Should i solder or crimp

Choosing the right contacts is not always easy, especially if you do not have engineers specialized in interconnect designs. The quick answer to the question is: neither. One will be more suitable in some cases, while in other cases it will not. This guide explains the key factors to consider when deciding which solution will be most suitable for your design.

This relates to aerospace and defense standards where most of the time contacts need to be crimped. MIL-DTL : This military standard indicates right in the title that the connectors must have removable crimp contacts except hermetic contacts which are soldered.

Both break down into a variety of specifications that dictate whether the contact type should be solder or crimp. Note: In the case of hermetic connectors, solder contacts are the standard since the contacts are non-removable encased in glass. Standards may often determine what type of contact you need, and it is likely that if you are in that situation, you already know what contacts and connectors you need. They are prevalent in aerospace and defense, but also railway and for certain machine tools.

Solder contacts have little solder buckets at the back. They are usually preloaded in the connectors. Unlike crimp terminations that require specialized tools, nearly any size wire and solder contact can be terminated with a basic soldering kit.

Because the tooling is so minimal and the only materials required are solder and flux, there can be significant cost savings. In short, the primary benefit of soldering lies in its affordability.

There are, however, disadvantages to soldering. The soldering process generates heat in the contacts, the connector, and even in the cable. This unavoidable heat generation has the potential to cause problems, especially when the temperature rises above the operational limits of the insert. Additionally, a soldered connection will require a RoHS-compliant solder. This is problematic because many solders contain lead, which is banned by RoHS.

Soldered connections can also be more sensitive to both corrosion and vibration if not performed properly. This can be especially problematic for applications that involve harsh environments. However, a proper solder connection will withstand vibration and shock like a crimp connection and may be less susceptible to corrosion. The soldering process is also more time-consuming than the crimping method, and it can create problems with both quality and reliability if not performed correctly.

This creates a rough, uneven, or lumpy surface, resulting in an unreliable bond. In fact, cracks may develop over time and cause serious issues.

If you often have to crimp professionally insulated terminals and connectors, you need precision pliers with lever travel ratio to reduce the required manual force and protect your hands.

These pliers are:. This robust mm short crimping tool for other end ferrules is made of chrome vanadium electric steel. It offers calibrated crimp pressure and adjusts itself to the respective core sleeve size used. An integrated toggle lever increases the force for fatigue-free work.

This tool is:. A lever transmission integrated into the pliers ensures fatigue-free working. Your email address will not be published. Save my name, email, and website in this browser for the next time I comment. Search the Magazine Search the shop.

Toggle navigation. Crimping: an alternative to soldering. How to use crimping tools Crimping is a reliable alternative to soldering. Crimping technique for smaller dimensions The crimping technique is suitable for even smaller grid dimensions. Product 1: KNIPEX crimp tool for insulated terminals and cable connectors KNIPEX pliers 97 21 are suitable for occasional work with insulated cable lugs of various types flat plugs, flat receptacles, fork notched lugs, loudspeaker cable lugs, notched lugs, butt connectors, etc.