Industrial Crimping Standards
A crimp is a cold weld. Under massive pressure, the terminal material deforms, breaking the oxide layer on the wire strands, and fuses the metals together. If done correctly, the electrical resistance of the crimp is equal to or less than an equivalent length of the wire itself.
IEC 60352-2 Requirements
This standard governs solderless crimped connections. The two most critical measurable factors on the factory floor are Crimp Height (CH) and Pull-out Force.
Minimum Pull-out Force (Copper)
Values scale with cross-sectional area. Below are standard thresholds for common sizes.
| Wire Size (mm²) | AWG Approx | Min Pull-out Force (N) |
|---|---|---|
| 0.25 | 24 | 32 |
| 0.50 | 20 | 60 |
| 1.00 | 18 | 108 |
| 2.50 | 14 | 230 |
| 4.00 | 12 | 310 |
| 6.00 | 10 | 360 |
Micrograph Analysis
To truly verify a crimp setup, a cross-section micrograph must be taken. We look for:
- No voids between strands.
- Symmetrical deformation (the "B-crimp" shape).
- Terminal wings touching but not piercing the base material.
- Flash (burrs at the bottom) kept under 0.1mm.