M81824/1-2 - Copper Alloy Terminal Butt Splice

M81824/1-2 – Uninsulated Butt Splice for 12-10 AWG Wire

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Overview

The M81824/1-2 is a military-specification, permanent electrical butt splice designed to create a high-reliability, in-line connection for 12 to 10 AWG wires. This is a crimp-style terminal, engineered to form a mechanically and electrically sound joint that often exceeds the performance of the original wire itself. As an uninsulated splice (defined by the /1 slash sheet), it is intended for use in applications where the connection is environmentally protected within a larger assembly or where post-insulation, such as heat shrink tubing, will be applied.

Fabricated from a high-conductivity, tin-plated copper alloy, the M81824/1-2 is designed to create a gas-tight, cold-weld connection when installed with the proper calibrated tooling. This is not a commercial-grade connector; it is a flight-certified component designed to withstand the severe vibration, thermal cycling, and demanding electrical loads inherent in aerospace systems.

Key Features

• Military Specification Compliance: Manufactured and qualified in strict accordance with MIL-DTL-81824/1, ensuring the highest standards of material, performance, and quality control.

• For 12-10 AWG Wire: Precisely dimensioned for the yellow color-code wire range (12 AWG to 10 AWG), ensuring a perfect fit for the specified crimp die.

• High-Conductivity Copper Alloy: Constructed from a premium copper alloy to ensure minimum electrical resistance and negligible voltage drop across the splice.

• Tin-Plated Finish: Tin plating provides excellent corrosion resistance and enhances the electrical conductivity of the crimped connection by breaking down oxides during the crimp process.

• Uninsulated Seamless Barrel: The uninsulated design is ideal for use inside protected enclosures or for custom insulation applications. The seamless barrel ensures uniform strength and crimp performance.

• Requires Calibrated Crimp: Designed as part of a complete crimping system that includes a specified tool and die set to produce a certifiable, airworthy connection.

Technical Specifications

• Part Number: M81824/1-2

• Component Type: Permanent Crimp Butt Splice, Uninsulated

• Governing Specification: MIL-DTL-81824/1

• Material: High-Conductivity Copper Alloy

• Finish: Tin Plated

• Insulation: None

• Wire Gauge Range: 12 AWG to 10 AWG

• Color Code (Tooling): Yellow

• Required Crimp Tool System: Daniels Manufacturing Corp. (DMC) M22520/1-01 tool with M22520/1-02 (or equivalent) die set.

Aircraft Compatibility

The M81824/1-2 is a universal wiring system component used in the manufacturing, repair, and modification of electrical harnesses on virtually all certified aircraft, including those from:

• Textron Aviation (Cessna, Beechcraft, Hawker)

• Boeing

• Airbus

• Bombardier

• Embraer

• Gulfstream

• And all other major OEMs.

Note: This is a standard wiring component. Applicability is determined by the wire gauge and the requirements of the specific wiring repair as detailed in the aircraft's maintenance and wiring diagrams.

Applications

• Permanent in-line splicing of power distribution and heavy-gauge signal wires.

• For use in wiring repairs within protected areas such as avionics bays, junction boxes, and enclosed wire runs.

• Ideal for creating a connection point where post-installation insulation (e.g., heat shrink tubing per SAE-AS23053) is required.

Why Choose M81824/1-2?

An airworthy electrical connection is a precisely engineered system, not just a collection of parts. The M81824/1-2 splice is the certified component designed to work with a calibrated tool to create a perfect crimp. Using a non-spec, commercial-grade butt connector or an improper tool will result in a mechanically weak, high-resistance connection that is susceptible to failure from vibration and corrosion. Such a failure in a 10-gauge power wire can lead to system malfunction or an in-flight fire. This military-specification splice is the only choice for a safe, certifiable repair.

The integrity of an M81824/1-2 splice is rooted in the physics of a high-reliability crimp. The specified, calibrated tool (e.g., M22520/1-01) with its matching die set does not merely crush the barrel; it performs a controlled plastic deformation. The die forces the splice barrel and the contained wire strands to flow and conform into a solid, geometrically precise mass. During this process, the soft tin plating acts as a lubricant and then extrudes, mechanically breaking down the non-conductive oxide layers present on the copper conductors and the splice interior. The immense, localized pressure creates such intimate, metal-to-metal contact that it forms a cold weld, resulting in a joint that is a single, gas-tight, electrically homogenous unit. A properly executed crimp is mechanically stronger than the wire itself and exhibits a resistance measured in micro-ohms, ensuring maximum current transfer with minimal heat generation.

Note: This is a flight-critical electrical component. Installation must be performed by a certified A&P or avionics technician trained and qualified in aerospace wiring practices (per FAA AC 43.13-1B, Chapter 11). The use of the specified, calibrated crimp tool and die set is mandatory for an airworthy connection. After crimping, the connection must be insulated if it is not located within an otherwise sealed or protected assembly.

Documentation

The military specification governing this part is publicly available through the Department of Defense ASSIST database.

• ASSIST Document Page for MIL-DTL-81824: http://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=54932