As the main cruise missile of the US military, the Tomahawk missile's wiring system needs to meet strict requirements such as extreme temperature changes, strong electromagnetic interference, radiation resistance, and lightweight. The core uses special cables that comply with the US military standard (MIL Spec). The specific model and insulation material can be analyzed comprehensively based on the publicly available military cable technical specifications and the application logic of similar equipment as follows:
1.Core wire model (inferred based on US military standards)
The cable selection of Tomahawk missiles highly relies on mature military standard systems. Although there is currently no direct disclosure of compatible models in public information, considering their combat environment and functional requirements, the following two types of US military standard cables are the most adaptable:
MIL-W-16878 series (main signal transmission cable)
This series is the mainstream choice for aerospace and guided weapons, meeting the signal transmission requirements of missile electronic systems. The typical models and parameters are as follows:
①Common sub models: M16878/4 (4-core), M16878/30-BVA (single core reinforced type), M16878/11 (FEP insulated type).
②Core features: The voltage level covers 250V-1000V, and the conductor is made of silver plated copper wire (twisted structure) to reduce contact resistance and improve corrosion resistance. The shielding layer is made of aluminum foil and silver plated copper braided mesh (coverage rate≥85%), which can effectively resist electromagnetic interference and adapt to high-precision signal transmission of missile guidance systems.
MIL-W-22759 series (power and control circuits)
Focusing on high-voltage power transmission and adaptability to harsh environments, some sub models may be used for missile engine control circuits, such as:
①Representative model: MIL-W-22759/32.
②Core features: The conductor is made of tin plated copper, and the insulation layer is made of cross-linked ethylene tetrafluoroethylene copolymer (XL-ETFE). The rated temperature is 150℃, and it has the ability to resist mold, moisture and heat, and high-energy radiation. It is suitable for power wiring in complex environments such as missile fuel tanks.
2.Key insulation materials and performance adaptability
The selection of insulation materials directly determines the reliability of cables throughout the entire lifecycle of missiles. Mainstream materials need to meet the requirements of high temperature resistance, chemical corrosion resistance, and lightweight:
Polytetrafluoroethylene (PTFE) and modified derivatives
①Application scenario: The core insulation materials of MIL-W-16878 series, such as M16878/4, M16878/5, etc., all use extruded PTFE insulation.
②Performance advantages: Long term temperature resistance range -65℃ to 200℃, enhanced models can be expanded to -70℃ to 260℃, resistant to chemical media corrosion such as fuel and hydraulic oil, and stable dielectric constant (dielectric loss tangent tanδ<0.002), ensuring low distortion transmission of guidance signals.
③Derivative material: Fluorinated Ethylene Propylene (FEP) is an improved version of PTFE used in models such as M16878/11. The insulation wall thickness can be reduced to 0.006 inches, achieving cable lightweighting (reducing weight by more than 25% compared to traditional materials) and adapting to the narrow wiring space inside missiles.
Cross linked ethylene tetrafluoroethylene copolymer (XL-ETFE)
①Application scenario: Insulation layer materials such as MIL-W-22759/32 are used for missile power management module circuits.
②Performance advantages: It combines the chemical resistance of ETFE with the high temperature resistance after cross-linking. It can withstand high temperature impacts exceeding 200℃ in the short term without thermal shrinkage and strong mechanical toughness, making it suitable for the instantaneous high temperature environment during missile launch.
3.Explanation of Technology Selection Logic and Confidentiality Restrictions
The cables of Tomahawk missiles need to balance "reliability" and "lightweight", for example, by combining silver plated conductors (to improve conductivity) with thin-walled insulation (PTFE/FEP), the weight of the cables can be reduced while meeting anti-corrosion requirements (single core cable tensile strength ≥ 50N); The design of the shielding layer is aimed at the electronic warfare environment, ensuring that the guidance signal is not affected by external electromagnetic interference.
Core principle of selection
As active equipment of the US military, the specific cable suppliers of the Tomahawk missile (such as Tyco Electronics, Amphenol and other military giants may participate in matching) and customized model parameters (such as precise matching of characteristic impedance and capacitance values) belong to military secrets, and public information can only be reasonably inferred through the technical specifications of general military standard cables.
Confidential information boundary
Its cable selection logic is highly homologous to US military equipment such as F-35 fighter jets and "Standard" series missiles, all based on MIL-W-16878, MIL-W-22759 series, and modified or optimized according to the special requirements of the weapon system.
Reference for similar equipment
In summary, the wire system of the Tomahawk missile is centered around MIL-W-16878 and MIL-W-22759 series military standard cables, with insulation materials such as PTFE, FEP, XL-ETFE, and PEEK being preferred for high-temperature and radiation resistant fluoropolymer materials. The overall design revolves around extreme environmental adaptability and signal transmission reliability, with specific details not yet fully disclosed due to military confidentiality requirements.
