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Key Points for Square‑End Forming of Multi‑Strand Braided Wire vs Single‑Strand Braided Wire with Medium‑Frequency Spot Welders

Aug 29,2026

In production of new‑energy flexible connections and electrical‑cabinet wire harnesses, square‑end forming on copper‑braided‑wire terminals is a key pre‑welding procedure.

Many operators reuse identical parameters and molds for single‑strand braided wire and multi‑strand combined braided wire. In fact they differ completely in structure, internal‑gap condition, stress state and heat dissipation, so their processes are not interchangeable. Mixed‑parameter application will cause batch‑level defects such as wire‑breakage, loose strands, internal voids, offset square forming, welding cold joints and product overheating.

I Core Structural Differences between Single‑Strand and Multi‑Strand Braided Wire

Single‑strand braided wire: Tight overall braiding, uniform structure and few internal gaps. It bears even force during square‑end forming with regular deformation and good process stability. The main difficulty lies in that excessive pressure may easily fracture copper wires and harden‑embrittle the wire.

Multi‑strand combined braided wire: Multi‑strand superposition brings abundant inter‑layer gaps, easy misalignment and uneven tightness. After compression, it tends to present compact surface but loose interior and unilateral suspension. The biggest hidden hazard is trapped internal air and inter‑layer voids, which readily cause delamination and cold joints in subsequent welding.

Brief summary: Single‑strand square‑end forming risks crushing, hardening and wire breakage; multi‑strand square‑end forming risks insufficient compaction, hollow interior and delamination.

II Key Points for Square‑End Forming of Single‑Strand Braided Wire

1.Adopt even stable pressure; prohibit violent high‑pressure squeezing

2.Control heat input and avoid high‑temperature damage

3.Arrange wire ends before welding; eliminate loose and upturned strands

III Key Points for Square‑End Forming of Multi‑Strand Braided Wire

1.Wires must be neatly placed without misalignment or crossing

2.Apply segmented gradient pressure; avoid harsh or violent compression

3.Appropriately extend pressure‑hold time to guarantee multi‑layer compaction and fitting

4.Use limit tooling to prevent offset and biased compression

IV Common Defects and Solutions

1.Broken, fuzzed or hardened single‑strand wire

Causes: excessive pressure, instant impact and excessive heat input.