Difference between revisions of "Soldering Irons"

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{{distinguish|Soldering (song){{!}}the song}}
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{{#set:
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{{about|the process|the material|Solder}}
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|Is equipment=True
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{{redir|Dry joint|types of switch or relay contacts|Dry contact}}
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|Is located in facility=PCB Lab
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{{redir|Cold joint|thermocouple contacts|Cold junction (thermocouple)}}
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|Is located in facility=The Hub
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|Is used in domain=Electronics
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|Has name={{PAGENAME}}
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|Has make=Weller
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|Has model=WES51
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|Has serial number=
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|Has life expectancy=
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|Has year of manufacture or purchase=
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|Has replacement cost=
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|Has function=Soldering Iron
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|Has icon=File:soldering_icon.png
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|Has icondesc=Soldering Iron
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|Has image=File:soldering.jpg
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|Has imagedesc=Soldering a component
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|Has description=Soldering is a process in which two or more items (usually metal) are joined together by melting and putting a filler metal (solder) into the joint
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|Has certification=https://georgefox.instructure.com/courses/1242
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|Has group=Circuit Board Design
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|Has ace=Karson Rhoads;krhoads20@georgefox.edu
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}}
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[[{{#show: {{FULLPAGENAME}}|?Has icon|link=none}}|140px|left|top|{{#show: {{FULLPAGENAME}}|?Has icondesc}}]]
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[[{{#show: {{FULLPAGENAME}}|?Has image|link=none}}|thumb|upright=1.5|{{#show: {{FULLPAGENAME}}|?Has imagedesc}}]]
  
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[[File:Desoldering.jpg|thumb|upright=1.5|Desoldering a contact from a wire]]
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Make: {{#show: {{PAGENAME}} |?Has make}}
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'''Soldering''' ([[General American|AmE]]: {{IPAc-en|ˈ|s|ɒ|d|ər|ɪ|ŋ}}, [[Received Pronunciation|BrE]]: {{IPAc-en|ˈ|s|ɒ|l|d|ər|ɪ|ŋ}}), is a process in which two or more items (usually metal) are joined together by melting and putting a [[filler metal]] ([[solder]]) into the joint, the filler metal having a lower [[melting point]] than the adjoining metal. Soldering differs from [[welding]] in that soldering does not involve melting the work pieces. In [[brazing]], the filler metal melts at a higher temperature, but the work piece metal does not melt. In the past, nearly all solders contained [[lead]], but environmental and health concerns have increasingly dictated use of [[lead-free solder|lead-free alloys]] for electronics and plumbing purposes.
 
  
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== Origins ==
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Model: {{#show: {{PAGENAME}} |?Has model}}
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[[File:Solder sugarlabs.jpg|thumb|right|Small figurine being created by soldering]]
 
  
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There is evidence that soldering was employed as early as 5000 years ago in Mesopotamia.<ref>{{cite book | title = Materials Handbook | first = George| last= Brady | publisher = McGraw Hill | pages = 768–70 | isbn = 0-07-007084-9 | year = 1996|display-authors=etal}}</ref> Soldering and [[brazing]] are thought to have originated very early in the history of metal-working, probably before 4000 BC.<ref>[http://www.weldinghistory.org/whistoryfolder/brazing/bh_pre1900s.html A History of Welding]</ref> Sumerian swords from ~3000 BC were assembled using hard soldering.
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Ace: {{#show: {{PAGENAME}} |?Has ace.Has name}} ({{#show: {{PAGENAME}} |?Has ace.Has email address}}).
  
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Soldering was historically used to make jewelry items, cooking ware and tools, as well as other uses such as in assembling [[stained glass]].
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Location: {{#show: {{PAGENAME}} |?Is located in facility}}
  
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== Applications ==
 
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Soldering is used in plumbing, electronics, and metalwork from [[Flashing (weatherproofing)|flashing]] to jewelry.
 
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Soldering provides reasonably permanent but reversible connections between copper pipes in [[plumbing]] systems as well as joints in sheet metal objects such as food cans, [[Flashing (weatherproofing)|roof flashing]], [[rain gutter]]s and automobile [[radiator]]s.
 
  
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[[Jewelry]] components, machine tools and some refrigeration and plumbing components are often assembled and repaired by the higher temperature silver soldering process. Small mechanical parts are often soldered or brazed as well. Soldering is also used to join lead [[came]] and [[Came glasswork|copper foil]] in [[Came glasswork|stained glass]] work.
 
