If you need to deliver electricity to a piece of equipment, then you may well need crimping. The process of creating electrical connectors involves joining a wire to a terminal is called wire crimping, which does not require any soldering. Still, though it’s less complicated than soldering, there are still things that can go wrong. In order to ensure that you have a clean and clear connection, you’ll need to be aware of potential problems that can occur, as well as how to resolve them. In this blog, we’ll run through some of the most common problems and provide some actionable advice to find a solution.  

And remember, the quality of your crimping will depend on the quality of the tool you use. At Wirefy, we specialize in manufacturing outstanding crimping tool sets for a wide range of jobs. 

Introduction to Common Wire Crimping Problems

There’s a science to wire crimping. If you follow the right methods, then you’ll end with a smooth connection — but there are also plenty of small issues that can cause problems. For example, it’s important to cut the wire to the right length; if it’s too short, then there won’t be enough exposed wire to fit into the barrel grip, which will impact connectivity. You can help minimize this risk by using Wirefy’s quality crimping tools to get the job done. 

Another issue is failing to put all the wire strands inside the barrel. This usually happens when the wire cut is not clean, which results in the wires “fanning out,” which impacts the strength of the connection. Many crimping problems can also be traced back to the type of terminal that has been selected for use, as well as the size of the wire — smaller wires tend to be more difficult to place, due to their lack of strength. 

How to Identify Common Wire Crimping Problems

You can usually tell that there’s a problem with wire crimping just by looking at it. Some common problems include poor wires. If they’re not in strong condition, then they won’t attach correctly. On a longer-term basis, crimping problems can lead to discoloration, abrasion, and burning. If you notice any of these issues, then you’ll need to redo the wiring — or call a professional if the problem looks like it is widespread. 

Tips For Preventing Common Wire Crimping Problems

It’s much easier to prevent a wire crimping problem in the first place rather than trying to fix the issue later on down the line. The first step towards ensuring that you don’t face any issues is to use the right wire crimper tool. It can seem as if you can use any tool when you’re wiring, but this isn’t the case. The right tool will depend on the wire that you’re trying to cut. Most crimping tools are designed with a particular wire size in mind, otherwise known as the wire gauge. 

If you take a look at the crimping tools we offer here at Wirefy, you’ll find that we offer sets that can be used for any crimping job. You’ll just need to switch out the die to the one that you need. 

It’s also recommended that you look at advice from the manufacturer of the terminal (and any other tool you’re using). They’ll usually suggest using a specific tool for the job, which can help to prevent many of the common problems. In most cases, it’s all because the wrong tool was used. 

Importance of Proper Wire Crimping Techniques

Wire crimping is something that can look easy, but there’s value in learning the correct techniques. Without following the correct methods, you may find that you run into a whole host of issues. At its core, wire crimping is preferred over soldering because of the quality of the connections that it offers. However, by using the incorrect method, the connection will suffer. 

Using the right technique won’t only ensure that the connection is strong. It’ll also help the connection to remain in place for many years. Using the wrong technique can lead to several issues, including corrosion and gas exposure, both of which can compromise electrical systems. In some cases, poorly crimped wires have been responsible for fires. 

Best Practices for Testing Electrical Connections

When it comes to wire crimping, the proof is in the results. Once you’ve finished, give the wire a slight tug; it should be firmly in place. You can then test the connection using a multimeter and test light. The reading on the meter should be the same as what has been indicated for the circuit. If there is a difference, then there’s a chance that you’ve done something wrong in the wire crimping process, which will require you to redo the job. 

The quality of your crimping will depend on the quality of the tools you use. If you’re looking for the best of the best, then be sure to browse our selection here at Wirefy. We have a host of electrical connectors and tools that’ll allow you to find the right product for your needs.

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