Direct electrical connection from wire to wireform spring...
Direct electrical connection from wire to wireform spring...
(OP)
I'm looking for suggestions on connecting wires to a wireform spring. Imagine a cotter key Link that needs to pass a current. My application is automotive, so 12V. I can either have an copper insert in a plastic injection part that will have interference contact with the spring and a spade terminal built in, or I was thinking I might be able to connect a spade terminal to the end of my spring. The spade connector I think is a very simple solution, but the wire is 2mm dia music wire ASTM A228, with hardness C41-60 (http://optimumspring.com/technical_resources/mater...). I don't know how well a spade terminal typically designed to grip a soft copper wire will do with hard music wire. Any thoughts on this? Or maybe soldering would be a viable option? Someone even mentioned stamping a spade terminal in the end of the spring might be an option, but I don't think that I agree. Any input is helpful. Thanks





RE: Direct electrical connection from wire to wireform spring...
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RE: Direct electrical connection from wire to wireform spring...
Thanks
RE: Direct electrical connection from wire to wireform spring...
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RE: Direct electrical connection from wire to wireform spring...
RE: Direct electrical connection from wire to wireform spring...
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RE: Direct electrical connection from wire to wireform spring...
If you're being cheap, then spot weld the copper wire straight on. A very common technique.
For reliability, you'd presumably have to be careful that movement and recurring stress is kept away from the spot welded section of the spring wire. In other words, that section of the spring wire (heat damaged by the process of spot welding) would be clamped in a fixed position, not flexing.