Hello all. I have to come up with a recommended maximum current carrying capacity for electrical leads in a microelectronic enclosure situation. The company I work for as an IT guy does the TO- & other / custom electronic enclosures for our customers to then populate - we make glass- & ceramic-to-metal seals in metal packages.
One of technical datasheets they had me come up with years ago needs updating, as we've been told by some of our customers that our data's extremely conservative.
Anyway, we traditionally deal with .018", .020", .025", .030", .040", .050", .060", .080", & .090" diameter leads, that are usually shorter than 1" long (some as long as 2", but VERY rare). Application can be open air, altitude to 80,000 feet, space applications, etc. Lead materials can be copper / glidcop, Kovar (iron-nickel-cobalt alloy / ASTM F-15), Alloy 52 (iron-nickel ASTM F-30), or a Cu core through an Alloy 52 wire (3:1 52 Alloy to Cu). NO insulation. Inside of packages can be nitrogen or other inert gas filled, population of the inside of the package can be anything - we won't know how crammed the package is. Our packs are open-cavity from say, .415" sq. x .150" high through 10"L x 3" wide x 1" high we'll say. The actual feedthru lead is the same regardless. Diameter of the glass or ceramic seal will vary. Temp rise can be significant, package materials can be braze / solder that reflows at lower temps, so we're looking at a maximum of 200° C package / environment temps.
We're obviously not talking about running cable through household walls here.
I've been looking at Fourier / Neher-McGrath, but I don't have enough info to really work with this, given my (pitiful) background.
This is the old data I have (oops! Table didn't copy & paste...):
[SIZE=-1]Material /
[/SIZE][SIZE=-1]Pin Diameter [/SIZE][SIZE=-1](Inches)[/SIZE] / [SIZE=-1]Pin Diameter [/SIZE][SIZE=-1](Millimeters)[/SIZE] / [SIZE=-1]Max. Recommended Current (Amps)[/SIZE]
[SIZE=-1]Kovar ASTM F-15 Alloy[/SIZE]
[SIZE=-1].020 / [/SIZE][SIZE=-1]0.51 / 1/0A[/SIZE]
[SIZE=-1].030 / [/SIZE][SIZE=-1]0.76 / [/SIZE][SIZE=-1]3.0A[/SIZE]
[SIZE=-1].040 / [/SIZE][SIZE=-1]1.02 / [/SIZE][SIZE=-1]5.0A[/SIZE]
[SIZE=-1].050 / [/SIZE][SIZE=-1]1.27 / [/SIZE][SIZE=-1]7.5A[/SIZE]
[SIZE=-1].060 / [/SIZE][SIZE=-1]1.52 / [/SIZE][SIZE=-1]10.0A[/SIZE]
[SIZE=-1].080 / [/SIZE][SIZE=-1]2.03 / [/SIZE][SIZE=-1]15.0A[/SIZE]
[SIZE=-1].090 / [/SIZE][SIZE=-1]2.29 / [/SIZE][SIZE=-1]18.0A[/SIZE]
[SIZE=-1]52 Alloy ASTM F-30 Alloy[/SIZE]
[SIZE=-1].020 / [/SIZE][SIZE=-1]0.51 / [/SIZE][SIZE=-1]1.0A[/SIZE]
[SIZE=-1].030 / [/SIZE][SIZE=-1]0.76 / [/SIZE][SIZE=-1]3.3A[/SIZE]
[SIZE=-1].040 / [/SIZE][SIZE=-1]1.02 / [/SIZE][SIZE=-1]5.5A[/SIZE]
[SIZE=-1].050 / [/SIZE][SIZE=-1]1.27 / [/SIZE][SIZE=-1]8.0A[/SIZE]
[SIZE=-1].060 / [/SIZE][SIZE=-1]1.52 / [/SIZE][SIZE=-1]11.0A[/SIZE]
[SIZE=-1].080 / [/SIZE][SIZE=-1]2.03 / [/SIZE][SIZE=-1]17.5A[/SIZE]
[SIZE=-1].090 / [/SIZE][SIZE=-1]2.29 / [/SIZE][SIZE=-1]20.0A[/SIZE]
[SIZE=-1]52 Alloy, Cu Core[/SIZE]
