Investigation on the Crimping Strain Characteristics and Reliability of Copper-Clad Aluminum Wire Assemblies

This investigation delineates the crimping strain characteristics and assesses the reliability of copper-clad aluminum (CCA) wire assemblies, particularly in aerospace applications where high reliability is paramount. The broader utilization of CCA wires is constrained by inherent challenges such as susceptibility to corrosion and complexities in achieving robust sealed crimp connections. Employing a rigorous methodological framework that includes crimp strain simulations and advanced electron microscopy techniques, this study aims to refine the crimping process and augment the material compatibility between connectors and wire insulation. The findings underscore the efficacy of annealing treatments in enhancing mechanical properties through grain refinement, thereby bolstering the reliability of the connections. This research contributes to the body of knowledge on the mechanical and chemical stability of CCA wires, promoting their expanded use in demanding reliability environments.