  
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Electronic soldering connects [[electrical wiring]] and [[electronic component]]s to [[printed circuit board]]s  by utilizing a metallic alloy substance called [[solder]]. This special alloy is melted by using a soldering iron, a wave bath, or a specialized oven, as it joins conductors to PCBs, terminals, and wires.
 
  
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== Solders ==
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__TOC__
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{{main|Solder}}
 
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Soldering filler materials are available in many different [[alloy]]s for differing applications. In electronics assembly, the [[eutectic]] alloy of 63% tin and 37% lead (or 60/40, which is almost identical in melting point) has been the alloy of choice. Other alloys are used for plumbing, mechanical assembly, and other applications. Some examples of soft-solder are tin-lead for general purposes, tin-zinc for joining [[aluminium]], lead-silver for strength at higher than room temperature, cadmium-silver for strength at high temperatures, zinc-aluminium for aluminium and corrosion resistance, and tin-silver and tin-bismuth for electronics.
 
  
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A eutectic formulation has advantages when applied to soldering: the [[liquidus]] and [[Solidus (chemistry)|solidus]] temperatures are the same, so there is no plastic phase, and it has the lowest possible melting point. Having the lowest possible melting point minimizes heat stress on electronic components during soldering. And, having no plastic phase allows for quicker wetting as the solder heats up, and quicker setup as the solder cools. A non-eutectic formulation must remain still as the temperature drops through the liquidus and solidus temperatures. Any movement during the plastic phase may result in cracks, resulting in an unreliable joint.
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==Description==
  
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Common solder formulations based on tin and lead are listed below. The fraction represent percentage of tin first, then lead, totaling 100%:
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'''Soldering''' is a process in which two or more items (usually metal) are joined together by melting and putting a filler metal (solder) into the joint, the filler metal having a lower melting point than the adjoining metal. Soldering differs from welding in that soldering does not involve melting the work pieces. In brazing, the filler metal melts at a higher temperature, but the work piece metal does not melt. In the past, nearly all solders contained lead, but environmental and health concerns have increasingly dictated use of lead-free solder for electronics and plumbing purposes.
  
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* 63/37: melts at {{convert|183|°C|°F|abbr=on}} (eutectic: the only mixture that melts at a ''point'', instead of over a range)
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Here is an example of this piece of equipment being used.
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* 60/40: melts between {{convert|183|–|190|C|F}}
 
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* 50/50: melts between {{convert|183|–|215|C|F}}
 
  
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For environmental reasons (and the introduction of regulations such as the European RoHS ([[Restriction of Hazardous Substances Directive]])), lead-free solders are becoming more widely used. They are also suggested anywhere young children may come into contact with (since young children are likely to place things into their mouths), or for outdoor use where rain and other precipitation may wash the lead into the groundwater. Unfortunately, most lead-free solders are not eutectic formulations, melting at around {{convert|250|°C|°F|abbr=on}}, making it more difficult to create reliable joints with them.
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Insert video media here.
  
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Other common solders include low-temperature formulations (often containing [[bismuth]]), which are often used to join previously-soldered assemblies without un-soldering earlier connections, and high-temperature formulations (usually containing [[silver]]) which are used for high-temperature operation or for first assembly of items which must not become unsoldered during subsequent operations. Alloying silver with other metals changes the melting point, adhesion and wetting characteristics, and tensile strength. Of all the brazing alloys, silver solders have the greatest strength and the broadest applications.<ref>[http://www.tinmantech.com/html/faq_brazing_versus_soldering.php How soldering differs from brazing<!-- Bot generated title -->]</ref> Specialty alloys are available with properties such as higher strength, the ability to solder aluminum, better electrical conductivity, and higher corrosion resistance.<ref name="Solder Product List">{{cite web|last=Kapp Alloy & Wire, Inc|title=Products|url=http://www.kappalloy.com/products-solder.php|publisher=Kapp Alloy & Wire, Inc|accessdate=5 March 2013}}</ref>
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==Documentation==
  
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==Flux==
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====Terminology====
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{{main|flux (metallurgy)}}
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<gallery>
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File:SolderingTips.jpg|Soldering Tip
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File:Solder.jpg|Solder
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File:Flux.jpg|Flux
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</gallery>
  
