Wire Compacting

Wire Compacting is a process in which stranded wire is heated and formed into a desired shape in order to better facilitate attachment to other components, using resistance welding or other joining processes. The process is similar to wire fusing but negates the need for a ferrule which can slow the manufacturing process and add weight to the finished product.

Resistance compacting (welding or brazing) is achieved using a welding power supply and a weld head fitted with specialized electrodes to deliver current and apply vertical force to join the wires, while ceramic tooling inserts apply a sideward force to assist in controlling the final shape:

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Wire compacting is an ideal solution for copper, with or without tin or silver coating. Depending on the parameters chosen, the degree of compacting strength can vary from light adhesion of the individual wires to a solid copper end. AMADA WELD TECH has successfully compacted wires up to 90 mm2. Twisted pairs and multiple sheathed cables are all good candidates for this process. Fully automated systems can be built for cutting and compacting braided wires off the roll so that their ends can be subsequently connected with terminals.

Aluminum and nickel plated copper wires are not well suited to compacting.

Compacting is typically used for wire harness assembly in the automotive industry. Other applications include:

  • Safety belt sensors
  • Electrical distribution from batteries
  • Temperature sensor connections
  • Airbag initiators
  • Y and T connections

Watch a video of the process.

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