Case 196 ยท Public preview
An Oversized Crimp Bore Can Damage the Barrel Without Compressing the Wire
Three field-returned cable assemblies had signal-integrity problems, with measured resistance through the suspect crimps ranging from 1.24 ohms to approximately one megohm.
Electrical resistance measurementConnector dissectionParallel and transverse microsectioningBackscattered-electron SEMEDS
What the evidence preview establishes
The crimp barrel bore was too large for the wire gauge. Crimping severely damaged or sheared the barrel while leaving the wire strands under-compressed, and the resulting open interfaces allowed potting epoxy to wick into the connection and electrically isolate the strands.
Why this case matters
A crimp can look aggressively compressed while still failing to consolidate the conductor. Match barrel bore to wire gauge, verify strand compression in cross-section, and prevent potting material from entering an interface that should be gas-tight.
Full evidence reserved for MEMBER and STOREThe complete case includes the evidence sequence, four interpreted figures, alternative explanations, limitations, and practical application guidance.