Industry professionals in North America rely on American Wire Gauge (AWG) standards to determine the best wire gauge for their residential or commercial applications. These standards also guide professionals in choosing wire according to the following properties:
- Area
- Current capacity (amps)
- Diameter
- Frequency (Hz)
- Resistance (ohms)
What Are AWG Standards?
AWG is the North American standard for sizing solid, round, single-strand wires. The electrical wire size is dependent upon its electrical resistance and current-carrying capacity. As the number of the wire gauge increases, the wire diameter decreases.
For example:
- The smallest wire gauge is 40 AWG, with a diameter of 0.08128 mm (0.0032″)
- The largest wire gauge is 0000 AWG, with a diameter of 11.7 mm (0.46″)
The cross-section and wire diameter standards exclude the insulation coating.
Analyzing Design in Accordance with Conductor Properties and AWG Standards
Wire gauge refers to the electrical resistance of a wire and its construction. Considering the following aspects is paramount when analyzing design concepts for wiring projects:
- Conductor shape and dimensions. Explore the properties of square vs. round wire conductors. While square wires have a 27% higher volumetric occupancy ratio than round conductors, square conductors have between 15% and 20% lower direct current resistance (DCR), translating to a reduction in power.
- Resistance factors. Electrical resistance obstructs current flow and is affected by the length, material, temperature, and thickness of the wire. Thinner wires contain fewer electrons and can increase resistance, while thicker wires carry more electrons, resulting in lower resistance. The wire gauge number indicates the wire size and level of electrical resistance.
- Weight. The weight of a wire influences its function and application.
General Properties of Aluminum/Copper Conductor Material
Aluminum and copper are low-resistance conductors that exhibit high corrosion resistance and excellent conductivity. To determine the best material for a given project, consider the following electrical and physical properties:
| Physical Properties | Copper | Aluminum |
|---|---|---|
| Density at 68 °F | 0.3212 pounds/inch³ | 0.09765 pounds/inch³ |
| Thermal capacity at 68 °F | 0.0921 BTU/pound/°F | 0.214 BTU/pound/°F |
| Thermal conductivity at 68 °F | 1.15 BTU/foot²/sec/°F/inch | 0.66 BTU/foot²/sec/°F/inch |
| Thermal coefficient of expansion, linear change in length at 32 °F | 16.9 × 10⁻⁶ | 23.8 × 10⁻⁶ |
| Melting point | 1,980 °F | 1,220 °F |
| Tensile characteristics, annealed, at 68 °F: Ultimate strength, Yield strength | 36,000–40,000 pounds/inch² 9,000–12,000 pounds/inch² | 9,000–14,000 pounds/inch² 4,000–7,000 pounds/inch² |
| Electrical Properties | Electrical Properties | Electrical Properties |
|---|---|---|
| IACS volume conductivity at 68 °F | 100% | 61.8% |
| Volume resistivity at 68 °F | 10.371 (ohm) × (circular mil)/foot | 16.782 (ohm) × (circular mil)/foot |
| Weight resistivity at 68 °F | 875.2 (ohm) × (pound)/mile² | 430.59 (ohm) × (pound)/mile² |
| Thermal coefficient of resistance at 68 °F Change in unit resistance at 68 °F | 0.00393 | 0.00408 |
Consult the Essex handbook for further details about aluminum and copper conductors.
General Conductor Resources
AWG determines the resistance of an electrical wire, as well as the amount of electrical current it can safely conduct. See the Essex handbook for more information regarding conductor properties.
Round Conductor Resources
According to AWG standards, round copper conductors range in size from 4 to 46 and are measured according to the following parameters:
- Single build diameter
- Heavy build diameter
- Triple build diameter
Download the AWG Round Copper Conductor Chart for more details regarding the AWG standards for round conductors.
Round Conductor Properties
There are minimum and maximum recommended winding tensions for round conductors. The wire should be adjusted based on the following factors:
- Coil type
- Payoff device
- Type of winder
- Softness of the wire
Square Conductor Resources
The AWG sizes for square conductors range from 0 to 14, with specifications that cover the following:
- Bare wire
- Double dacron wires
- Heavy build film-insulated
Download the Square Conductor AWG Standards Chart for more information regarding square conductors.
Square Conductor Properties
Square conductors are specified according to the following properties:
- Density
- Melting point
- Thermal capacity
- Ultimate strength
- Yield strength
Download the Essex handbook for more information regarding square conductor properties.
AWG Conductors and Expertise from Custom Coils, Inc.
When developing an electrical project, it is crucial to understand wire gauge specifications. Selecting the proper type of AWG wire and determining if you need square or round conductors can be challenging.
At Custom Coils, Inc., our experienced team is committed to going the extra mile throughout the product development cycle to meet or exceed customer expectations. Since 1978, we have helped our customers navigate complex design requirements, supporting them through research cycles, testing and prototype projects, and full-scale production runs.
We implement best manufacturing practices to build superior products, and our team is readily available to offer ongoing customer support and guidance. Our facilities are ISO 9001:2015 and ISO 13485 certified for exceptional quality control, with all of our parts meeting UL, NEMA, and ISO standards.
Contact us to learn more about AWG standards, or request a quote to get started with your project. You can also schedule a free consultation to discuss your needs.