Non-automotive electrical question

At work we have a drying oven that has an on-going problem. It is an electrically heated oven with 10 infrared panels. Each panel has a solid twisted wire that has to connect to a hi-temp stranded wire. Each wire is carrying about 10 amps. This connection between the dis-similar wires is what keeps burning out. Here are the 2 wires in question.

Originally the connection was a stainless (?) crimped barrel and over time they have worked but eventually failed. So far, the best replacement was stainless steel nuts, bolts and washers holding things together.
I really doubt solder would hold up to the heat and I don't have any other ideas for a positive and long lasting
connection. Any ideas would be appreciated.

Thanks,

Jeff

 

Could you solder a lug on each, and bolt them together?

 

This oven easily runs over the melting point of regular solder. I have to guess the heating element wire is Nichrome wire or something like it and the stranded wire is nickel plated copper. I don't know what would stick (solder) to either
one or not melt away or soften in use. Seems a mechanical connection gets the nod, but I need to find what would work best.

 

Soldering would only work with 750 degree silver solder. That would likely damage the wire though.
A true stainless steel crimp, installed on meticulously clean wires with a professional ratcheting crimper that is properly adjusted, then covered with a stiff high temperature sleeve is the only way to make a reliable connection.
The heating wire is likely nichrome, and should be cleaned using a stainless steel brush. Using a steel brush or sandpaper will introduce contaminants and corrosion.
I am an electrical contractor with over 45 years in the trade.

 

Thanks for the reply. Would I be able to find the parts needed at Grainger or McMaster Carr?

 

Yes grainger, I don't know about McMaster.
The most critical part is the crimping tool. An inexpensive ratcheting crimper will work if properly adjusted but you would have to ruin several splices until you got the tension right and would need to know how it looks when correct. Better to call some electrical supply houses (wholesale, not home depot) and inquire as to where you can rent one.

 

I would try the crimp connector suggested by ribald1,

 

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OK, I will see what Grainger has. What about the stiff high temperature sleeve? Is that silicone or ceramic or ?

 

I would agree, mainly because he boasts about his experience. That and it makes sense.

 

If adjusted properly that unit will work. The good ones have torsion dials on the side that let you set compression pressure. With that one it has to be done by trial and error based on looking at the finished crimp.

 

Says the guy who tells everyone he doesn't see my posts as he has blocked me.

 

Sean, It would be really nifty if you did not shit in this thread too.

 

That looked to me like a poke & a compliment all wrapped up in one. Have the days of having a sense of humor really passed. ?

 

Sadly, in this case it has. I participate here for an exchange of ideas and information about our Rancheros. I have learned so much from so many people and I hope I have been able help someone out in return. But there is a line of negative energy that does not seem to go away, and I watch, in silence as it goes on and on. It really stinks the place up at times and it does nobody any good. A joke is one thing. But to constantly do the same thing is really not needed. It does not help you build a better car or me solve a problem.
This website is a resource, a real and valuable resource that can only run on contributions of time, thought and experience. I try to treat it with care and respect as I am a guest here. I could only hope that we could all arrive on the same page someday.

 

I agree with you 100% , but I don't foresee that happening in the near future, as far as stinking the place up I've farted in here once or twice, having a sense of people & a sense of humor is not a bad quality. You are right this is a GREAT forum with an equally diverse forum of contributors that combined makes it a pleasure to be a participant.

 

Amen!

Now get that thing back together again! Make Humpty Dumpty proud.

 

Like I said diversity is a good thing, it's all in the perception of how you view it.

 

As Ribald suggested, over the weekend I am going to research some stainless crimp connectors and a decent quality crimper.

This is a shot of the connection and the back of the panel and the patch connection I made.

This one is solid copper with a stainless steel screw. I had recently used a brass connector and those burned up pretty quick so the search is
on for stainless steel bits.