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The purpose of [[Flux (metallurgy)|flux]] is to facilitate the soldering process. One of the obstacles to a successful solder joint is an impurity at the site of the joint, for example, dirt, oil or [[oxidation]]. The impurities can be removed by mechanical cleaning or by chemical means, but the elevated temperatures required to melt the filler metal (the solder) encourages the work piece (and the solder) to re-oxidize. This effect is accelerated as the soldering temperatures increase and can completely prevent the solder from joining to the workpiece. One of the earliest forms of flux was [[charcoal]], which acts as a [[reducing agent]] and helps prevent oxidation during the soldering process. Some fluxes go beyond the simple prevention of oxidation and also provide some form of chemical cleaning (corrosion).
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[[Media:WES51_OI_PL.pdf|Soldering Iron User Manual]]
  
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For many years, the most common type of flux used in electronics (soft soldering) was [[rosin]]-based, using the rosin from selected [[pine tree]]s. It was nearly ideal in that it was non-corrosive and non-conductive at normal temperatures but became mildly reactive (corrosive) at elevated soldering temperatures. Plumbing and automotive applications, among others, typically use an acid-based ([[hydrochloric acid]]) flux which provides rather aggressive cleaning of the joint. These fluxes cannot be used in electronics because their residues are conductive leading to unintended electrical connections, and because they will eventually dissolve small diameter wires. Many fluxes also act as a [[wetting agent]] in the soldering process,<ref>[http://www.indium.com/products/solderfabrications/fluxes.php Solder Flux]</ref> reducing the [[surface tension]] of the molten solder and causing it to flow and wet the workpieces more easily.
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==Training==
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====Operation====
  
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Fluxes for soft solder are currently available in three basic formulations:
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The Soldering Iron is an amazing tool that allows us to construct circuits with sturdy connections between components. The detailed steps to do this can be found in videos on the Description section.  
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# Water-soluble fluxes -  higher activity fluxes which should be removed with water after soldering (no [[Volatile organic compound|VOC]]s required for removal).
 
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# No-clean fluxes -  mild enough to not "require" removal due to their non-conductive and non-corrosive residues.<ref name="indiumcorporation"/> These fluxes are called "no-clean" because the residue left after the solder operation is non-conductive and won't cause electrical shorts; nevertheless they leave a plainly visible white residue that resembles diluted bird-droppings. No-clean flux residue is acceptable on all 3 classes of PCBs as defined by IPC-610 provided it does not inhibit visual inspection, access to test points, or have a wet, tacky or excessive residue that may spread onto other areas. Connector mating surfaces must also be free of flux residue.  Fingerprints in no-clean residue are a class 3 defect<ref>IPC-A-610 revision E section 10.6.4</ref>
 
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# Traditional [[rosin]] fluxes - available in non-activated (R), mildly activated (RMA) and activated (RA) formulations. RA and RMA fluxes contain rosin combined with an activating agent, typically an acid, which increases the wettability of metals to which it is applied by removing existing oxides. The residue resulting from the use of RA flux is [[corrosive]] and must be cleaned. RMA flux is formulated to result in a residue which is less corrosive, so that cleaning becomes optional, though usually preferred.  R flux is still less active and even less corrosive.  
 
  
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Flux performance must be carefully evaluated for best results; a very mild 'no-clean' flux might be perfectly acceptable for production equipment, but not give adequate performance for more variable hand-soldering operations.
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====Demonstration====
  
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==Processes==
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Before using a Soldering Station, students will need to read some documentation, watch some videos, and pass a quiz on Canvas. Upon completion, students will be given the following PCB and components to assemble the circuit below. Upon completion, they will have the PCB Lab volunteers assess their work and confirm operation. The deliverable will include a video of the working device and a crisp "Thumbs Up" from the PCB Lab Volunteer to assure that the student successfully completed the task.
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[[File:Brazing and soldering processes - AWS A3.0 2001.svg|thumb|right|300px|Brazing and soldering processes [[classification chart]]<ref>AWS A3.0:2001, Standard Welding Terms and Definitions Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying, American Welding Society (2001), p. 118. {{ISBN|0-87171-624-0}}</ref>]]
 
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There are three forms of soldering, each requiring progressively higher temperatures and producing an increasingly stronger joint strength:
 
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# soft soldering, which originally used a tin-lead [[alloy]] as the filler metal
 
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# silver soldering, which uses an alloy containing [[silver]]
 
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# [[brazing]] which uses a [[brass]] alloy for the filler
 
