What percentage of the cable’s breaking force do swaged terminals withstand? Our fittings will withstand the cables breaking strength when properly designed and applied. However the architecture of your end use product will ultimately determine the fitting design. We are accustomed to pushing the limits of designs to minimize fitting volume, while maximizing mechanical properties of assemblies and their attachments. As a general rule, fitting length and shear stress are inversely correlated. Thus, the shorter the fitting, the greater the shear stress, the lower the fitting holding force.
EFFECT OF CABLE CONSTRUCTION ON FITTING ATTACHMENT & ASSEMBLY STRENGTH
Does the cable construction affect the assembly tensile strength?
Strands (eg: 1×3, 1×7, 1×19) and single wires are more difficult to attach fittings which will achieve full tensile capability of the strand or wire. Cables (eg: 7×7, 7×19, 8×19, 7×37) are much easier to swage fittings onto which will achieve the cable’s full rated tensile strength.
How much of the wire, strand, or cable tensile strength is reduced by welding an attachment?
Generally a 40% – 60% reduction in base material tensile strength will result. We use a variety of welding techniques including YAG laser, fiber laser, resistive, and plasma. Strand employs proprietary techniques and has been successful in achieving up to 80% of base material tensile after welding.
SIZE OF WELDED BEADS
How large of a ball can you weld onto a wire, strand, or cable?
There is no limit to diameter if the ball is a separate piece. If the bead is to be homogenously created from the wire, strand, or cable, then a 150% increase (2.5x) in diameter can be achieved.
For example, a wire of Ø0.020” may have up to a Ø0.050” bead welded at both proximal and distal ends.