Crimped and soldered terminals

[Phil Scott]

..
In corrosive environments, stranded wire will corrode into the
crimmped terminal and around the wire, insulating the wire
from the terminal slightly causing it to burn, then fail..
thats common.

Accordingly battery cable manufacturers most often solder
their wire into the crimped terminal ends.

This practice is seen pervasively in marine environments on
both low amperage control circuits, and on power circuits.



Use of solder on power circuit terminals however has many
problems, namely the solder melting out of the joint if the
wire warms too much...and extrusion of the solder under
compressive stress if screw connectors are used.. the military
specs some are referring to cover that aspect... but not the
other aspects.


Use of solder in an already crimped terminal serves to
increase the electrical contact area, thats good, and to
preclude corrosive gases, vapors and oils from the joint (by
wicking up the bare wire).... that is seen commonly be the
cause of failure in those situations.


For the last 100 years... and currently.... most if not all
controls systems and component manufacturers dip wire ends in
solder that are to be fit under screw head connectors... the
practice is at least 90% common.... thats with *control
circuits.

The practice is not common with power circuits for the reasons
mentioned but is still seen in some situations (primarily
corrosive environments... anyone can purchase NEC approved
soldered connectors of course for those purposes... those are
also pervasively common, especially in the electronics
industry.)



Phil Scott
Mechanical/ Electrical engineer and industrial controls
contractor since 1852 (I'm very old)

 

[TimPerry]

.
In corrosive environments, stranded wire will corrode into the
crimmped terminal and around the wire, insulating the wire
from the terminal slightly causing it to burn, then fail..
thats common.

Accordingly battery cable manufacturers most often solder
their wire into the crimped terminal ends.

This practice is seen pervasively in marine environments on
both low amperage control circuits, and on power circuits.



Use of solder on power circuit terminals however has many
problems, namely the solder melting out of the joint if the
wire warms too much...and extrusion of the solder under
compressive stress if screw connectors are used.. the military
specs some are referring to cover that aspect... but not the
other aspects.


Use of solder in an already crimped terminal serves to
increase the electrical contact area, thats good, and to
preclude corrosive gases, vapors and oils from the joint (by
wicking up the bare wire).... that is seen commonly be the
cause of failure in those situations.


For the last 100 years... and currently.... most if not all
controls systems and component manufacturers dip wire ends in
solder that are to be fit under screw head connectors... the
practice is at least 90% common.... thats with *control
circuits.

The practice is not common with power circuits for the reasons
mentioned but is still seen in some situations (primarily
corrosive environments... anyone can purchase NEC approved
soldered connectors of course for those purposes... those are
also pervasively common, especially in the electronics
industry.)



Phil Scott
Mechanical/ Electrical engineer and industrial controls
contractor since 1852 (I'm very old)

Phil, what brought this on? was there something i missed?

a while back in a different group i mentioned tinning a speaker wire before
attaching it to a speakon connector as was roundly criticized as a fool
and/or ignoramus. maybe so, but the cable works fine. (cables i built 30
years ago with tinned ends work fine too). i do see the point about solder
being a soft alloy but it seems of you squish down hard enough it just
doesn't matter.

 

[Billy H]

You and he both are idiots.

So nice to be put in the same bracket as Telford and Brunel, but remember
Roy, when there are more than one person, 'he' is not the word to use. It
would have been more correct linguistically to say 'you and them are all
idiots', although of course incorrect in fact.

 

[Phil Scott]

Just two week ago I was called out to a home with an
electric furnace. 22 amps were flowing thru a tight fitting
spade lug connected to a contactor (actually there are 4
separate circuits identical to this one for a total of 88
amps @ 240 VAC using 4 separate contactors). Only this one
particular spade was close to the melting point. So I used
a new laser guided no-contact infrared thermometer to
measure the temperature. It was much higher than the other
three circuits, yet the amperage was 22 amps just like the
rest. I cut off the spade lug and two inches of wire (8
gauge stranded), then crimped on a new one. I measured the
temp again and the temp was lower. Then I soldered that new
crimp with 60/40 rosin. I measured again and found the temp
to be 8 degrees F lower. I am convinced that a combination
of crimping and soldering is best. It also guarantees there
will not be future oxidation at the joint. The wire is
copper, the spade is tin or Nichol coated, as is the
contactor, that creates an electrolysis when heated, like a
Peltier junction. The solder helps alleviate that I think.
You may disagree but I believe my eyes and hands-on
experience.

Thats what I call good documented experience, and its
intuitively correct as I see it for the reasons you
state....so much for the mil specs or crimp only being
gospel...



Phil Scott

 

[Phil Scott]

Roy Fuchs, It's clear to everyone in this newsgroup that you
have many serious mental defects. You are the laughing
stock, the local idiot, you are and have been, the butt of
many jokes.



I feel sorry for you. I knew before I ever placed my post,
that I would be reading you, calling me an idiot, but it did
not deter me from posting anyway.



This is the one and only time, I will ever respond to
anything you have to say, so no matter what reactions you
have to me, I will ignore everything you "Roy Fuchs", have
to say. I would invite everybody else to never respond to
anything you ever post again.

a kill file works best... you should be able to find a news
reader that has a kill file feature. or maybe yours already
does, look in the messages handling options or whatever.

its 'block sender' in MS Outlook express.


Phil Scott

 

[Spokesman]

Roy Fuchs, It's clear to everyone in this newsgroup that you have many
serious mental defects. You are the laughing stock, the local idiot, you
are and have been, the butt of many jokes.



I feel sorry for you. I knew before I ever placed my post, that I would be
reading you, calling me an idiot, but it did not deter me from posting
anyway.

He is trying to Royally Fuch everyone here.

 

[Phil Scott]

I killfiled Roy on advice from a good newsgrouping netizen.
Cheers Phil.

Another thing I do is kill file anyone that proves to be an
abusive idiot... the first time I see them respond that way to
some other person. Its not like the abuse is a rare anomaly,
those types screw up everything they touch.


I don't wait until they crap on my plate directly. thats
been a relief.

Sometimes I log on and go through my news groups and kill file
anyone that seems to have been simply dull or pedantic over
time.

That way I end up with a very pleasant and enlightening read
every day, I feel better, I am nicer to my customers and they
pay me well as a result.


Putting up with jerks to any degree at all has many hidden
liabilities.

There have been some recent studies reported in the main line
news that simply seeing or being around when some jerk attacks
another person... creates great stress. all unnecessary of
course...but grossly damaging to ones health and career none
the less.




Phil Scott

 

[Keith]

BWUAhahahahahah!

Filter your news, and you filter your mind, and not in a good way,
idiot.

DimBulb, did it really take you *five* tries to post this drivel?

 

[Keith]

**** off, little boy. I only posted THAT POST one time.

You sliily wabbit, you answered _one_ post *five* times. Can't you keep
your mini-mind straight long enough to answer at one sitting?

If my bulb is "dim" as you say, yours has had a broken filament for
decades running.

Folks, google DarkMatter and "dim-bulb". The moron doesn't think a 100W
lightbulb heats a room as fast as a 100W heater, hence the dim-bulm
moniker.

What a Maroon!