 is now very well-established as a material for use in overhead line systems for high-speed lines. The vertical suspension cable connecting the aerial messenger to the contact wire is subjected to extreme mechanical, electrical, and thermal loads. As it passes through, the power consumption of an ICE, Shinkansen or TGV train will rapidly heat these suspension cables. At the same time, the suspension cables have to compensate for the strong vibrations in the entire overhead contact line section, as caused by the pantograph’s high contact pressure. This is where Histral® H88 keeps going long after conventional materials used in overhead line construction have failed.
- Shielding braids: As a result of its exceptional strength, Histral® H88 is particularly suitable for shielding cables subject to excessive mechanical stress. Another advantage here is the possibility of miniaturisation. Our material offers a space-optimised solution especially in cases where many cables must be installed in cramped conditions.
- Manufacturing: Automation technology and robotics make exceptionally high demands on wires used for signaling. Histral® H88 offers a reliable solution for constantly cycling loads such as bending, and torsion combined with strong vibrations.
- Membrane connections for loudspeakers: Connecting cables in loudspeakers are exposed to extremely strong vibrations. Here, wires made from Histral® H88 are processed into special-purpose braids that are used to connect up the membranes (oscillating coil).
- Medical technology: Histral® H88 has been a reliable component in signal cables for specialised micro-operation devices for several years. In cardiac catheter exams, for example, a miniature camera is guided through the veins to the heart. In some cases, connecting cables may be subjected to high tensile loads because of cables being suddenly jerked or kinked in the process. Maximum reliability in the smallest of installation spaces is essential here. Not least because the safety of the patient is paramount.
- Miniaturisation: The exceptionally high mechanical strength offered by the Histral® H88 alloy means that the material can be easily drawn into wires with a diameter of 0.025 mm (AWG 50) without losing performance capabilities.
- Microdata lines: Electronic devices are becoming smaller and smaller, and yet even more powerful. From clamshell mobile phones and laptops to other miniaturised devices, ultra-thin wires are used for data transmission in all these products. Silver-coated single-end conductors with diameters as small as 0.025 mm (AWG 50), with strands up to 7x Ø 0.025 mm (AWG 42) are used here.
| Nominal values | Tempered |
|---|---|
| Resistivity* (Ohm mm²/m) | 0.0203 |
| Electrical conductivity* (%IACS) | >85 (bare, silver) >79 (nickel) |
| Tensile strength* (N/mm²) | 414 |
| Elongation* (%)≥414 | 8 |
| Temperature coefficient of resistance (1/°C) | 0.00300 |
| Density (g/cm³) | 8.9 |
* Data depend on coating conditions, degree of cold working and thermal treatments during manufacturing process
Specifications
- ASTM B624 together with ASTM B8, ASTM B298/ASTM B961 and ASTM B355
- SAE AS 29606
- SAE AS 22759
- EN 2083
- EN 4434
Availability**
- Coating: bare, silver, nickel
- Temper: thermal stress-relieved
- Concentric lay conductors – manufactured from 0.32 mm single-end conductors (AWG 28) > Ø ≥ 0.025 mm (AWG 50)
- Stranded conductors – manufactured from 0.32 mm single-end conductors (AWG 28) > Ø ≥ 0.05 mm (AWG 44)
- Bunched conductors – manufactured from 0.32 mm single-end conductors (AWG 28) > Ø ≥ 0.05 mm (AWG 44)
- Braided conductors – manufactured from 0.32 mm single-end conductors (AWG 28) > Ø ≥ 0.127 mm (AWG 36)
- Other diameters, special designs or special coatings (e.g. gold) on request
** Depending on material combination & construction
Special properties of Aerumtec’s Histral® H95:
- Environmentally friendly: As with the entire Histral® range of materials, H95 is environmentally friendly and fully RoHS compliant. Our product is therefore a sustainable alternative to the health hazards posed by copper-cadmium alloys. If you are thinking of switching to environmentally friendly materials, we will be happy to advise you and support you with any certified products you may require.
- Excellent conductivity: The conductivity of Histral® H95 exceeds 5% IACS (International Annealed Copper Standard) in its bare and silver state. In combination with the highly corrosion-resistant nickel coating, values between 70% and 80% are still achieved. The product therefore exceeds requirements from standards for high-strength and simultaneously highly conductive conductor materials.
- Exceptionally high mechanical strength: Histral® H95 is a high-strength and highly conductive copper alloy that significantly exceeds the properties of conventional copper-cadmium alloys. The extreme tensile strength of this material makes it the ideal choice for small installation spaces or low-weight applications that are at the same time exposed to high mechanical or thermal stresses. With these characteristics, the product is predestined for applications in aerospace, medical technology and robotics.
- High temperature resistance: Histral® H95 maintains its excellent mechanical and electrical properties even in high-temperature applications up to 260 °C. If cable production involves a sintering process, steps must be taken to avoid temperatures >380 °C. The sintering process must last only a few seconds. The subsequent cooling process must be completed carefully and with a low temperature gradient; quenching must be avoided.
- Best flex life performance: Compared with other electrical conductor materials, Histral® H95 achieves optimum values in terms of fatigue strength. A high level of reliability and a long service life are achieved with all cables moved cyclically – whether by bending, torsion, vibration, or oscillation. In the standardised test according to ASTM B470, a wire made of Histral® H95 can withstand thirty times more load cycles than an identical wire made of electrolytic copper. Our material is therefore recommended for use in drag chains under heavy load as well as in robotics or in the high-vibration environment of an aircraft fuselage.
- Low weight: Alongside its good fatigue strength, the excellent conductivity of Histral® H95 also makes it an ideal choice for applications in the aerospace industry. In the adverse environmental conditions present in aircraft or rocket interiors, both data lines and power cables must always function safely and reliably. For power transmission cables, the key design criterion here is the length-specific resistance. As the conductivity of Histral® H95 is close to that of electrolytic copper, the load-bearing cable cross-section increases only slightly with the same maximum resistance. The increase in mechanical reliability therefore only results in a slight increase in weight.
Histral® H95 can be used for the following applications:
- Aerospace: Histral® H95 meets the requirements of the ASTM B624, SAE AS22759, EN 2083 and EN 4434 standards. The extremely high strength of the cables offers an optimum level of safety during installation and operation. Good conductivity also facilitates weight-saving designs.
- Shielding braids: As a result of its good fatigue behaviour, Histral® H95 is particularly suitable for shielding cables subject to excessive mechanical stress. Another advantage here is the possibility of miniaturisation. In cases where many different wires need combining into one cable, excellent shielding in a minimal installation space is extremely important.
- Manufacturing: Automation technology and robotics make exceptionally high demands on wires used for signaling. Constantly changing loads accompanied by strong vibrations and oscillations present a particular challenge to cable flexibility.
- Miniaturisation: The exceptionally high mechanical strength offered by the Histral® H95 alloy means that the material can be easily drawn into wires with a diameter of 0.05 mm (AWG 44) without losing performance capabilities.
Further information
Alloy metals and their impact on
copper wires for electric conductors
Do you have special requirements? Contact us!
Not sure which of our Histral®H high strength alloys is suitable for your application? Get in contact with us! We are happy to advise you!
