Durability Evaluation on Metallic Joints of Copper Wire with Insulating Coat

A new brazing method was investigated in order to improve the strength of insulated copper wires jointed by fusion technology. This process of the brazing method is composed of fusing and brazing for joining brass terminal and insulated copper wire. Shear tests of the joint were carried out at room temperature after each test, namely, 2000h exposure at 150°C or 250°C, 1000 thermal cycle test between -55°C and +150°C, and salt spray test at 35°C for 2000h. After durability test, We observed the joint interface and find Cu, Ag, P and a little Zn. In these tests, the fracture are observed at the base metal without damage at joint region. Moreover, the strength of the joint between a wire without insulating coat and a brass terminal was also evaluated, and equivalent strength is obtained as that given in case of the wire with insulating coat.