402-1002
Manual 11Apr03 Rev OEC 0990-0492-03
Making and Instructions for Interpretation of Cross-Sections
for F-Crimp Terminals
� 2003 Tyco Electronics
Corporation,
Harrisburg, PA
All International Rights Reserved
For latest revision call AMP* FAX/Product Info number 1-800-522-6752.
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LOC B
1. INTRODUCTION
Performance tests such as agency approval testing and/or product qualification testing are normally
used to evaluate product performance and to confirm conformance to requirements. For any testing to
be valid, it is imperative to crimp the terminal with the correct wire size, use the specified application
tooling and crimp height, and ensure conformance to the other parameters as specified in the
application specification.
A cross-sectional photograph can be used to further evaluate the crimped termination when additional
diagnostics are determined to be necessary. The cross-section should be used as a reference image
for comparison to future cross-sections. This reference image should be made with new crimp tooling
to ensure that damaged tooling does not provide an incorrect reference image.
In the event that there are differences between the information presented in this manual
versus the information found in the application specification, the application specification
will take precedence.
2. PROCEDURE FOR MAKING CROSS-SECTIONAL PHOTOGRAPHS
Before making any cross-sectional photographs, it is necessary to ensure that the crimp meets the
parameters as listed in the applicable application specification (114 series) or the information provided
with the application tooling if an application specification does not exist. These parameter include:
x Verifying that the correct Tyco Electronics application tooling is used to crimp the terminal.
x Verifying that a valid wire or wire combination is being used.
x Verifying that Tyco Electronic components (crimpers and anvils) are being used for the crimp
tooling. The components must be in good condition and properly aligned.
x Verifying that the correct crimp height dimension is being used for the particular terminal/wire/tool
combination per available documentation.
x Verifying that the other crimp features (bellmouth, flash, no missed, loose or cut wire strands, wire
brush, insulation placement, etc.) meet the requirements of the application specification.
Once it has been verified that the crimp meets the requirements as specified in the application
specification and/or the documentation provided with the application tooling, the cross-section can be
made. Most commercial cross-sectioning equipment consists of several modules: cutting, grinding,
etching and imaging. Please refer to the instructions provided with the cross-sectioning equipment for
proper technique. The following rules need to be followed when making cross-sections:
x The cross-section must be made perpendicular to the crimp in both the X and Y-axis as shown in
Figure 1. Figure 2 shows a terminal that has been cut on an angle.
NOTE
402-1002
Rev O 2 of 10
Figure 1
Figure 2
x The cross-section must always be taken in the area where it is recommended to measure crimp
height. (Refer to the application specification and instruction sheet 408-7424 for proper crimp-
height measurement locations and procedures.)
x The cross-section photograph must clearly show the wire strands and the terminal’s material.
Figure 3 provides an example of a good cross-sectional photograph made using a curved anvil.
Figure 4 provides an example of a good cross-sectional photograph made using a flat anvil.
Terminal cut straight and
perpendicular to X and Y-axis.
Terminal cut on an angle.
402-1002
Rev O 3 of 10
Figure 3
Figure 4
3. COMMON CROSS-SECTION PREPARATION ERRORS
x The cross-section must avoid being made through a serration. Interpreting a cross-section that
has been taken through a serration provides an inaccurate view of the crimp. If a cross-section is
taken through a serration, part of the terminal will appear to be thicker than the rest of the terminal.
Another indication is that there is a gap between the walls of the terminal and the deformed
strands. Figure 5 provides an example where the cross-section was taken through a serration.
Flat from anvil is
visible.
Wire strands are well-
defined.
Example of a terminal crimped
with a flat anvil configuration.
No extreme discoloration
of the terminal’s
material.
402-1002
Rev O 4 of 10
Figure 5
x The cross-section must be properly polished and etched. Improper polishing can give the
appearance of cracks. Improper application of the etching solution can also distort the
appearance of the cross-section by not sufficiently showing the details. Figure 6 provides an
example of a terminal that has been improperly polished and etched. If the terminal is exposed to
the etching solution too long, the image becomes very dark and it is difficult to see any details of
the wire strands and/or the terminal material. This condition is shown in Figure 7.
Figure 6
Material
appears to be
thicker than rest
of terminal.
Gaps between deformed wire
strands and sides of terminal wall.
Cannot conclusively
determine if this is a
crack because of poor
sample preparation.
No or poor definition
of wire strands.
402-1002
Rev O 5 of 10
Figure 7
x If the terminal is cut on an angle when the cross-section is being prepared, the terminal will need
to be rotated in order for the cross-section to be in focus. When this occurs, the bottom or sides of
the terminal will be visible in the cross-sectional photograph. Figure 8 shows an example where
the bottom of the terminal is visible instead of just seeing the sectioned portion of the terminal.
