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Fuse block wiring.

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Old Jun 29th, 2018, 19:35   #11
Waddii
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Now I am only offering this as data, and I'm not commenting on anyone's preferences, but an unimaginable amount of time ago I worked at Joseph Lucas, at Great King Street in Birmingham, in their 'Proving Lab'. Amongst many experiments was a series to compare wire joining methods in the real life car environment and maybe you can guess why most car connectors are crimped on? No, it is not about cost.

A properly made crimp is surprisingly reliable and outperforms soldered joints when subject to vibration! The reason is that at the copper/solder interface migration of the solder metals (Lead and Tin) into the copper causes embrittlement, then vibration can then produce fatigue failure in the embrittled metal. The crimp does not suffer from this problem as the copper maintains it's full malleabilty. It does eventually fail from fatigue but much later than the soldered joint.
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Old Jun 30th, 2018, 15:55   #12
Ron Kwas
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Waddii;

Please be careful not to oversimplify...

I agree Crimps are fine for vehicles, but crimping actually can also result in increased susceptibility to mechanical fatigue...in this case, due to embrittlement by "work-hardening" of the malleable copper as it is compressed into the crimp barrel by the significant forces involved...that is why all terminals, and their associated wiring, be they soldered or crimped, in addition to being considered electrically, must also be considered (and often have provisions made for) the mechanical forces at work in their final position and application...it's less of an issue with cars (although we accept that they are a high vibration environment), than the military and aerospace areas where these factors are studied and tested extensively...

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Old Jun 30th, 2018, 17:16   #13
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Thanks Ron, I agree there are many factors to consider, including how well any joint is made.

Nevertheless the basic differences were significant, but as you rightly say there are plenty of other failure modes available too.

Last edited by Waddii; Jun 30th, 2018 at 17:19.
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