Wire Gauge to Terminal Size Chart: AWG, Metric, and Indian Standards
Comprehensive AWG to metric wire size conversion chart, terminal color coding, strip lengths, and wire-terminal matching guide for Indian manufacturers.
Shivam Das
Marketing Head, Anjali Machine Tools
21 July 2025
Wire gauge compatibility is fundamental to crimp quality. Using the wrong wire gauge with a terminal produces either an under-crimped connection (wire too small for the barrel) or an over-crimped one (wire too large). Both fail quality standards and create reliability risks.
Indian manufacturers work with both AWG (American Wire Gauge) and metric (mm2) wire sizes, depending on the customer and application. This reference covers the conversions, matching rules, and practical guidance needed for production.
AWG to Metric Conversion Chart
| AWG | Cross-section (mm2) | Diameter (mm) | Resistance (ohm/km at 20C) | Common Application |
|---|---|---|---|---|
| 30 | 0.05 | 0.25 | 339 | Signal wires, sensor circuits |
| 28 | 0.08 | 0.32 | 213 | Low-current signal wires |
| 26 | 0.13 | 0.40 | 134 | Electronics, sensor wiring |
| 24 | 0.20 | 0.51 | 84.2 | Instrumentation, data cables |
| 22 | 0.33 | 0.64 | 52.9 | Automotive signal circuits |
| 20 | 0.50 | 0.81 | 33.3 | Automotive low-current |
| 18 | 0.82 | 1.02 | 20.9 | Appliance wiring, automotive |
| 16 | 1.31 | 1.29 | 13.2 | Automotive power, appliance |
| 14 | 2.08 | 1.63 | 8.28 | Automotive power circuits |
| 12 | 3.31 | 2.05 | 5.21 | Power distribution |
| 10 | 5.26 | 2.59 | 3.28 | Heavy power circuits |
| 8 | 8.37 | 3.26 | 2.06 | Battery cables, main power |
| 6 | 13.3 | 4.12 | 1.30 | Large power feeds |
| 4 | 21.2 | 5.19 | 0.815 | Battery interconnects |
Note: AWG is an inverted scale — smaller numbers mean larger wire. Metric (mm2) is a direct measurement of conductor cross-section area.
Common Metric Wire Sizes (Indian Market)
Indian automotive and appliance manufacturers commonly use these metric sizes:
| Metric (mm2) | Nearest AWG | Common Use in India |
|---|---|---|
| 0.35 | ~22 | Automotive signal circuits |
| 0.50 | ~20 | Automotive low-current, indicator lamps |
| 0.75 | ~18 | Appliance wiring, automotive general |
| 1.00 | ~17 | Automotive, appliance power |
| 1.50 | ~16 | Automotive power, control panel |
| 2.50 | ~14 | Power circuits, motor feeds |
| 4.00 | ~12 | Heavy power, starter circuits |
| 6.00 | ~10 | Battery cables, alternator feeds |
| 10.0 | ~8 | Main power distribution |
| 16.0 | ~6 | High-current power, EV auxiliary |
| 25.0 | ~4 | EV high-voltage, industrial power |
Terminal Color Coding
Insulated crimp terminals follow a universal color code:
| Terminal Color | AWG Range | Metric Range | Barrel ID (mm) |
|---|---|---|---|
| Red | 22-16 | 0.5-1.5 mm2 | 1.5-2.5 |
| Blue | 16-14 | 1.5-2.5 mm2 | 2.5-3.5 |
| Yellow | 12-10 | 4.0-6.0 mm2 | 4.0-5.5 |
For wire sizes outside these ranges (smaller than 22 AWG or larger than 10 AWG), terminals are typically uninsulated and require heat-shrink tubing for insulation if needed.
Strip Length Guidelines
The wire strip length must match the terminal barrel length for proper crimping:
| Wire Gauge Range | Typical Strip Length | Notes |
|---|---|---|
| 26-22 AWG (0.13-0.33 mm2) | 3-4 mm | Small terminals, precision stripping |
| 22-16 AWG (0.33-1.5 mm2) | 4-6 mm | Standard automotive terminals |
| 16-10 AWG (1.5-6.0 mm2) | 6-8 mm | Larger barrel terminals |
| 10 AWG and above (6.0+ mm2) | 8-12 mm | Power lugs and large terminals |
Always check the terminal manufacturer’s specification for the exact strip length. Over-stripping wastes conductor and risks short circuits. Under-stripping puts insulation inside the conductor barrel.
Minimum Pull Force by Wire Gauge
For quick reference, the minimum pull-out force each wire gauge must achieve after crimping:
| AWG | mm2 | Min. Pull Force (N) |
|---|---|---|
| 26 | 0.13 | 13 |
| 22 | 0.33 | 36 |
| 20 | 0.50 | 58 |
| 18 | 0.82 | 89 |
| 16 | 1.3 | 133 |
| 14 | 2.1 | 222 |
| 12 | 3.3 | 312 |
| 10 | 5.3 | 356 |
Values per UL 486A-486B. For the complete table and testing procedure, see our crimp pull test guide.
Wire Gauge Ranges by Industry Application
Automotive (ICE Vehicles)
- Signal circuits: 0.35-0.50 mm2
- Lighting: 0.75-1.50 mm2
- Power windows/locks: 1.50-2.50 mm2
- Starter motor: 6.0-16.0 mm2
- Main battery cable: 25.0-50.0 mm2
Automotive (EV — High Voltage)
- Low-voltage auxiliary: 0.35-2.50 mm2 (same as ICE)
- High-voltage traction: 10.0-95.0 mm2
- Charging circuit: 6.0-25.0 mm2
Home Appliances
- Control circuits: 0.75-1.00 mm2
- Motor feeds: 1.50-2.50 mm2
- Heating elements: 2.50-4.00 mm2
Control Panels
- PLC I/O wiring: 0.75-1.50 mm2
- Power circuits: 2.50-6.00 mm2
- Main bus: 10.0-25.0 mm2
Matching Wire to AMT Applicators
AMT’s crimping applicators handle the standard wire gauge ranges used in automotive and appliance manufacturing:
| AMT Product | Wire Range |
|---|---|
| Unique S/F | Standard automotive (0.35-6.0 mm2 with appropriate dies) |
| Unique E/F | Standard automotive range |
| RXA S/F | Standard automotive range |
| RXA E/F | Standard automotive range |
| Regular | Standard automotive range |
| Pneumatic | Extended range: 10-20 mm2 |
For larger wire gauges (above 20 mm2), the Pneumatic Crimping Applicator provides the additional force needed for power cable terminals.
Conclusion
Matching wire gauge to terminal size correctly is the foundation of crimp quality. Use this chart as a quick reference, but always verify against the terminal manufacturer’s specification sheet for each specific terminal part number.
For crimping applicators that handle the full range of automotive and industrial wire gauges, explore AMT’s product range. For wire-terminal compatibility questions, contact us — our team in Pune can recommend the right applicator and crimper set for your production needs.