Information on the most widely used ASTM standards within the materials testing industry
For Electrical Lugs, cable crimp.
Wire terminal, cable lug, wire crimp, solder, lugs etc., is widely use
is various industry. The quality of a crimp joint depends on the
strength of the joint as well as its electrical conductivity. Crimp
joint testing can ensure the integrity of the final product. In general,
wire connection lug testing can be broken into two categories;
destructive pull testing and non-destructive pull testing. These tests
both aim to determine a tensile force that the test wire can withstand.
To meet the requirements of standard specifications, the tensile force
that a wire can withstand must be greater than the minimum tensile
strength defined by the standard.
Pull-force testing (crimp pull
test) is a destructive test for crimped wire connections. It measures
the tensile force to separate a crimped terminal from its conductor. In
the test, one end of the wire is secured, and a constant axial pull is
applied. The force increases until the terminal pulls off or the wire
breaks, and the peak force at failure is recorded to indicate crimp
quality. Pull testing also ensures good electrical contact
(metal-to-metal) at the terminal, preventing poor connections. A
repeatable pull test also helps calibrate the crimping equipment.
General introduction
Wire terminal, cable lug, wire crimp, solder, lugs etc., is widely use is various industry. The quality of a crimp joint depends on the strength of the joint as well as its electrical conductivity. Crimp joint testing can ensure the integrity of the final product. In general, wire connection lug testing can be broken into two categories; destructive pull testing and non-destructive pull testing. These tests both aim to determine a tensile force that the test wire can withstand. To meet the requirements of standard specifications, the tensile force that a wire can withstand must be greater than the minimum tensile strength defined by the standard.
Pull-force testing (crimp pull test) is a destructive test for crimped wire connections. It measures the tensile force to separate a crimped terminal from its conductor. In the test, one end of the wire is secured, and a constant axial pull is applied. The force increases until the terminal pulls off or the wire breaks, and the peak force at failure is recorded to indicate crimp quality. Pull testing also ensures good electrical contact (metal-to-metal) at the terminal, preventing poor connections. A repeatable pull test also helps calibrate the crimping equipment.
How the tensile test (pull force) works:
Handheld or benchtop dynamometers can be used to perform tensile tests. Handheld pressure gauges measure tension (tensile or compression) directly when force is applied, and these portable pressure gauges can be mounted to a small test bench if required. For greater consistency, the motorized test bench automates pull speed and data acquisition.
Specialized clamps securely hold crimp terminals and wires in the tensile tester. For example, cable cam clamps tighten themselves under load to distribute force and prevent slippage. The crosshead of the tester is constantly pulled (typically ~25 mm/min per standard) until it fails. Modern testers show peak tensile force, which reflects the strength of the joint. Since the test pulls until it fails, it can reveal whether the crimp holds or the wire breaks.
Test standards references
ANSI/EIA 364-38B : Cable pull-out test procedure for electrical connectors
ASTM B913 -05 : Standard Test Method for Evaluation of Crimped Electrical Connections to 16-Gauge and Smaller Diameter Stranded and Solid Conductors
BS 5G 178-1 : Crimped joints for aircraft electrical cables and wires. Specification for design requirements (including tests) for components and tools
BS EN 2591 : Aerospace series – elements of electrical and optical connection, test methods
BS EN 61300-3-11 : Fibre optic interconnecting devices and passive components – basic test and measurement procedures Part 3.11: examinations and measurements – engagement and separation forces
BS EN 60352-2 : Solderless connections. Crimped connections. General requirements, test methods and practical guidance
DEF STAN 59-71 : Crimped electrical connectors for copper conductors
IEC 60512-13-1 : Connectors for electronic equipment – tests and measurements – Part 13-1: mechanical operation tests – test 13a: engaging and separating forces
MIL C-39029 /31B : Contacts, electrical connector, pin, crimp removable
NASA STD-8739.4 : Crimping, interconnecting cables, harnesses, and wiring
SAE USCAR21: Performance Specification for Cable-to-Terminal Electrical Crimps
SAE USCAR38: Performance Specification for Ultrasonically Welded Wire/Cable Termination
Key Features
Cable lug pull tester, wire connector strength tensile test, crimp test, pull testing machine for wire lug, wire terminal; wire bond tensile strength testing machine.
These tests both aim to determine a tensile force that the test wire can withstand.
To meet the requirements of standard specifications, the tensile force that a wire can withstand must be greater than the minimum tensile strength defined by the standard.
ASTM B913: Standard Test Method for Evaluation of Crimped Electrical Connections to 16-Gauge and Smaller Diameter Stranded and Solid Conductors.
ISO 1966: Crimped joints for aircraft electrical cables
ASTM F458: Standard Practice for Nondestructive Pull Testing of Wire Bonds1,2
EIA 364-08B: Crimp Tensile Strength Test Procedure for Electrical Connectors
SAE/AS 7928: Terminal, Lug, Splice, and Crimp Copper Strength Specifications
Main technical specification
| Load capacity | 100N, 200N, 500N, 1Kn, 2KN, 5KN |
| Frame proof load capacity | 150% of rate capacity |
| Multiple load cell in one machine function | YES |
| Load Accuracy | Class 1/0.5 according ISO7500-1 |
| Load cell overload capacity | 150% of rate capacity |
| Load measuring resolution | 1/500000 FS, stepless |
| Position / displacement resolution | 0.001mm |
| Crosshead travel | 1150mm |
| Tensile test space | 800mm |
| Compression test space | 900mm |
| Standard tensile test fixture | Corrugated Opposite clamping |
| Compression platen diameter | Φ100mm |
| Testing speed range | 0.001 mm/min~500 mm/min, stepless, adjustable arbitrarily |
| Weight | 110kg |
| Standard Power | 220/110V, 50/60HZ, 1 phase |
| Dimensions | 520×410×1500mm |
| Analysis software | SmartTest English version |
| Working system | MS Win10 / Win11 |
Main accessories (Standard delivery with machine)
| High Stiffness Frame: | 1 set |
| Servo driving system: Servo motor: | 1 set |
| Loadcell: | 1 set |
| Decelerator and deceleration system | 1 set |
| Leading screw: | 1 set |
| Wire terminal tensile test fixture | 1 set |
| Compression test fixture(Φ100mm) | 1 set |
| Professional testing software(FastTest, English version) | 1 set |
| Bending test fixture | 1 set |
| Computer | 1 set |
| Printer | 1 set |
| Documents (Manual, packing list, certificate) | |
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