SAE USCAR-38

SAE USCAR-38

This performance specification, SAE USCAR-38, is produced by the United States Council for Automotive Research (USCAR) and describes the basic test methods and requirements for ultrasonically welded cable termination-type connections, that are subjected to an ultrasonically welded connection with a bus, terminal, or device, including welded eyelet or battery connections. It is widely used across automotive wiring harness, electric vehicle, and electrical connection system manufacturing industries. Presto Stantest’s precision tensile testing instruments help manufacturers evaluate weld bond strength and verify termination performance in compliance with SAE USCAR-38 requirements.

Significance

This test specification subjects parts under test to environmental exposures to simulate a lifetime of field exposure for a road vehicle, with exposures including thermal shock, temperature-humidity cycling, and mechanical abuse. USCAR-38 details general testing requirements, including visual inspection, welded termination cross-section analysis, and weld bond tensile and peel strength evaluations. These rigorous assessments ensure ultrasonically welded terminations maintain reliable mechanical and electrical performance throughout a vehicle's operational life, reducing connection failures in safety-critical automotive systems.

Scope

The procedure codes in this specification are intended for use only in performance testing and development of welded cable terminations, which are included in the electrical connection system used in road vehicle applications operating at ambient temperatures of 125°C maximum. Applicable wire sizes include copper wire between 0.22 and 150 mm² and aluminium wire between 0.5 and 150 mm². The specification applies to wiring harness suppliers, automotive OEMs, and quality inspection bodies requiring validated test procedures for ultrasonic wire termination production control and compliance verification across road vehicle electrical system manufacturing.