ASTM B913-05(2010)
(Test Method)Standard Test Method for Evaluation of Crimped Electrical Connections to 16-Gauge and Smaller Diameter Stranded and Solid Conductors
Standard Test Method for Evaluation of Crimped Electrical Connections to 16-Gauge and Smaller Diameter Stranded and Solid Conductors
SIGNIFICANCE AND USE
This test method establishes the requirements for a standardized method of evaluating the performance of crimped-type electrical connections having solid or stranded conductors.
In order to achieve a successful crimped connection, the crimping tool must deform the material of the crimp barrel or barrel tab(s) around the conductor. As a consequence, the conductor surfaces are placed under compression by the crimp terminal and areas of contact are established between the conductor and the crimp barrel. These areas provide the desired electrical connection. A reliable crimped connection is one that is capable of maintaining the contact between the conductor and crimp barrel so that a stable electrical connection is maintained when it is exposed to the conditions it was designed to endure during its useful life.
Evaluation testing is designed to ensure that a particular design crimped connection system consisting of conductor and component and associated tooling is capable of achieving a reliable electrical and mechanical connection. After the evaluation is completed, if any change in the system parts is made, the system should be reevaluated using the same procedures.
After completion of the evaluation test, the tensile pull strength results may be used to develop acceptance requirements to be used in inspection of subsequent production lots of crimped connections. An example of such an acceptance requirement is shown in Appendix X1.
The aging test, 33 days exposure at 118°C, has been used in the telecommunications industry to simulate 40 years of service at a moderately elevated temperature of 50°C, an environment that components experience within large banks of telephone equipment. This environment is similar to that seen in a wide range of electronic systems operating indoors containing active components that dissipate power. The test is designed to reproduce the stress relaxation of copper alloys in such service and has been used extensively in evaluating w...
SCOPE
1.1 This test method establishes the requirements for a standardized method of evaluating the quality of crimped-type electrical connections to solid or stranded conductors. This test method applies to 16-gauge and smaller diameter copper wire, coated or uncoated.
1.2 This test method is applicable to connection systems intended for indoor use, or for use in environmentally protected enclosures. Additional testing may be required to assure satisfactory performance in applications where high humidity or corrosive environment, or both, may be present.
1.3 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to become familiar with all hazards including those identified in the appropriate Material Safety Data Sheet (MSDS) for this product/material as provided by the manufacturer, to establish appropriate safety and health practices, and determine the applicability of regulatory limitations prior to use.
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NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation: B913 − 05(Reapproved 2010)
Standard Test Method for
Evaluation of Crimped Electrical Connections to 16-Gauge
and Smaller Diameter Stranded and Solid Conductors
This standard is issued under the fixed designation B913; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 3. Terminology
1.1 This test method establishes the requirements for a
3.1 Definitions—Many terms related to electrical contacts
standardized method of evaluating the quality of crimped-type
used in this test method are defined in Terminology B542.
electrical connections to solid or stranded conductors.This test
3.2 Definitions of Terms Specific to This Standard:
method applies to 16-gauge and smaller diameter copper wire,
3.2.1 crimp, v—to establish an electrical and mechanical
coated or uncoated.
attachmentbetweenthetwomembersbymechanicallydeform-
1.2 This test method is applicable to connection systems
ing one contact member around another. In most cases, one
intendedforindooruse,orforuseinenvironmentallyprotected
member is a wire or group of wires, the other is a hollow
enclosures. Additional testing may be required to assure
cylinder or partial cylinder that is deformed around the wires.
satisfactory performance in applications where high humidity
3.2.2 crimp barrel, crimp tab, n—the portion of the crimp
or corrosive environment, or both, may be present.
terminal that is deformed in the crimping operation.
1.3 The values stated in SI units are to be regarded as
3.2.3 crimped connection, n—a mechanical and electrical
standard. No other units of measurement are included in this
connection between a conductor and a component. The con-
standard.
nection is made by compressing (crimping) the component
1.4 This standard does not purport to address all of the
(crimp barrel) or tab(s) of the component about the conductor
safety concerns, if any, associated with its use. It is the
using a tool specifically designed for the purpose
responsibility of the user of this standard to become familiar
with all hazards including those identified in the appropriate
3.2.4 crimp terminal, n—an electrical component designed
Material Safety Data Sheet (MSDS) for this product/material to be electrically and mechanically attached to a wire by
as provided by the manufacturer, to establish appropriate
deforming a portion of the component in a crimping operation
safety and health practices, and determine the applicability of
toformanattachmenttothewire.Theotherendoftheterminal
regulatory limitations prior to use.
usually has a ring, fork, spade, tab, or related configuration
designed to attach to another connection such as a screw or
2. Referenced Documents
terminal block.
