"cavelamb" wrote

Just a suspicion, but it seems to me that the problem here is a result of
the swaging process itself.

When the swage is squeezed, there should be uneven compression which would
cause the material to yield unevenly - leading to rather high localized
stress
concentrations. In-service vibration, over time, should lead to exactly
the
kind of cracks described by GBM.

FWIW, for highly stressed aircraft cables, the terminals (ends) are
*Rolled*
rather than squoze...

Richard

Could be, but experience shows that this type of failure does not occur in
fresh water. The experts advise that it is the presence of chlorides in
crevices with an oxygen deficient atmosphere and stress that cause the
failure. The whole swage and the wire strands are stressed to various
degrees.

GBM