Why Crimped Connector Mechanics Failure?

Crimped connectors mechanism, due to the key role played, they are required to have high durability even under harsh operating conditions. In the case of unexpected/early failure, thorough diagnosis and deep understanding of the main failure causes are the starting point to preclude future occurrence and improve the system reliability. Therefore, the present post gathers the main failure mechanisms in crimped connectors and indicates some of the characterization tools used for suitable failure analyses.

IEC Electropedia

Failure mode: “Manner in which a failure occurs. A failure mode may be defined by the function lost or other state transition that occurred.”

Failure mechanism: “Process that leads to failure. The process may be physical, chemical, logical, or a combination thereof.”

Failure cause: “Set of circumstances that lead to failure. A failure cause may originate during specification, design, manufacture, installation, operation or maintenance of an item.”

Crimped Connectors Mechanics

Due to the functionality, the large contact resistance in excess of the threshold indicated by the specification and/or abnormal heating is the main failure modes of any types of connector. According to the literature^1-5 typical failures in crimped connectors can be ascribed to one of the following factors.

1. Stress relaxation (Creep and recrystallization)
2. Under/over crimping

1. Galvanic
2. Pore corrosion
3. Surface contamination