# Automotive Thermocouple Wire

> Exhaust gas temperature, EV battery thermal management, engine testing and brake development. Fast-response thermocouple conductors for automotive R&D and production testing.

## Applications

| Scenario | Requirement | Solution |
|---|---|---|
| Exhaust Gas Temperature (EGT) | Pre-turbine and post-catalyst temperature for engine calibration, OBD diagnostics and component protection. 200–1050 °C, high vibration. | Type K, φ0.25–0.5 mm stranded |
| EV Battery Thermal Management | Cell, module and pack-level temperature sensing for charge control, thermal runaway detection and lifetime prediction. | Type T or K, φ0.1–0.5 mm |
| Engine Dynamometer Testing | Development and durability testing — oil, coolant, intake air and exhaust temperature. Hundreds of channels per test cell. | Type K, φ0.25–1.0 mm |
| Brake System Testing | Disc and pad temperature during fade and thermal fatigue testing. 200–800 °C, rapid thermal cycling. | Type K, φ0.25–0.5 mm |
| Turbocharger Development | Compressor outlet and turbine inlet temperature. Extremely fast thermal transients — requires minimum wire diameter for response. | Type K, φ0.1–0.25 mm |

## Considerations

| Factor | Guidance |
|---|---|
| Vibration resistance | Engine-mounted thermocouples experience 10-50 g vibration. Stranded wire is essential — solid wire work-hardens and fractures. 7-strand construction is standard; 19-strand for extreme applications. |
| Fast thermal response | Turbocharger and EGT measurements require millisecond-level response to capture transient events. φ0.1-0.25 mm bare wire provides τ ≈ 0.05-0.3 s. Halving diameter improves response time roughly 4×. |
| EV battery safety | Battery thermal runaway detection requires multiple thermocouples per module with fail-safe behaviour. Type T is preferred for its accuracy at 20-80 °C and its non-magnetic properties (does not interfere with current sensors). |