2.1 ASTM Standards:
B8 Specification for Concentric-Lay-Stranded Copper 4. Summary of Test Method
Conductors, Hard, Medium-Hard, or Soft
4.1 A test lot of test specimens of the crimp terminal
B258 Specification for Nominal Diameters and Cross-
crimpedtoashortlengthofwireisprepared.Thewireispulled
SectionalAreasofAWGSizesofSolidRoundWiresUsed
from a group of the specimens in a tensile pull and the force
as Electrical Conductors
compared to set requirements based on wire diameter. A
B542 Terminology Relating to Electrical Contacts and Their
separate group of specimens is subjected to an electrical test
Use
where resistance stability of the specimen is evaluated during
deflectionofthewireattheexitofthecrimpedconnection.The
This test method is under the jurisdiction of ASTM Committee B02 on
group is then aged for 33 days at 118°C and periodically
Nonferrous Metals and Alloys and is the direct responsibility of Subcommittee
retested in the electrical test. The electrical test results are
B02.11 on Electrical Contact Test Methods.
compared to a standard value based on wire diameter.Atest lot
Current edition approved Oct. 1, 2010. Published October 2010. Originally
passes the evaluation if it passes both the mechanical pull test
approved in 2000. Last previous edition approved in 2005 as B913 – 05. DOI:
10.1520/B0913-05R10.
and the electrical test. In Method B, additional pull tests are
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
performed on subgroups of parts during and after the aging test
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
to provide information on progressive degradation in perfor-
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website. mance.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
B913 − 05 (2010)
5. Significance and Use 7.2 Oscilloscope, with adequate preamplifiers to measure
dynamic change of 100 6 10 µV. An oscilloscope with a
5.1 This test method establishes the requirements for a
recording device is preferred as it can provide a permanent
standardized method of evaluating the performance of
record of the results.
crimped-type electrical connections having solid or stranded
conductors. 7.3 Fixture with Two Clamps, to securely hold the crimp
terminal and end of the wire while making an electrical
5.2 In order to achieve a successful crimped connection, the
connection to each, and allow for manual deflection of the wire
crimping tool must deform the material of the crimp barrel or
at the exit of the crimp terminal through 15° in all directions.
barrel tab(s) around the conductor. As a consequence, the
A fixture with two vise-like clamps mounted about 80 mm
conductor surfaces are placed under compression by the crimp
apart on an insulating base has proved suitable. Spring clips
terminal and areas of contact are established between the
often used with 16 to 24-gauge wire are not adequate; a higher
conductorandthecrimpbarrel.Theseareasprovidethedesired
force clamp is needed.
electrical connection.Areliable crimped connection is one that
is capable of maintaining the contact between the conductor 7.4 dc Power Supply, capable of providing 100-mA milli-
and crimp barrel so that a stable electrical connection is amps current through the sample with noise or ripple less than
maintainedwhenitisexposedtotheconditionsitwasdesigned 10 µV on the measured sample
to endure during its useful life.
7.5 Oven, capable of maintaining a temperature of 118 6
5.3 Evaluation testing is designed to ensure that a particular 2°C and with a working volume adequate to contain the crimp
design crimped connection system consisting of conductor and test specimens and allow air circulation around them.The oven
component and associated tooling is capable of achieving a shall use air from the indoor environment as the air source, no
reliable electrical and mechanical connection. After the evalu- other humidity control is required.
ation is completed, if any change in the system parts is made,
8. Test Specimen
the system should be reevaluated using the same procedures.
8.1 Prepare the following quantities of test specimens of the
5.4 After completion of the evaluation test, the tensile pull
crimped connection made with the wire and crimp component
strength results may be used to develop acceptance require-
to be evaluated. For Test MethodA, prepare 64 specimens, for
ments to be used in inspection of subsequent production lots of
Test Method B, prepare 94 test specimens. For crimped
crimped connections. An example of such an acceptance
connections that will be manufactured with adjustable crimp
requirement is shown in Appendix X1.
dies, prepare 64 (Test Method A) or 94 (Test Method B) test
5.5 The aging test, 33 days exposure at 118°C, has been
specimens each made with the smallest and largest die setting
used in the telecommunications industry to simulate 40 years
to which the dies will be set in the manufacture of the actual
of service at a moderately elevated temperature of 50°C, an
connections. The wire length beyond the crimp barrel shall be
environment that components experience within large banks of
200 mm, minimum. In each test method, the 64 or 94
telephone equipment. This environment is similar to that seen
specimens provide four extra specimens beyond those actually
in a wide range of electronic systems operating indoors
required for testing, the remaining four can be used in test set
containing active components that dissipate power. The test is
up or retained as examples of the manufactured test specimens
designed to reproduce the stress relaxation of copper alloys in
since the testing is destructive. Specifications B8 and B258
such service and has been used extensively in evaluating wire
define wire gauge (diameter) and wire stranding.
wrap connections. It also accelerates other thermally activated
8.2 Document the following items at the time that the
processes such as oxidation although their acceleration factors
specimens are prepared:
may be different from that of copper stress relaxation.
8.2.1 Gauge of wire,
5.6 The aging test accelerates stress relaxation processes
8.2.2 Wire conductor stranding,
and other thermally activated processes but does not address
8.2.3 Wire coating or plating,
some other possible hazards such as corrosion. Additional
8.2.4 Wire manufacturer,
testing may be appropriate if the intended service environment
8.2.5 Wire manufacturer’s part number for the wire used,
presents such hazards.
