The Science of Solderless Crimp Joints
In high-vibration automotive and aviation assemblies, mechanical crimping is preferred over soldered wires because solder wicks up copper strands, creating rigid stress concentration points prone to fatigue fracture.
Common Crimping Defects:
- Incorrect Crimp Height: Over-crimping crushes copper strands; under-crimping creates high contact resistance and thermal runaway.
- Insulation Wings Gripping Conductor: Wire stripped too short causes insulation to enter the wire crimp zone.
- Missing Conductor Brush: Wire strands must extend 0.5mm to 1.0mm past the front bellmouth to ensure full contact area.