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Test methods for crimp connections

In cable assembly, reliable crimp connections are essential for a secure electrical and mechanical connection. Various test methods are used to ensure consistently high quality. Here is an overview of the most important methods:

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Visual inspection of crimp contacts

Visual inspection is the first and quickest quality control of crimp connections. It is carried out with the naked eye or with optical aids such as a magnifying glass or microscope.

Test criteria

  • Correct crimp shape without deformations or cracks
  • No open strands or protruding wires
  • Correct insulation position - no insulation too wide or too short
  • Uniform crimp notches
  • No soiling or oxidation

Visual inspection is an essential first step, but is not enough on its own to guarantee all quality features.

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Pull-out force measurement of crimp connections

The mechanical strength of a crimp connection is determined by measuring the pull-out force. The connection is subjected to a defined tensile force in a special testing machine until it is released.

Test procedure:

  • A crimp contact is clamped in a tensile testing machine.
  • A controlled pulling force is applied until the wire comes loose.
  • The measured force is compared with the specifications of the relevant standard (e.g. IPC/WHMA-A-620).

Objective: To ensure that the crimp is mechanically stable and does not fail under normal load.

Crimp height measurement for quality control

Crimp height measurement is a simple and effective method of checking the correct crimping of a crimp.

Test method:

  • The height of the crimped crimping point is measured using a dial gauge or a digital caliper gauge.
  • The crimp height determined is compared with the manufacturer's specifications.
  • Deviations indicate too weak or too strong compression.

Advantages: Fast and non-destructive testing, ideal for series inspection.

Micrograph creation and microanalysis of crimp contacts

Micrograph analysis is a high-precision method for evaluating the internal structure of a crimp connection. The crimp is prepared and analyzed under a microscope.

Procedure:

  • The crimp is embedded in resin and precisely cut open
  • The cut surface is ground and polished
  • The cross-sectional structure, the contact surfaces and any air inclusions are analyzed under the microscope

This method is particularly important for highly sensitive applications, e.g. in medical technology, aviation or the automotive industry.

Conclusion

The quality of crimp connections can be ensured through the targeted use of these test methods. The combination of visual inspection, mechanical tests and microanalyses enables reliable quality assurance – a decisive factor for durable and safe cable assemblies.

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