See full version: How to test strength of wire soldering
Although standards define a minimum acceptance-value for the pull force according to the wire diameter and AWG conductor size, it is of greater importance to the manufacturer and user to know that joints can definitely sustain higher loads. So an increasing axial force is applied to the connection until either the terminal and wire separate or the wire breaks.
This is crucial as enough force must be applied to break down the layer of non-conductive oxides that may build up on the stripped conductor and the plating on the inside of the terminal. This is necessary to provide a good metal-to-metal contact. If this does not occur, electrical resistance can increase. [links]
There are many standards to adhere to and each manufacturer or user might have different requirements to fulfil. But one thing in common is that international and industry standards all prescribe procedures for testing the tensile strength of wire terminals in a repeatable manner. [links]
It is essential that there is no jerking or sudden application of force. This is the reason why standards state that there should be a 'constant rate of pull' and most define a pull rate at which tests should be performed. The only practical way to achieve repeatability for pull force tests is to set a speed by using a motorised pull tester such as the WTST range of testers. here
Overcrimping a crimp termination will reduce the circular area of the conductor and thereby increase electrical resistance. more
The quality of a crimp joint depends on the mechanical strength of the joint as well as its electrical conductivity. If results from pull force tests are within an allowed range, it assures that the proper crimp force has been applied during the crimping process.
This is crucial as enough force must be applied to break down the layer of non-conductive oxides that may build up on the stripped conductor and the plating on the inside of the terminal. This is necessary to provide a good metal-to-metal contact. If this does not occur, electrical resistance can increase.
Crimp joint testing (commonly known as "pull testing") ensures the integrity of the final product but, more importantly, it ensures the effectiveness of the crimping tool itself since it can be calibrated according to test results. Calibration is best carried out in response to Statistical Process Control (SPC) analysis which can be gathered from data obtained by pull testers. more
Although standards define a minimum acceptance-value for the pull force according to the wire diameter and AWG conductor size, it is of greater importance to the manufacturer and user to know that joints can definitely sustain higher loads. So an increasing axial force is applied to the connection until either the terminal and wire separate or the wire breaks.
The quality of a crimp joint depends on the mechanical strength of the joint as well as its electrical conductivity. If results from pull force tests are within an allowed range, it assures that the proper crimp force has been applied during the crimping process.
Structures around the world require wire connections to lift and hold heavy objects. Applications that depend on wire connection strength need to be tested to guarantee a safe reliable product. The planning stages that determine how to test your wire connection and what equipment to use are an important part of the testing process. There are a few essential considerations that must be made before testing. What are the wire connection strength requirements that must be met? What are the standards that need to be followed for your customers or industry? Are there recommendations from the manufacturers of the lugs, crimps or solder connections? From your experience, what particular problems should be addressed during testing? In general, wire connection lug testing can be broken into two categories; destructive pull testing and non-destructive pull testing. These tests both aim to determine a tensile force that the test wire can withstand. To meet the requirements of standard specifications, the tensile force that a wire can withstand must be greater than the minimum tensile strength defined by the standard. For assistance in planning your wire testing, our engineers are standing by for consultation. For your convenience, TestResources has compiled a list of ASTM, Automotive and Aerospace standards that apply to tensile testing of lugs. These standards apply to pull testing wire, pull testing lugs, and pull testing electrical connections. Also included are TestResources grips for lug testing, grips for tensile testing, and grips for pull testing crimps and machines for wire testing. TestResources universal material testing machines are effectively used for determining the strength of wire connections. TestResources test machines meet the requirements specified in many standard test procedures for constant-rate-of-extension and constant-rate-of-load machines. This allows the machines to be programmed to perform many unique testing procedures. Load cells are fitted to specific load applications to ensure the highest resolution of tests.
Forces up to 10 kN (2,250 lbf)
Low force tabletop systems
Modular series of five frame options with adjustable test space
Affordable testing option for tension, compression, bend, peel and much more more
Forces up to 5 kN (1,125 lbf)
Low force tabletop systems
Tests at speeds up to 2,500 mm/min (100 in/min)
Best for high travel or high elongation test requirements
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Forces up to 10 kN (2,250 lbf)
Low force tabletop systems
Modular series of five frame options with adjustable test space
Affordable testing option for tension, compression, bend, peel and much more here
Applications that use wire with a required connection strength need to be tested to guarantee a safe a reliable product. Determining how to test your wire connection and what equipment to use is an important part of the testing process. There are a few important considerations that must be made before testing. What are the wire connection strength requirements that must be met? What are the standards that need to be followed for your customers or industry? Are there recommendations from the manufacturers of the lugs, crimps or solder connections? From your experience, what particular problems should be addressed during testing? In general, wire connection lug testing can be broken into two categories; destructive pull testing and non-destructive pull testing. These tests both aim to determine a tensile force that the test wire can withstand. To meet the requirements of specific standard specifications, the tensile force that a wire can withstand must be greater than the minimum tensile strength defined by the standard.
For your convenience, TestResources has compiled a list of ASTM, Automotive and Aerospace standards that apply to tensile testing of lugs. These standards apply to pull testing wire, pull testing lugs, and pull testing electrical connections. Also included are TestResources grips for lug testing, grips for tensile testing, and grips for pull testing crimps and machines for wire testing. TestResources universal material testing machines are effectively used for determining the strength of wire connections. TestResources test machines meet the requirements specified in many standard test procedures for constant-rate-of-extension and constant-rate-of-load machines. This allows the machines to be programmed to perform many unique testing procedures. Load cells are fitted to specific load applications to ensure the highest resolution of tests.
Forces up to 5 kN (1,125 lbf)
Low force tabletop systems
Tests at speeds up to 2,500 mm/min (100 in/min)
Best for high travel or high elongation test requirements more
Rated to 20 kN (4,500 lbf)
Designed to strip electrical wire from electrical terminals
Standard units include twelve slots of diameters ranging from 1 mm to 6 mm (0.04 in. to 0.24 in.) [links]