Cardas Cold Forging

Thank you Bobby, you addressed my question from 4/2 about whether the enamel is removed. Can you add any more details about how they remove it prior to the cold forge process? I suspect that is not easy in the absence of tinning the wire.

One thing I haven't seen addressed either in the Cardas video or in this thread is that Cardas wire is coated - from their website:

As each strand is drawn, the resultant ultra pure surface is immediately given a urethane enamel "Litz" coating. This is a continuous process that results in a perfectly insulated strand and ultimate longevity of the conductors. Ordinary uncoated copper stranding corrodes in a relatively short time. Cardas meticulously maintains the purity of the conductor strands until they are sealed at termination.

In their previous soldering process it is my understanding the wire was "tinned" in a solder pot to remove the enamel coating. In the ultrasonic welding link posted above, enamel coatings are removed by "high frequency vibration." How is the enamel removed in the Cardas "Cold Forging" process, or is it simply mashed into the connection?

You left the e out of blue, here is the correct link;
http://www.bluejeanscable.com/articles/ultrasonic-welding.htm
This is a pretty cool process. Here is another article;
http://www.ktu.lt/lt/mokslas/zurnalai/mechanika/mechtu_65/Kuprys365.pdf

Geez Bobby, sorry but I totally missed tuboglo's post. I am on board with the process since I use high pressure hydraulic crimpers on the cables I make; using a similar die, two crimps and trim the spades, very similar to the Cardas video, but of course not the same pressure or degree of fusion. I much prefer that crimped connection to soldered connections I have done, but I haven't tried it on litz wire. I am glad to hear those who have had cold forging done to their Cardas cables prefer the sound, although I would expect nothing less from Cardas.