Crimping and Welding of Military Connectors

Compared with welding, crimping has the following advantages:

1. The quality of welding depends largely on the level of the operator. If the operation level is low, virtual welding and false welding will occur. The crimping quality is mainly guaranteed by crimping tools, and the crimping process has good termination quality and reliability.

2. As the density of electrical connectors increases, the pinhole spacing decreases, which makes soldering more and more difficult. The crimping is to connect the pinhole to the wire first and then insert it into the plug or socket to avoid the difficulty caused by the increased density.

3. After welding, the flux needs to be cleaned, high-density products are difficult to clean, and the residual flux is easy to cause corrosion. The crimping does not need to be cleaned and there is no gas volatilization, which is conducive to improving the operating environment.

4. No power supply is required for crimping, more suitable for field operation.

Compared with welding, crimping has the following disadvantages:

The termination part is located inside the connector insulator, which is not as intuitive as soldering and easy to check. Its crimping quality is affected by many factors such as wire diameter, crimping tool, crimping force, and material rigidity and dimensional accuracy of the retainer.

Sunkye Connection Technologies provides a wide product portfolio with a complete interconnect solutions offering. Sunkye connectors and cables assemblies are complementary with Sunkye backshells and conduits.