Methods of Connecting Electrical Wires

Yes, such twisted connections could last over a decade, but today there are many more modern methods of connecting electrical wires, and they are all more reliable than simple twisting.

Notably, nine out of ten electrical faults and malfunctions occur precisely at wire connection points, so it is absolutely essential to ensure a high-quality, secure connection.

Twisting Electrical Wires

Regardless of opinion, twisting remains today the simplest, easiest, and fastest method of connecting electrical wires. As mentioned earlier, a properly made twist can reliably last a decade or more. However, a major drawback is the strong influence of human error—different electricians may perform the same connection differently. Also, even a well-executed twist may degrade over time due to external factors like high humidity, mechanical stress, or continuous heavy electrical load.

No mechanical twist can guarantee 100% reliability and safety. Moreover, it is strongly advised not to twist copper wires with aluminum ones.

Soldering and Welding Electrical Wiring

Connecting electrical wires via soldering or welding is the most reliable method. Soldering works best with copper wires. Although various fluxes exist for soldering aluminum wires, it is still best to avoid such connections.

Copper wire soldering is done using a standard soldering iron and solder. A 100W soldering iron is sufficient. Before soldering, wires must be tinned (coated with a thin layer of solder). Ordinary rosin or specialized fluxes may be used. Then, wires are carefully twisted and soldered. The solder must cool naturally to prevent cracks.

The result is highly reliable. However, soldering is labor-intensive. Also, under constant mechanical stress, the wire may be damaged at the end of the tinned section. In modern practice, soldering is less popular than in the 1990s.

Another method is welding the ends of twisted wires. This requires a high-power transformer and a carbon electrode. The transformer output voltage should be between 10–36 V, with a power rating of 400–600 W. The heat from the electrode and electric arc melts the wire ends, ensuring a very strong electrical contact. Welding is even more labor-intensive than soldering.

After soldering or welding, insulation should be done using special heat-shrink tubing, which resembles a standard cable tie. When heated, this tubing tightly covers the connection point, ensuring maximum insulation quality. As an alternative, use three or more layers of standard insulating tape.

Terminal Connectors

In modern practice, the most popular methods of connecting electrical wires involve various terminal connectors, of which there are many types available today. Terminal blocks provide a secure connection with minimal effort. A terminal block consists of an insulating housing containing metal contacts designed to hold wires securely.

The most common types include:

• Terminal blocks: A strip with a set number of contact slots. Connection is achieved by tightening the inserted wires into the slots. This method is fast, reliable, and high-quality.
• Spring-loaded terminals: Connection is even simpler. Just strip the wire and insert it into the hole, where it is secured by a spring. This method allows connecting both aluminum and copper wires. Spring terminals prevent corrosion since the wires do not touch each other.
• Branching connectors ("nuts" or "olives"): Known as "olives" in everyday language. These connectors allow for branching electrical wires. They consist of two plates with grooves for wires, secured with four screws. A third plate acts as a separator between aluminum and copper wires during connection.

Any of the above methods can be safely used if properly and carefully implemented. In such cases, no connection issues should arise.