Figure 8
Bottom of terminal is visible. Should only
be able to see cut portion of crimp.
402-1002
Rev O 6 of 10
4. INTERPRETATION OF CROSS-SECTIONAL PHOTOGRAPHS FOR TOOLING ISSUES
The following cross-sectional photographs provide representative examples of various conditions that
are related to worn/damaged tooling or applicator adjustments.
Variations in feed and/or variations in setting of feed lengths can result in flash. Flash is formed when
the terminal’s base material extrudes into the clearance between the anvil and wire crimper. Variations
of this nature typically result in the tips of the terminal not being symmetric. Figure 9 shows an
example of this condition.
Figure 9
While symmetry of terminal tips is a desirable condition, a condition of this nature is
acceptable. Symmetry variations are common with end feed terminals since the
terminal is susceptible to twisting once it leaves the strip guides.
Misalignment of crimp tooling can result in variations regarding the shape. Common variations include
significant flash without having any signs of anvil damage and irregular curvature of the crimp profile.
Figure 10 shows an example of these conditions.
Terminal tips are not symmetric. This condition is
acceptable, even though having symmetric tips is
the most desirable condition.
Minor flash
caused by feed
variation.
NOTE
402-1002
Rev O 7 of 10
Figure 10
Damaged anvils result in excessive flash. One way to identify a damaged anvil is the lack of a
distinctive flat at the bottom corners of the crimp profile. This condition is shown in Figure 11. Damage
to the anvil can also result in cracks being formed in the bottom corner of the crimp. This condition is
shown in Figure 12.
Figure 11
Refer to the application specification to determine the amount of flash that is
permissible.
Significant flash, even though anvil flat is present. The
vertical line indicates that the anvil was not damaged in
the area where the cross-section was taken.
Irregular
curvature is a
result of tooling
misalignment.
Excessive flash – both
width and height. No
flat from anvil.
Flash present in
addition to flat from
anvil. Rounded
transition is indicative
of damage to the
anvil.
Flash Height
Flash
Width
NOTE
402-1002
Rev O 8 of 10
Figure 12
Collisions between the crimper and anvil can damage both pieces of tooling. Figure 13 shows a crimp
that was made by tooling that was damaged by colliding with one another.
Figure 13
5. INTERPRETATION OF COMMON CROSS-SECTION CHARACTERISTICS
A cross-sectional photograph is a diagnostic tool that can be used to evaluate a crimped termination as
previously stated in Sections 1 and 2. In order for a cross-sectional photograph to be of value, the
crimp must be made using the correct combination of terminal, wire and application tooling and that the
crimp is made to the crimp height specified for this combination. The crimp must also meet all other
crimp parameters as specified in the applicable application specification. The following cross-sectional
photographs are representative of various conditions typically seen.
Close up of a crack in the corner of a terminal.
Indentations in crimp profile that were caused by
anvil colliding with wire crimper.
Flash resulting from damage to anvil as a result of
colliding with wire crimper.
402-1002
Rev O 9 of 10
Figure 14 is an example of a cross-sectional photograph of a good crimp. The wires are deformed, the
terminal tips are symmetric and the anvil flats are visible.
Figure 14
Figure 15 shows a crimp where one of the terminal tips touches the bottom of the crimp. This condition
is permissible if all other specified crimp parameters are met.
Figure 15
All wire strands are deformed.
Tip of terminal touching bottom of
crimp.
Anvil flats are visible.
402-1002
Rev O 10 of 10
Figure 16 shows a crimp where both tips of the terminals are touching the sides of the crimp. A wire
strand is trapped in the upper left corner of the crimp, but it is thoroughly deformed. This condition is
permissible if all other specified crimp parameters are met.
Figure 16
Voids are acceptable in a crimp since a successful crimp is dependent on the generation of “adhesion”
between the wire strands and between the strands and the body of the terminal. Adhesion occurs
through the disruption of the surface films due to the deformation of two metal surfaces in contact and
as they move relative to one another. Metallic bonding occurs across this interface and the
combination becomes a homogeneous mass in an electrical sense. Voids may be present in the crimp
since full interface contact will be obtained at deformations that are far less than required to form a
void-less, homogeneous mass. Figure 17 shows a crimp that has several voids present.
Figure 17
Terminal tips touching sides of crimp.
Trapped strand that is
thoroughly deformed.
Voids present in a crimp.
Since wire strands show
significant deformation,
this condition is acceptable.
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