MIL-STD-981C
5.5.9.6 Terminations. The recommended method to anchor the lead is shown in Figures 1 and 2. The lead anchor shall be performed with minimum use of tape wrap to keep outgassing low. (See 5.5.9.5.)
5.5.9.7 Magnet wire to terminal post connections. Recommended magnet wire (wire or coil) to terminal post connections are depicted in Figure 3 a-h, j, k, m, n, and p. For high voltage, corona-free connections, no protruding wires are allowed and balling of the joint is recommended. Care shall be exercised when using the heat shrink tubing to avoid the concentration of heat at the solder joint. Heat shall be controlled in accordance with manufacturer's stated recommended conditions.
5.5.9.8 Antirotation feature. Each terminal lead shall be internally constructed as illustrated on Figure
4 or equivalent. Flattened or dimpled area thickness shall be no less than one-half the lead diameter and shall not exhibit sharp edges. The radius, R, shall be no greater than twice or less than one times the diameter of the terminal lead. This radius shall be formed prior to soldering. The antirotation feature shall be completely contained within the magnetic device package. Antirotation is not applicable to all axial leaded parts listed for Families 04, 13, 14, 50, 51 and 52.
5.5.9.9 Terminal twist. Finished devices with solid wire terminals shall meet the terminal twist test in accordance with MIL-STD-202, method 211, test condition D without causing discontinuity in the winding. When the bending of the terminal leads, as specified in MIL-STD-202, is impractical, the device shall be held stationary. The lead shall be clamped in a hand chuck and the chuck rotated as required. During the twist test, the winding shall be monitored for open circuit with equipment able to detect dropouts of 100 microseconds or less.
5.5.9.10 Toroidal winders. Shuttle rings and sliders must be inspected for nicks, burrs and rough spots. Inspect the toroid for physical damage after removal from the shuttle.
5.5.9.11 De-reeling. De-reeling (de-spooling) devices shall be such that they do not cause variations in tension beyond the control of the tension device (see 5.5.9.1). All portions of the device which contact the magnet wire (pulleys, sliders, spool flange, etc) shall be free of nicks, burrs, and rough spots.
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