[SIZE=-1].020 / [/SIZE][SIZE=-1]0.51 / [/SIZE][SIZE=-1]3.0A[/SIZE]
[SIZE=-1].030 / [/SIZE][SIZE=-1]0.76 / [/SIZE][SIZE=-1]9.0A[/SIZE]
[SIZE=-1].040 / [/SIZE][SIZE=-1]1.02 / [/SIZE][SIZE=-1]15.0A[/SIZE]
[SIZE=-1].050 / [/SIZE][SIZE=-1]1.27 / [/SIZE][SIZE=-1]24.0A[/SIZE]
[SIZE=-1].060 / [/SIZE][SIZE=-1]1.52 / [/SIZE][SIZE=-1]35.0A[/SIZE]
[SIZE=-1].080 / [/SIZE][SIZE=-1]2.03 / [/SIZE][SIZE=-1]52.0A[/SIZE]
[SIZE=-1].090 [/SIZE][SIZE=-1]2.29 / [/SIZE][SIZE=-1]65.0A[/SIZE]
[SIZE=-1]CDA101 / OFH Copper [/SIZE][SIZE=-1]or GlidCop[/SIZE]
[SIZE=-1].020 / [/SIZE][SIZE=-1]0.51 / [/SIZE][SIZE=-1]4.0 - 10.0 [/SIZE][SIZE=-1](7.0)[/SIZE]
[SIZE=-1].030 / [/SIZE][SIZE=-1]0.76 / [/SIZE][SIZE=-1]9.0 - 17.0 [/SIZE][SIZE=-1](15.0)[/SIZE]
[SIZE=-1].040 / [/SIZE][SIZE=-1]1.02 / [/SIZE][SIZE=-1]16.0 - 27.0 [/SIZE][SIZE=-1](25.0)[/SIZE]
[SIZE=-1].050 / [/SIZE][SIZE=-1]1.27 / [/SIZE][SIZE=-1]25.0 - 42.0 [/SIZE][SIZE=-1](36.0)[/SIZE]
[SIZE=-1].060 / [/SIZE][SIZE=-1]1.52 / [/SIZE][SIZE=-1]36.0 - 60.0 [/SIZE][SIZE=-1](47.0)[/SIZE]
[SIZE=-1].080 / [/SIZE][SIZE=-1]2.03 / [/SIZE][SIZE=-1]64.0 - 107.0 [/SIZE][SIZE=-1](73.0)[/SIZE]
[SIZE=-1].090 / [/SIZE][SIZE=-1]2.29 / [/SIZE][SIZE=-1]81.0 - 135.0 [/SIZE][SIZE=-1](87.0)[/SIZE]
Copper's data in parenthesis was a recommended target. Again, this is old data that was handed down to me by an old engineering guy who's long since retired & his sources are long unknown.
Can anyone here help guide a non-EE guy along here? Thanks VERY much for your time, it's greatly appreciated. Happy to furnish additional info about the materials as needed, just need to know what you guys need...
Fred
One of technical datasheets they had me come up with years ago needs updating, as we've been told by some of our customers that our data's extremely conservative.
Anyway, we traditionally deal with .018", .020", .025", .030", .040", .050", .060", .080", & .090" diameter leads, that are usually shorter than 1" long (some as long as 2", but VERY rare). Application can be open air, altitude to 80,000 feet, space applications, etc. Lead materials can be copper / glidcop, Kovar (iron-nickel-cobalt alloy / ASTM F-15), Alloy 52 (iron-nickel ASTM F-30), or a Cu core through an Alloy 52 wire (3:1 52 Alloy to Cu). NO insulation. Inside of packages can be nitrogen or other inert gas filled, population of the inside of the package can be anything - we won't know how crammed the package is. Our packs are open-cavity from say, .415" sq. x .150" high through 10"L x 3" wide x 1" high we'll say. The actual feedthru lead is the same regardless. Diameter of the glass or ceramic seal will vary. Temp rise can be significant, package materials can be braze / solder that reflows at lower temps, so we're looking at a maximum of 200° C package / environment temps.
We're obviously not talking about running cable through household walls here.
I've been looking at Fourier / Neher-McGrath, but I don't have enough info to really work with this, given my (pitiful) background.
