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-rant- chinesium wires

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tooki:

--- Quote from: coppercone2 on September 11, 2023, 01:17:15 am ---now if you can get a machine pin dupont that might make things a little easier then those fucking folds. you just gotta put it in, instead of put it in and hold it steady.

--- End quote ---
Are you aware of any machined “dupont” style terminals? All the machined ones I’m aware of use round pins and sockets, which don’t mate anywhere near as firmly as top-quality stamped terminals (Amphenol Mini-PV and Dubox, Molex SL, etc.). Even round sockets that are stated to be compatible with 0.025” square pins don’t have nearly the same removal force.

A machined terminal made for square pins would be awesome…

(If one already has the indent crimpers for machined pins, at least it’s possible to make male terminals by using a bit of brass or phosphor bronze tube as a butt splice, crimping both the wire and a standard square pin into the tube.)

nctnico:

--- Quote from: tooki on September 11, 2023, 11:13:04 am ---
--- Quote from: coppercone2 on September 11, 2023, 01:17:15 am ---now if you can get a machine pin dupont that might make things a little easier then those fucking folds. you just gotta put it in, instead of put it in and hold it steady.

--- End quote ---
Are you aware of any machined “dupont” style terminals? All the machined ones I’m aware of use round pins and sockets, which don’t mate anywhere near as firmly as top-quality stamped terminals (Amphenol Mini-PV and Dubox, Molex SL, etc.). Even round sockets that are stated to be compatible with 0.025” square pins don’t have nearly the same removal force.

A machined terminal made for square pins would be awesome…

--- End quote ---
Tektronix used to have dual tongue type header connectors on their logic analyzer. Works fantastic. I have never seen these pin header connector for sale though.

Ian.M:
Its even possible to solder plain aluminum with ordinary SnPb or Pb-free solder without special 'aluminum' flux.  A freshly cleaned aluminum surface is solderable, but one with a layer of aluminium oxide is not.  Unfortunately the aluminum oxide layer forms extremely rapidly in air at elevated temperatures, and in minutes at room temperature, so you have to exclude air from the work - either with an oil stable at soldering temperatures or with copious quantities of a good gel flux.

What does this mean for soldering CCA wire?
As Tooki mentioned you have to be fast getting the wire tinned.  If heavily tinned, you can then reflow it to form a joint with a previously heavily tinned terminal. Use plenty of flux.  However that copper layer dissolves in the solder very quickly, so if  the solder film gets scraped off while reflowing it, the exposed aluminium will oxidise and will be difficult or impossible to re-tin. 

Then there's the issue of stranded wire embrittlement at the surface of the joint.  Aluminum is less ductile than copper,  its copper coating will have been scavenged by the solder, necking each strand down and leaving a thin ring of exposed aluminum, and aluminum in contact with copper is extremely vulnerable to corrosion, so unless you get *all* the flux residue cleaned off and the joint coated with lacquer to exclude air and moisture, you are setting yourself up for failure if you solder stranded CCA.

tszaboo:
I feel your pain. Once we had to strip apart industrial equipment and trash all the wiring in it because it was made from this crap. The wires were supposed to be rated for 50A and made from this old thing called copper. But the purchaser wanted to save some money. So we a paid for it 7 times. Buy, Assemble, ship to Europe, Test, Disassemble in a hurry, Fail to deliver in time, Buy proper cable in a hurry, Assemble by engineers. On hundreds of cables.
Though as I remember that was some sort of coated steel wires.

nctnico:

--- Quote from: free_electron on September 10, 2023, 11:05:35 pm ---Cursed to the 100th generation be they who invented wires made from chinesium.

--- End quote ---
Where did you buy these? Local or from China? My experience is that the stuff you source from China directly (through Aliexpress, Amazon, Ebay) is of higher quality compared to Chinese stuff you buy locally.

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