How to connect nichrome with copper?

Question

Do it yourself

I want to make insoles with autoheating. There is nichrome 0.4mm. It is necessary to securely fasten the leading copper stranded wire with nichrome at different lengths. Given that the insoles will be in a constant state of operation, I'm afraid that the fasteners may crumble. Aluminum clips can rest against the leg. What are the possible options in this case?
I saw on YouTube a dude using a lighter to fuse nichrome with a thin copper wire. I tried to solder with a burner, nichrome heated up to bright white, but neither copper nor nichrome soldered ...

Answer 1

Nichrome can be irradiated using an aspirin tablet as a flux. After that, soldering nichrome with copper is already easy. But.
1. Before tinning, nichrome must be cleaned with fine sandpaper.
2. Vapors of acetylsalicylic acid (aspirin) are poisonous, do not inhale and ventilate well!

Answer 2

Heating of this kind, in clothes, is made of carbon filament or carbon tape,
it is attached by simply winding the tape around the wire and fixing it with foil on top for reliability.
But if you want exactly nichrome, but you don’t like the crimp connection in the sleeve, then welding.
you need a piece of a graphite electrode, well, at least a graphite brush from an electric motor and a powerful power supply that will not die from a short circuit.
there is a welding method in the same YouTube, after some practice you will get neat balls of strong welding.
Threat
, I made heating from narrow copper tape, it is convenient to fasten it with a snake, it sticks and soldered with a bang.
but it is not wear-resistant, it can only be used on hard surfaces.

Answer 3

All the heaters that I dismantled (seats and insoles) were made of medium wire - ala twisted pair wire.
They did not live long, and therefore dismantled
Connect by crimping into a thin sleeve