Crimping 3 or 4 wires together

[ezalys]

Hey all,

I’m looking for the most reliable, milspec, aerospace, NASA approved way to join 3-5 stranded 24 AWG wires together where there’s likely to be a lot of vibration. I understand that solder has a nasty habit of wicking up the strands, and the point at which the unwetted wire meets the wetted wire can be brittle and unreliable. I also understand that solder isn’t a great mechanical joint. I’m therefore looking for a good crimp I can use to splice several wires together. Any recommendations? Also, if I’m wrong about solder joint reliability, I’d be interested too!

Thanks!

[Neilm]

Given the vibration requirements in that sort of application, I doubt you will find a single crimp that could go that. I have seen crimps that look like a Y and will join three wires together. You could use several of them if you can find one that will crimp the metal wire and hold the insulation as a support as well.

[No.Mad]

Hi ezalys,

answer for your question is in IPC 620A standard. It covers all topics regarding harness making, looming, splicing and crimping.

What is my favourite is soldered splice: simply strip 10 - 12mm of a wire insulation, place it together tightly but don't twist them. To hold them together you should use single strand copper wire to make a braid like in the picture here: https://cdn.instructables.com/FN1/KYZT/JNIRDS9X/FN1KYZTJNIRDS9X.LARGE.jpg?auto=webp&width=599&crop=3:2

Apply flux, solder wires and then clean with with proper solvent. After that go for final touch - give it some snugly and warm heatshrink

I'm attaching also two pages from IPC standard so you could have a better understanding of criteria. Have fun and practice bruv!

Regards

[timelessbeing]

I’m looking for the most reliable, milspec, aerospace, NASA approved way

Are you launching a satellite?

[Kjelt]

Download NASA-STD-8739.4A – 2016-06-30
Page 70 and further.
Some of those solutions need special ferrules $0,30 a piece but min order 1000 pcs or such madness.
Just use a standard copper tinned Ferule that matches the best of your need and use that.

[coppercone2]

we need to cut costs for the non existing company for no reason at all

just give them a twist and wrap it in electrical tape!1!1