Basic requirements information

Q: Are you using solid or stranded wire?

A: Stranded wire with equal strand diameters provide optimal crimp performance. Stranded wire of equal strand diameter ensures optimum crimp compression and avoids any voids in the crimp. We understand this is not always practical for every application, wires of different strand diameters as well as solid stranded wire may be used in many applications. Consult your sales representative if you have further questions. 


Q: What size wire are you using?

A: Generally the wire size will be determined by the current demanded. Different applications will require different wire sizes. How much current will the connection see? Continuous current or intermittent current? What environment will the wire be subjected to? Temperature requirements? All these questions need to be answered in order to select the correct wire material and correct wire size.


Q: Do you require open barrel or closed barrel?

A: Open barrel “F” crimp design has become one of the most standard crimps we have. It allows us to verify a good crimp through use of a crimp micrometer to measure a crimp height.


Q: Do you need insulation support or non-insulation support?

A: Insulation support is provided through the use of an extra barrel behind the wire/crimp barrel. The insulation crimp/support lessens stresses on the wire crimp and are highly recommended in any cases where the wire may be experiencing any preload of bending. An insulation barrel will help ensure the integrity of your wire crimp is intact.


Q: Are you utilizing a high temperature application?

A: There are steel and brass options. Steel options operate up to 250°C, whereas brass has a reliable connection up to 110°C. Brass connections provide a higher conductivity/better connection.


Q: How do serrations impact my application?

A: Serrations will improve cold welding ensuring you have the best possible electrical connection. Serrations also have a huge impact on the mechanical performance of your crimp. The use of serrations will cause the wire to extrude into the serration and increase the tensile strength required to pull the wire out of the crimp, a very desirable attribute.