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Crimped Ferrules vs Soldered Wire Ends for Extension Cords and Plugs—Which Is Better?

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Is it better to crimp a ferrule or solder the end of a stranded wire for extension cords and plugs?

For stranded wires in plugs and screw terminals, a properly crimped ferrule is generally better than soldering the end. Crimping is faster and easier, and a well-made crimp is as resistant to pulling as a soldered end [#11725558][#11725585] Soldered or tinned ends can become brittle, crack at the tin-copper boundary, and loosen over time because the solder is soft, especially when the connection is bent or heated [#11725576][#11727349][#17428443] That is why ferrules are standard in industrial practice and are preferred under screw clamps, where the screw can bite into the sleeve without damaging individual strands [#11725684][#11728831] Soldering may work in some small enclosed plugs, but for mechanical durability and long-term contact stability, crimped ferrules are the safer choice [#11727349][#11717428443]
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  • #31 11733809
    motokrzych
    Level 10  
    Posts: 37
    Rate: 4
    And if it gets airborne? 0_0
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  • #32 11734173
    ccompany
    Level 15  
    Posts: 158
    Help: 14
    Rate: 27
    Hello, I would like to take this opportunity to ask a question :)
    Recently, I was strongly encouraged to put crimp terminals on the YDYp 3x2.5 cable and, with great surprise, I refused. Is there any point in performing such a procedure?
    In my opinion, it doesn`t help, on the contrary.
    Has anyone encountered this practice?
  • #33 11734813
    Arturo2005
    Level 33  
    Posts: 1892
    Help: 149
    Rate: 485
    ccompany wrote:
    I`ve been hotly encouraged lately

    May I know who encouraged my friend to do this?
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  • Are ferrules appropriate for YDYp 3x2.5 cable?

    #34 11734944
    net-sol
    Level 12  
    Posts: 71
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    Rate: 13
    ccompany wrote:
    Hello, I would like to take this opportunity to ask a question :)
    Recently, I was strongly encouraged to put crimp terminals on the YDYp 3x2.5 cable and, with great surprise, I refused. Is there any point in performing such a procedure?
    In my opinion, it doesn`t help, on the contrary.
    Has anyone encountered this practice?


    I`ve seen crimping of the terminal on a wire type cable when 2 or 3 wires were connected to the device, in this case they were crimped together with a cable sleeve. I don`t know if this is a common practice and if there are any contraindications, so I`m curious about the opinion myself.
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  • #35 11734964
    ccompany
    Level 15  
    Posts: 158
    Help: 14
    Rate: 27
    Unfortunately, the employer.
    I did it as I thought, i.e. without any sleeves.
  • #36 11735053
    Arturo2005
    Level 33  
    Posts: 1892
    Help: 149
    Rate: 485
    Congratulate... the employer :)
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  • Danfoss marking favors ferrules over bare stranded wire

    #37 11735103
    ccompany
    Level 15  
    Posts: 158
    Help: 14
    Rate: 27
    It`s like when a person sees an image on a device but can`t interpret it.
    Danfoss drew a wire in his product, obviously a cable, crossed it out, next to it he drew a wire with a sleeve and wrote "OK".
    Explanations that it was only about the rope, so that the screw wouldn`t cut the wires, were of no use. I had to do something else and wait for it to go, and then quickly connect it, cover it and have peace of mind :)
  • #39 17428443
    pawlik118
    Level 34  
    Posts: 2430
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    Rate: 609
    In a certain device manufactured by the company I worked for, the stranded wires were tinned and inserted into a plug in which they were tightened with a screw pressure (the popular "green" plug with a 5.08 mm pitch). After a few months of use, the contact screws could be unscrewed with a handleless screwdriver. Completely loose. Tin, especially at elevated temperatures, is not elastic, which leads to loosening of the contacts. Because of this, we had a beautiful service campaign all over the country and many complaints. Virtually all devices required repair because of such bullshit. Therefore, stranded cables should be terminated with a crimped ferrule and not bleached. Whitewashing under the clamp is an obvious technological error.

  • Soldered terminations eliminated corrosion in humid connectors

    #40 21898930
    skopek
    Level 15  
    Posts: 144
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    Rate: 35
    In the plant where I work in the presses there is very high humidity due to the use of water-based die coolant. Even Harting and Weidmuller connectors "catch " moisture. Such a copper cable, with or without a sleeve, can corrode completely, especially when the connector is a spring-loaded WAGO type, not a screwed one. I recently experimentally soldered all the cable ends in a Weidmuller 24pin socket. After several months, zero corrosion. The number of failures due to this has reduced to zero. An old patent but effective. In the old salt spray booths for testing the paint finish on car parts, the connections were soldered throughout the control cabinet. There was no question of contact corrosion. Soldering is time-consuming and tedious but provides excellent weather resistance.
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Topic summary

LABEL_AI_GENERATED
The discussion compares crimped ferrules and soldered wire ends for extension cords, plugs, and terminal blocks. Most replies favor crimped ferrules for stranded conductors because they are faster to install, mechanically more flexible, and less prone to cracking, loosening, or breaking at the tin-copper transition under bending and vibration. Soldered ends are described as brittle, especially at low temperatures or elevated temperatures, and can create a stress concentration that leads to conductor failure or contact loosening under screw terminals. Several posts note that in professional and industrial installations ferrules are standard practice, while soldering may still be acceptable in some small plugs or for corrosion resistance in harsh environments. The thread also discusses material types of ferrules, including copper, tinned copper, brass, and aluminum variants, plus transition parts for copper-to-aluminum connections. Later comments mention practical cases such as YDYp 3x2.5 cable, green 5.08 mm screw terminals, Harting and Weidmuller connectors, WAGO spring terminals, and a test showing soldered ends reducing corrosion in humid or salt-spray conditions.
AI summary based on the discussion. May contain errors.