  
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The alloy of the filler metal for each type of soldering can be adjusted to modify the melting temperature of the filler. Soldering differs from gluing significantly in that the filler metals directly bond with the surfaces of the workpieces at the junction to form an electrically conductive gas- and liquid-tight bond.<ref name=indiumcorporation>[http://www.indium.com/_dynamo/download.php?docid=27 Soldering 101 - A Basic Overview]</ref>
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<gallery>
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File:blinkypcb.jpg|[[Media:Blinky.zip|PCB]]
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File:ne555.png|[https://www.digikey.com/product-detail/en/texas-instruments/NE555P/296-1411-5-ND/277057 555 timer]
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File:res1k.jpg|[https://www.digikey.com/product-detail/en/stackpole-electronics-inc/CF14JT1K00/CF14JT1K00CT-ND/1830350 1 K<span title="&amp;Omega;">&Omega;</span> resistor]
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File:res470k.jpg|[https://www.digikey.com/product-detail/en/stackpole-electronics-inc/CF14JT470K/CF14JT470KCT-ND/1830415 470 K<span title="&amp;Omega;">&Omega;</span> resistor]
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File:cap1uF.jpg|[https://www.digikey.com/product-detail/en/UVP1H010MDD1TD/493-12697-1-ND/4328314?utm_campaign=buynow&WT.z_cid=ref_octopart_dkc_buynow&utm_medium=aggregator&curr=usd&site=us&utm_source=octopart 1 <span title="&amp;mu;">&mu;</span>F capacitor]
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File:red_led.jpg|[https://www.digikey.com/product-detail/en/lite-on-inc/LTL-4223/160-1127-ND/200395 red LED]
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File:battcon.jpg|[https://www.xump.com/science/9V-Battery-Snap-Connector-Leads.cfm?SID=12&gclid=EAIaIQobChMI04mUoZaF2QIVAm5-Ch0pDgDrEAQYAiABEgKI1_D_BwE 9V Battery connector]
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File:Blinking LED Circuit.gif|Completed PCB
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</gallery>
  
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Soft soldering is characterized by having a melting point of the filler metal below approximately {{convert|400|°C|°F|abbr=on}},<ref>{{cite book | title = The Basics of Soldering | first = Armin | last= Rahn | publisher = John Wiley & Sons | chapter = 1.1 Introduction | isbn = 0-471-58471-1 | year = 1993}}</ref> whereas silver soldering and brazing use higher temperatures, typically requiring a flame or carbon arc torch to achieve the melting of the filler. Soft solder filler metals are typically alloys (often containing [[lead]]) that have [[liquidus]] temperatures below 350&nbsp;°C.
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[[File:Soldering_course_circuit.jpg|none|thumb|583x583px]]
  
