Yet 90% of the connections in the millions of cars on the road are crimped. National and international standards for HV connections use crimps.
Yes, exactly.
Properly crimped connections are in effect "pressure welds" with gastight connections and exceptionally reliable.
Exactly as I said: In reference to
small terminals, and,
Unless you use the exact, correct crimp tool - which major manufacturers do.
The simply "squashing" plier type tools generally sold for DIY use do not apply sufficient pressure to exclude gas. Properly matched, professional grade tools do, the force is enough to slightly extrude the crimp and the wire in it, making the metals flow together and conform.
eg. This type of thing is a toy.
Or these for larger colour coded crimps, equally bad:
Economy Multi Crimp Strip Tool CT1 for Red, Blue and Yellow pre-insulated terminals. Available to BUY Online with Bulk savings!
www.hilltop-products.co.uk
Small connector terminals need a different tool for each maker and series; eg. the black ones you posted are similar to such as Molex SL and Harwin M20 - but the crimp inserts for each make are rather different and need totally different tools, to guarantee proper reliability:
**broken link removed**
There is no way you can know what tool is needed for unbranded kits such as you showed; and even if you did, would you spend £200 - £400 on the matching tool, on the offchance the next kit you bought had the exact same type of pins?
The only way to be sure of a good permanent connection on small crimp terminals like those in DIY situations where you do not have the exact tool is to also solder them.
Once you get up to such as the colour coded types, proper compound action tools with dies that prevent the terminal just squashing out at the sides are relatively cheap and readily available.
Larger still, terminal lugs are pretty standardised in relatively few sizes to match standard cables and heavy duty tooling is not all that expensive - far cheaper than kitting up for a range of small pin crimps!