8.2.6 Type of wire insulation,
8.2.7 Terminal supplier name,
6. Interferences
8.2.8 Terminal supplier’s part number for the terminal,
6.1 The wire strain relief included in some crimp terminals
8.2.9 Crimping tool supplier name,
may mask the performance of the crimped connection to the 8.2.10 Crimping tool supplier part number, and
wire. The strain relief shall be disabled prior to testing the
8.2.11 Crimping tool die setting (if applicable).
specimens in this test method.
8.3 The test specimens shall meet the following require-
ments:
7. Apparatus
8.3.1 All strands of the conductor(s) shall be in the crimp
7.1 Tensile Test Stand, Load cell and grips, or Holding barrel and there shall be no evidence of missing, broken,
Fixtures, adequate to measure the force required to pull the damaged, or loose strands of the conductor(s).
crimp terminal off the wire at the speed specified in this test 8.3.2 Conductors shall not be pre-soldered or solder-dipped
method. prior to crimping.
B913 − 05 (2010)
8.3.3 Wireistobestrippedimmediatelybeforecrimpingfor 9.1.3.2 Clamp the crimp terminal and the other end of the
a distance that is proper to full insertion into the crimp barrel. wire in the measurement fixture in such a way that the wire
Strip the other end of the wire for 25 mm to allow for position incorporates enough slack that the movement de-
connection to electrical measuring devices. scribed later in this section can be performed. In clamping the
crimp terminal, avoid applying clamping force to the crimp
8.3.4 The crimp indent shall be in the intended position and
barrel. Secure electrical connections shall be established and a
orientationonthebarrelinaccordancewiththedesignintentof
100-mA current passed through the wire and crimp barrel. Set
the manufacturer’s die set and crimp barrel.
the oscilloscope to a sweep rate of 100 ms/cm and a sensitivity
8.3.5 There shall be no cracking or rupture in any portion of
such that 100 µV provides a vertical deflection of one quarter
the barrel, tabs, and so forth.
to three quarters of full-scale. Use ac coupling of the oscillo-
8.3.6 The crimp barrel shall show no evidence of re-
scope to the test specimen. While monitoring the voltage
crimping (double crimping) in the same location. Barrels may
across the connection on the oscilloscope, grasp the wire at a
be crimped in more than one location in accordance with the
point approximately 25 mm from the barrel and move it
manufacture’s design.
throughapproximately30°ofarc15°eithersideofcenterthree
8.3.7 When a terminal is equipped with an insulation grip or
times. Observe and record the maximum voltage wave peak to
support, the wire insulation shall be in its intended position
peak observed on the oscilloscope during the wire movement.
within the grip or support after crimping. The grip or support
shall, as designed, mechanically secure or support the wire
NOTE 1—In the event that a failure occurs, it is recommended that a
insulation. length of wire of the type in the crimped terminal be tested in the fixture
using the same measurement system. If a failure is observed with the wire
8.3.8 On pre-insulated terminals or splices, the insulated
alone, the clamps at each end of the test specimen may be inadequate to
sleeve shall remain in its proper position on the crimp barrel
hold the parts securely.
after crimping and shall not show evidence of cracking or
9.1.3.3 Place the test specimens in an oven where the
spalling.
temperature is maintained at 118 6 2°C. Position them in the
8.3.9 When sleeving is used to insulate uninsulated crimped
oven to allow free circulation of air about them.
barrels, the sleeving shall be a snug fit and shall cause no
9.1.3.4 Remove the test specimens from the oven after 24 h
evidence of damage to the wire insulation.
and allow them to return to room temperature.
8.3.10 The conductor must be fully seated in the barrel and
9.1.3.5 Repeat the dynamic voltage drop measurement.
may extend beyond the barrel but not into the tongue area or
Record the results.
plug end of terminal lugs to the extent that it will interfere with
9.1.3.6 Repeat the dynamic voltage drop measurements
proper connection of the terminal to another part in the manner
after the samples are baked for 7, 15, and 33 days, cumulative.
intended.
After the 33-day measurement, the test is complete.
8.3.11 If more than one conductor is crimped in a single
crimp terminal, the wires must not be twisted together before
9.2 Test Method B:
crimping.
9.2.1 Follow the same procedure as Test Method A for the
Visual Test of Samples and the Tensile Pull Strength Test
9. Procedure
9.2.2 Select 60 specimens and perform an initial measure-
ment using the Dynamic Voltage Drop Test using the same
9.1 Test Method A:
procedure as in Test Method A.
9.1.1 Visual Test of Samples—Visually inspect all test speci-
9.2.3 Place all 60 test specimens in an oven where the
mens to determine if they meet the applicable requirements of
temperature is maintained at 118 6 2°C. Position them in the
the Test Specimens section of this test method.
oven to allow free circulation of air about them.
9.1.2 Tensile Pull Strength Test—Perform the tensile (pull)
9.2.4 Remove th
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