The strongest connection of large cross-section wires without thickening by twisting

Splicing stranded wires with a large cross-section only by twisting is subsequently accompanied by oxidation, deterioration of contact and an increase in resistance. Plus, ordinary twisting has an unesthetic appearance and a significant thickening at the junction. A more correct and reliable connection method would be soldering, but on thick wires from 10 mm sq. It's difficult to do this with a soldering iron. Of course, you can use a crucible, but not everyone has one. Let's look at a simple and reliable way to solder thick wires with a regular soldering iron.
The strongest connection of large cross-section wires without thickening by twisting

Tools and materials:


  • solder;
  • flux or alcohol solution of rosin;
  • soldering iron;
  • thin copper wire;
  • stripper or mounting knife.

Preparing wires and soldering


The ends of the wires must be cleaned of insulation with a stripper or knife. It is enough to open about 1 cm each. The exposed stranded strands should be fluffed up and joined at the ends.
The strongest connection of large cross-section wires without thickening by twisting

The strongest connection of large cross-section wires without thickening by twisting

When connected, they will fan out, so you will need to gently squeeze them with your fingers.
The strongest connection of large cross-section wires without thickening by twisting

The cores at the splice point are wrapped with thin copper wire, preferably thicker than the individual wires in the wires being connected. It can be obtained from the cable PVZ, ShVVP and the like.
The strongest connection of large cross-section wires without thickening by twisting

The winding should be carried out at medium frequency. If you lay the coil to the coil, the result will be neater and stronger. When winding, the wire should be tensioned; upon completion, its ends are connected by twisting or inserted into cores. The resulting bandage must be finally tightened. To do this, the connected wires are stretched. The more you pull them, the more the veins are compressed by the bandage. As a result, the connection will be no less resistant to breaking than a solid cable.
The strongest connection of large cross-section wires without thickening by twisting

The exposed conductors at the splice site must be coated with flux or an alcoholic rosin solution. After this, the bandage and cores are heated with a soldering iron.
The strongest connection of large cross-section wires without thickening by twisting

Solder is applied to the hot areas. As it melts, the soldering iron tip needs to be moved further to heat new places. Molten tin penetrates under the bandage and the voids between the interposed core wires. The solder does not drip and lies very smoothly.
The strongest connection of large cross-section wires without thickening by twisting

The proposed soldering method produces a very mechanically strong connection. Using a bandage eliminates wastage of tin, since it does not flow down and hang in drops. The splice itself looks neat and creates minimal resistance. If you use a sufficiently powerful soldering iron, then each connection can be prepared in a couple of minutes.

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Comments (15)
  1. Guest Yuri
    #1 Guest Yuri Guests July 19, 2019 08:31
    6
    "British" will be more reliable.
  2. Guest Yuri
    #2 Guest Yuri Guests July 21, 2019 07:12
    3
    Small BUT. This is only permissible at low voltage. At 220 volts and above, soldering with tin is unacceptable. The difference in the resistance of tin and copper will lead to heating and subsequently burnout.T
    Only welding on a carbon electrode. Preferably on a copper-plated one.
    1. Novel
      #3 Novel Guests July 22, 2019 07:30
      2
      It depends on what current flows through this junction. For a low load it is quite acceptable.
    2. Igor
      #4 Igor Guests 27 July 2019 20:28
      5
      Please clarify how the voltage applied to the solder will affect the amount of its heating?
    3. Electrician
      #5 Electrician Guests July 29, 2019 07:19
      9
      Oh yeah. Tell me why are you leaving your comment, to show your incompetence? Or you can't sleep without leaving another rant? Resistance difference? Oh my God, I almost broke my forehead with the cotton. What is the significance of voltage class to resistance? Do you know that in 6-10 kV couplings the ends are connected by a strip joint or soldering with POS-30 solder? Do you know that wires on 0.4 - 10 kV lines are connected by twisting without soldering? And you know what the resistance is at the twisting point. Carbon electrode welding?
      1. Foreman
        #6 Foreman Guests 6 February 2020 17:04
        0
        Who came up with this nonsense - making twists on a 10 kV line? Name the point of PUE, SNiP, maybe GOST 10434 has changed? Although I have seen apartments and cottages with power wiring made from telephone noodles (TRP 2x0.4), it’s good that there are things in the world that will never leave us without work!
    4. Guest Vladimir
      #7 Guest Vladimir Guests 30 July 2019 13:58
      0
      In your opinion, Ohm’s law “does not work” at the junction point?
      1. Igor
        #8 Igor Guests 30 July 2019 17:09
        0
        Can you tell me how you apply it to soldering?
    5. Guest Vladimir
      #9 Guest Vladimir Guests 30 July 2019 16:27
      0
      Unfortunate electrician...
    6. Sergius
      #10 Sergius Guests July 31, 2019 01:18
      1
      Excerpt from the PUE rules: clause 2.1.21. Connection, branching and termination of wires and cables must be carried out using crimping, welding, soldering or clamping (screw, bolt, etc.) in accordance with current instructions.
    7. Passing by
      #11 Passing by Guests August 1, 2019 06:46
      0
      There are many of you like that. It will heat up and fall off. And then people suffer with the same auto electrics.
    8. Guest Sergey
      #12 Guest Sergey Guests August 1, 2019 11:41
      4
      Apparently that’s why soldering copper with tin is used everywhere in power supplies and powerful inverters, right??)) or maybe Yuri’s brain is sealed off..
    9. Guest Anatoly
      #13 Guest Anatoly Guests 9 September 2019 18:56
      1
      I just laughed. Give a calculation of heating at a current of, say, 50 amperes, on a wire solder of 6 square meters. mm. Just don’t forget to calculate and take into account the area of ​​the soldered contact.
  3. Dya Vitya
    #14 Dya Vitya Guests September 10, 2019 07:39
    0
    For this purpose I have a turbocharged lighter and solder with flux inside. I connect both stranded and single-core wires. Everything takes seconds...
  4. ozi
    #15 ozi Guests 10 September 2019 14:48
    0
    With twisting and normal flux, my results are more compact and neat.