Re: Solder vs. Crimp - Part 3 - Feeling Scientific
Ok - I can't resist. I am an Electrical Engineer. I have a BSEE and an MSEE. I am a member of Tau Beta Pi (engineering honor society) and Eta Kappa Nu (electrical engineering honor society) I haven't paid my IEEE dues in a long time, but I was once a member. Before I continue, this subject is better suited to an ME as we are talking about mechanical failure. However, I'll share my experience.<br /><br />I worked in A&D (Aerospace and Defense) for about 9 years total. 4 with the Electronics Research Lab at NU and 5 with Raytheon.<br /><br />Finally, I rewired my 79 Formula with twin 350s from scratch and have since done projects on several other boats.<br /><br />At the research lab I designed and built telemetry systems for the airforce geophysics lab and SDI program office. All of these systems flew either on rockets into space or, in a few cases, the space shuttle. Since these were "one shot" projects for the most part, they had to meet the requirements for space flight and be of the highest possible quality. All subsystems were tested individually and as part of the system for vibration and force at extreme environmental conditions on large shock tables in environmental chambers.<br /><br />95% of all electrical connection on these systems were mechanical (i.e., solderless). All circuit boards were what are called wire wrap boards where a wire gun is used to warp wire around a gold plated post. Most connectors had the terminals crimped onto the wires and then each inserted into a locking connector shell. Each terminal had a special crimper designed specifically for that terminal type and that type only.<br /><br />Some connectors did have solder connections where the leads had to be soldered into the connector. These solders joints had to be made by skilled techs and each examined under magnification for voids, cracks and proper wetting. They also required strain relief and in most cases even be potted. These cables were few and far between.<br /><br />My experience at Raytheon was much the same except due to high volumes, we used printed circuit boards soldered in a wave solder machine and conformal coated for corrosion protection.<br /><br />I think most of this debate comes down to something mentioned earlier- a bad crimp made with a cheap tool is a bad connection! So, when crimping is discussed people get the wrong idea because many have never seen it done properly. In the case of marine connections, we are talking about using double ratcheting crimpers and a high quality terminal like those made by Ancor Marine.<br /><br />If you use a cheap crimper or even a pair of pliers, you had better solder it because it won't last.
<br /><br />Thank you to all of you for trying to get folks to do the job right and keep em safe.. 
