Method and apparatus for crimping an electrical terminal to an electrical wire

1. A method for crimping an electrical terminal to an electrical wire having electrical conductors, the method comprising:

positioning the electrical wire and the electrical terminal between opposing crimp tooling members of a crimp tool; and

pressing a crimp barrel of the electrical terminal against the electrical conductors of the electrical wire during a high speed crimping operation using the crimp tooling members such that the crimp barrel is crimped around the electrical conductors to mechanically and electrically the electrical conductors to the crimp barrel, wherein the crimp tooling members move relative to each other at a speed of at least approximately 30 meters per second and press the crimp barrel against the electrical conductors such that at least some contact portions of metallic surfaces of at least some of the electrical conductors melt and form hot weld bonds with one or more contact portions of the metallic surfaces of one or more adjacent electrical conductors during the high speed crimping operation.

2. The method of claim 1 , wherein pressing the crimp barrel against the electrical conductors comprises moving the crimp tooling members toward each other at a speed that is sufficiently high to cause the at least some contact portions of the metallic surfaces to melt.

3. The method of claim 1 , wherein pressing the crimp barrel against the electrical conductors comprises creating frictional forces between adjacent electrical conductors that generate a sufficient amount of heat to melt the at least some contact portions of the metallic surfaces.

4. The method of claim 1 , wherein pressing the crimp barrel against the electrical conductors comprises applying frictional energy between adjacent electrical conductors over a duration of time that is short enough to melt the at least some contact portions of the metallic surfaces.

5. The method of claim 1 , wherein the electrical conductors are aluminum electrical conductors, and wherein pressing the crimp barrel against the electrical conductors using the crimp tooling members comprises wiping adjacent electrical conductors against each other such that oxide layers of the adjacent electrical conductors are displaced to expose the contact portions of the metallic surfaces of the electrical conductors.

6. The method of claim 1 , wherein pressing the crimp barrel against the electrical conductors comprises forming the hot weld bonds before an oxidation layer is formed on the at least some contact portions of the metallic surfaces at the locations of the hot welds.

7. The method of claim 1 , wherein pressing the crimp barrel against the electrical conductors using the crimp tooling members comprises melting at least one contact portion of a metallic surface of the crimp barrel such that the at least one contact portion of the metallic surface of the crimp barrel forms a hot weld bond with one or more contact portions of the metallic surface of one or more of the electrical conductors.

8. The method of claim 1 , wherein pressing the crimp barrel against the electrical conductors using the crimp tooling members comprises moving the crimp tooling members toward each other using an explosive charge.

9. The method of claim 1 , wherein pressing the crimp barrel against the electrical conductors using the crimp tooling members comprises moving the crimp tooling members toward each other using at least one of compressed gas, compressed fluid, combustion of a fuel, a spring, an electromagnetic pulse, a rail gun, or a linear engine.