What is the acceptable method of attaching a terminal to a wire for general electrical use in aircraft?

Crimping is the accepted method for attaching a terminal to a wire for general electrical use in aircraft due to its reliability and effectiveness in creating a secure connection. This technique involves deforming the terminal around the wire, ensuring a firm grip that minimizes the risk of connection failure.

The crimping process does not require additional materials like solder, which can add excess weight or become brittle under temperature fluctuations, making it less suitable for aviation applications. Additionally, crimped connections provide a robust, mechanical bond that can withstand vibrations commonly experienced in aircraft environments, further enhancing longevity and reliability.

Furthermore, crimping avoids the potential issues associated with welding, such as heat distortion, which can damage insulation or alter the properties of the wire. Twisting wires together can lead to poor contact, increased resistance, and can easily come apart under stress or vibration, making it an unsuitable choice for critical electrical connections in aircraft systems. Thus, crimping stands out as the most appropriate and industry-approved method for this purpose.