Welding, the more traditional and economical method of terminating a connector, involves melting and cooling an alloy of lead, tin, brass, or silver into a solder cup to bond a conductor to the connector's contacts.

Welding, the more traditional and economical method of terminating a connector, involves melting and cooling an alloy of lead, tin, brass, or silver into a solder cup to bond a conductor to the connector's contacts.

Connectors use welding technology rather than crimp terminals that require special tools. Wires and welding contacts of almost any size can be terminated using the basic welding process. Because fewer molds, only need solder and flux, so you can save a lot of costs. In short, welding is the main benefit of the connector.

Terminal din 41612 type h connectors Thermal failure of the manufacturer process

But welding technology has its drawbacks. The welding process creates heat in the connectors' contacts and cables. This inevitable heating can cause problems, especially if the temperature rises above the limit temperature range of the insert, which is most likely to cause failure. In addition, the connector contacts require RoHS compliant solder for welding connections.

In addition, the welding process is more time-consuming than the crimp method. If done incorrectly, quality and reliability problems may result. For example, if the solder is not fully melted, automotive connectors can result in "cold" solder joints, which will result in rough, uneven, or caked welded surfaces, leading to unreliable bonding.

When using the connector, if the application temperature is too high, it will lead to some faults in the connector, and the thermal failure of the connector is usually divided into two forms.

In general, there are two main problems with connector overheating. The first is that the connector has lost its normal contact force, which may be caused by the thermal expansion effect between the spring material of the connector and the plastic housing. The lower spring material is caused by the reduction of the connector strength of the new energy vehicle and the stress relaxation of the spring material.

The second fault problem is the formation of an insulating film on the surface of the connector contact material, which usually results in the formation of a complete conductive barrier at the connector's separable interface. Due to the degassing of the plastic casing or other adjacent volatile materials, diffusion of non-precious metals on the contact surface and subsequent oxidation can form a film.

A common effect of connector thermal failure is that an increase in contact resistance reduces transmission performance, while a decrease in contact force results in a decrease in the actual contact area.

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