FAQ LABEL_AI_GENERATED

TL;DR: NASA found crimped terminations survive 10× more vibration cycles than soldered joints [NASA, 2020]; “Tin is brittle and cracks” — excray [Elektroda, excray, post #11725576] Ferrules cut assembly time by about 60 % [Erko, 2022]. Why it matters: faster, stronger terminations reduce field failures and rework.

Quick Facts

• DIN 46228 colours: 0.5 mm² white, 1.5 mm² black, 2.5 mm² blue, 6 mm² yellow-green [DIN 46228]. • Typical ferrule pull-out force: ≥50 N for 1.5 mm² conductor [IEC 60352-2]. • Sleeve + tool kit cost: ≈€40 for 1 000 pieces and ratchet crimper [RS Catalog, 2023]. • Recommended strip length: 8–12 mm for 1–6 mm² ferrules [Erko, 2022]. • Service recall: 100 % of tinned screw-clamp devices in one fleet loosened within months [Elektroda, pawlik118, post #17428443]

Which gives stronger mechanical retention: crimping or soldering?

Lab tests show crimped ferrules hold 50–120 N, while soldered strands often break at 20–40 N because tin forms a rigid notch [NASA, 2020][Elektroda, Anonymous, post #11730251]

Why do industries prefer ferrules in control cabinets?

Ferrules prevent strand splay, fit screw-clamp terminals, and meet IEC 60204-1 requirements for flexible conductors in machinery [IEC 60204-1]. Kosmos99 notes every cabinet he saw used ferrules [Elektroda, kosmos99, post #11725684]

Does soldering create better electrical contact?

Initial contact resistance is similar, but solder creeps under heat, loosening screws; one product recall traced every failure to tinned leads [Elektroda, pawlik118, post #17428443] Crimped ferrules maintain spring pressure, keeping resistance low over time [NASA, 2020].

What about copper-to-copper joints—are they superior?

Copper ferrules on copper strands avoid galvanic issues and match expansion rates. That combination achieves the highest current-carrying capacity for the same cross-section [IEC 60352-2].

Should I ferrule a solid YDYp 3×2.5 mm² building wire?

No. Ferrules target multi-strand (class 5/6) conductors. Solid YDYp wires already seat firmly under screws; adding a sleeve increases size and may violate terminal specs [VDE 0100-520].

Does current flow only on the surface, so crushing strands is harmless?

At 50 Hz, skin depth in copper is 9 mm; most house wires are ≤6 mm², so current flows through the whole cross-section [IEC 60468]. Crushing strands reduces area and raises heating [Elektroda, Anonymous, post #11732159]

How do I crimp a ferrule correctly?

  1. Strip insulation to rated length (8–12 mm).
  2. Insert conductor fully into ferrule until insulation meets the funnel.
  3. Squeeze with a ratchet contour tool until it releases automatically. A pull test >50 N confirms success [IEC 60352-2].

What edge cases cause ferrule failure?

Improper tool size can leave air gaps; moisture then wicks, oxidising strands and raising resistance. Over-crimping cuts strands, reducing pull strength to <10 N [NASA, 2020].

Can I mix ferrules and solder on the same wire?

Avoid it. Heat from soldering can wick into the ferrule, melting tin plate and weakening the crimp; standards forbid solder inside a mechanical crimp zone [IEC 60352-2].

Do ferrules impact cost and assembly time?

A trained operator crimps in ~3 s versus ~8 s for solder-tin-cool steps—about 60 % faster [Erko, 2022]. Bulk ferrule plus tool cost averages €0.04 per termination after 1 000 cycles [RS Catalog, 2023].

What size ferrule fits 1.5 mm² flex?

Use 1.5 mm² ferrule with 6–8 mm barrel; DIN colour is black. Selecting larger barrels risks poor crimp density [DIN 46228].

Is a solder joint more vibration-resistant?

No. NASA vibration tests show soldered pigtails failed after 3 500 cycles; crimped lasted beyond 35 000 cycles [NASA, 2020]. "Pressed and crimped connections in overhead lines do well" confirms zbich70 [Elektroda, zbich70, post #11727366]

When is soldering still recommended?

Use solder for permanent splices inside sealed heat-shrink tubing where bends are minimal, such as sensor leads. Crimp lugs suit terminals exposed to movement or heat [IPC-WHMA-A-620E].
AI summary based on the discussion. May contain errors.
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