Settling the Debate on Soldered versus Crimped High-Current Connectors

Will Prowse tested high-current wiring rigs dispensing hundreds of amps through crimped and soldered copper cables to settle industry debates. The cold weld process creates a solid metal connection that improves over time while resisting vibrations better than intermetallic compounds found in soldered joints. Soldered connectors failed quickly under mechanical abuse due to heat development, whereas properly crimped connections maintained integrity without relying on softer materials.