Join Date: Feb 2008
Thanked 0 Times in 0 Posts
Rep Power: 9
Copper is very soft and ductile so cutting through a crimped connection smears the metal and indeed makes it look like a "solid mass" of metal. A proper metallurgical inspection of a crimped connection involves slicing a section of the crimp with a microtome and looking at the surface with SEM. The interstitial spaces are always present, and can be very small, on the order of angstroms, but no amount of force can fuse copper wires into a solid mass. Unless you melt it, which I wouldn't recommend.
Crimping is a great mechanical connection, and a servicable electrical connection. Solder, especially modern, lead-free solders, are also very soft, and better yet, not prone to embrittlement. A proper solder joint fills interstitial spaces, and a proper crimped connector will deform the soldered wire and make an excellent connection.
I sometimes use solder joints and sometimes crimped connectors, and sometimes both.
I am simply putting in my 2cents worth of 30 years of electrical engineering, take it or leave it, as usual.
Oh, and how about the electrical failure that roasted 3 astronauts in the Apollo project?
...just because all the other kids jump off the Empire State Building doesn't mean I'm going to.