This is the old data I have (oops! Table didn't copy & paste...):
[SIZE=-1]Material /
[/SIZE][SIZE=-1]Pin Diameter [/SIZE][SIZE=-1](Inches)[/SIZE] / [SIZE=-1]Pin Diameter [/SIZE][SIZE=-1](Millimeters)[/SIZE] / [SIZE=-1]Max. Recommended Current (Amps)[/SIZE]
[SIZE=-1]Kovar ASTM F-15 Alloy[/SIZE]
[SIZE=-1].020 / [/SIZE][SIZE=-1]0.51 / 1/0A[/SIZE]
[SIZE=-1].030 / [/SIZE][SIZE=-1]0.76 / [/SIZE][SIZE=-1]3.0A[/SIZE]
[SIZE=-1].040 / [/SIZE][SIZE=-1]1.02 / [/SIZE][SIZE=-1]5.0A[/SIZE]
[SIZE=-1].050 / [/SIZE][SIZE=-1]1.27 / [/SIZE][SIZE=-1]7.5A[/SIZE]
[SIZE=-1].060 / [/SIZE][SIZE=-1]1.52 / [/SIZE][SIZE=-1]10.0A[/SIZE]
[SIZE=-1].080 / [/SIZE][SIZE=-1]2.03 / [/SIZE][SIZE=-1]15.0A[/SIZE]
[SIZE=-1].090 / [/SIZE][SIZE=-1]2.29 / [/SIZE][SIZE=-1]18.0A[/SIZE]
[SIZE=-1]52 Alloy ASTM F-30 Alloy[/SIZE]
[SIZE=-1].020 / [/SIZE][SIZE=-1]0.51 / [/SIZE][SIZE=-1]1.0A[/SIZE]
[SIZE=-1].030 / [/SIZE][SIZE=-1]0.76 / [/SIZE][SIZE=-1]3.3A[/SIZE]
[SIZE=-1].040 / [/SIZE][SIZE=-1]1.02 / [/SIZE][SIZE=-1]5.5A[/SIZE]
[SIZE=-1].050 / [/SIZE][SIZE=-1]1.27 / [/SIZE][SIZE=-1]8.0A[/SIZE]
[SIZE=-1].060 / [/SIZE][SIZE=-1]1.52 / [/SIZE][SIZE=-1]11.0A[/SIZE]
[SIZE=-1].080 / [/SIZE][SIZE=-1]2.03 / [/SIZE][SIZE=-1]17.5A[/SIZE]
[SIZE=-1].090 / [/SIZE][SIZE=-1]2.29 / [/SIZE][SIZE=-1]20.0A[/SIZE]
[SIZE=-1]52 Alloy, Cu Core[/SIZE]
[SIZE=-1].020 / [/SIZE][SIZE=-1]0.51 / [/SIZE][SIZE=-1]3.0A[/SIZE]
[SIZE=-1].030 / [/SIZE][SIZE=-1]0.76 / [/SIZE][SIZE=-1]9.0A[/SIZE]
[SIZE=-1].040 / [/SIZE][SIZE=-1]1.02 / [/SIZE][SIZE=-1]15.0A[/SIZE]
[SIZE=-1].050 / [/SIZE][SIZE=-1]1.27 / [/SIZE][SIZE=-1]24.0A[/SIZE]
[SIZE=-1].060 / [/SIZE][SIZE=-1]1.52 / [/SIZE][SIZE=-1]35.0A[/SIZE]
[SIZE=-1].080 / [/SIZE][SIZE=-1]2.03 / [/SIZE][SIZE=-1]52.0A[/SIZE]
[SIZE=-1].090 [/SIZE][SIZE=-1]2.29 / [/SIZE][SIZE=-1]65.0A[/SIZE]
[SIZE=-1]CDA101 / OFH Copper [/SIZE][SIZE=-1]or GlidCop[/SIZE]
[SIZE=-1].020 / [/SIZE][SIZE=-1]0.51 / [/SIZE][SIZE=-1]4.0 - 10.0 [/SIZE][SIZE=-1](7.0)[/SIZE]
[SIZE=-1].030 / [/SIZE][SIZE=-1]0.76 / [/SIZE][SIZE=-1]9.0 - 17.0 [/SIZE][SIZE=-1](15.0)[/SIZE]
[SIZE=-1].040 / [/SIZE][SIZE=-1]1.02 / [/SIZE][SIZE=-1]16.0 - 27.0 [/SIZE][SIZE=-1](25.0)[/SIZE]
[SIZE=-1].050 / [/SIZE][SIZE=-1]1.27 / [/SIZE][SIZE=-1]25.0 - 42.0 [/SIZE][SIZE=-1](36.0)[/SIZE]
[SIZE=-1].060 / [/SIZE][SIZE=-1]1.52 / [/SIZE][SIZE=-1]36.0 - 60.0 [/SIZE][SIZE=-1](47.0)[/SIZE]
[SIZE=-1].080 / [/SIZE][SIZE=-1]2.03 / [/SIZE][SIZE=-1]64.0 - 107.0 [/SIZE][SIZE=-1](73.0)[/SIZE]
[SIZE=-1].090 / [/SIZE][SIZE=-1]2.29 / [/SIZE][SIZE=-1]81.0 - 135.0 [/SIZE][SIZE=-1](87.0)[/SIZE]
Copper's data in parenthesis was a recommended target. Again, this is old data that was handed down to me by an old engineering guy who's long since retired & his sources are long unknown.
Can anyone here help guide a non-EE guy along here? Thanks VERY much for your time, it's greatly appreciated. Happy to furnish additional info about the materials as needed, just need to know what you guys need...
Fred
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