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In this soldering process, heat is applied to the parts to be joined, causing the solder to melt and to bond to the workpieces in a surface alloying process called [[wetting]]. In stranded wire, the solder is drawn up into the wire between the strands by [[capillary action]] in a process called 'wicking'. Capillary action also takes place when the workpieces are very close together or touching. The joint's [[tensile strength]] is dependent on the filler metal used;  in electrical soldering little tensile strength comes from the added solder which is why it is advised that wires be twisted or folded together before soldering to provide some mechanical strength for a joint. A good solder joint produces an electrically-conductive, water- and gas-tight join.
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====General Procedure====
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# First things first, you need to learn how to use the soldering irons! Soldering is not difficult, but understanding some basic concepts will go a long way toward a successful experience. As part of your training, you will need to read some documentation and watch some videos.
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# After scouring the web for examples of soldering training, we really liked the lessons captured in the [https://www.youtube.com/playlist?list=PL926EC0F1F93C1837 PACE] series, despite the fact that they were filmed in the 80's. These videos are well produced (for something possibly older than your parents) and have a lot of good information. The quizzable information is in the very first, fifth, and sixth videos, but the other videos have great examples of good and bad soldering joints. Another more modern video from [https://www.youtube.com/watch?v=ZwU9SqO0udU Beauty and the Bolt] is also insightful. This video is a little more modern, and a good resource, but not as technically interesting. It talks a bit about desoldering as well as soldering wires together and how to use heat shrink and electrical tape. A more modern series is available from [https://www.howcast.com/guides/930-how-to-solder Howcast]. It wouldn't hurt at all to watch this series, but we will just focus on a couple for the quiz. Finally, there is an official training video from the [[Maker Hub]] that is tailored to our specific space and equipment. This video will give you the information you need to perform the live solder demonstration required for your soldering certification.
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# This nostalgic set of [https://www.youtube.com/playlist?list=PL926EC0F1F93C1837 videos] from PACE are quite old, but surprisingly still quite relevant. The style makes you think that you will be getting ready to watch an old Disney cartoon - you aren't. Don't get disappointed.
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# '''Basic Soldering Lesson 1:''' This is by far the longest of the videos at (20:44), but also packed with the most pertinent information. It provides great background on solder, flux, wetting, and then mechanics of the iron and the joint. We do not have the student handbook that is mentioned. We suspect that you can manage without that. Here are some key ideas that you should watch for:
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## What is solder? What temperatures do the different solders melt at?
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## What is flux?
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## What is wetting?
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## What are the different aspects of a soldering iron?{{#evu:https://www.youtube.com/watch?v=vIT4ra6Mo0s}}
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# '''Basic Soldering Lesson 2-5:''' These videos are worth watching, but they are not essential for this training.
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## [https://www.youtube.com/watch?v=Mrhg5A1a1mU&index=2&list=PL926EC0F1F93C1837&t=0s Basic Soldering Lesson 2] - "Soldering To PCB Terminals" (6:50)
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## [https://www.youtube.com/watch?v=_GLeCt_u3U8&index=3&list=PL926EC0F1F93C1837&t=0s Basic Soldering Lesson 3] - "Cup Terminals" (4:19)
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## [https://www.youtube.com/watch?v=hvTiql-ED4A&index=4&list=PL926EC0F1F93C1837&t=0s Basic Soldering Lesson 4] - "Bifurcated Terminals" (2:45)
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## [https://www.youtube.com/watch?v=sN3V8hMiUb4&index=5&list=PL926EC0F1F93C1837&t=0s Basic Soldering Lesson 5] - "Hook and Pierced Terminals" (1:19)
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# '''Basic Soldering Lesson 6:''' Good explanation of a "semi-clenched" method for soldering an axial-lead component. This technique allows the component to be held in place for soldering without any extra tape or glue (or a potentially burnt finger).{{#evu:https://www.youtube.com/watch?v=AY5M-lGxvzo}}
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# '''Basic Soldering Lesson 7:''' Applying the "clenching" idea to an IC. Typically, we will not use this technique, but will instead hold the part and "tack" these same leads with solder - just to hold it. The rest of the video has great examples of IC's being soldered.{{#evu:https://www.youtube.com/watch?v=VgcPxdnjwt4}}
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# '''Basic Soldering Lesson 8-9:''' We don't normally see too many of these any more, but again, nice examples of good joints that are similar to components we still use. Rather than flatpack or planar components, we generally use "surface-mount" now. But, the soldering part is still useful to watch. The techniques are similar. Our PCB's will generally come "pre-tined" and the component leads are already bent, but the rest of the soldering is the same.
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## [https://www.youtube.com/watch?v=sTv3gK9tAKA&index=8&list=PL926EC0F1F93C1837&t=0s Basic Soldering Lesson 8] - "Integrated Circuits" (1:16)
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## [https://www.youtube.com/watch?v=Nq5ngauITsw&index=9&list=PL926EC0F1F93C1837&t=0s Basic Soldering Lesson 9] - "Integrated Circuits: The Flatpack & Other Planar-mounted Components" (6:20)
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# '''Howcast How to Solder:''' This set of [https://www.howcast.com/guides/930-how-to-solder videos] from Howcast is worth watching, but we will only highlight a couple of them here that talk about removing solder.
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# '''How to Remove Solder'''{{#evu:https://www.youtube.com/watch?v=-lnRf2biz50}}
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# '''How to Remove Through-Hole Components'''{{#evu:https://www.youtube.com/watch?v=zjQf0ajBYmM}}
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# '''Maker Hub Video:''' This video contains specific information for soldering in the Maker Hub as well as a basic overview of what will be expected in your live demonstration.{{#evu:https://www.youtube.com/watch?v=4v98_f7JFdo}}
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#
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# Acquire a soldering station. For this procedure, this particular station will be referenced, the Weller WES51.[[File:...solderingiron.png|none|thumb|300x300px]]
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# You can power it on using the switch on the left and control the temperature in °F using the temperature knob on the right. 650-750 °F is a good temperature range to keep it at. When the light is solid green, the iron is not heated up yet. When it is heated to the temperature you set on the temperature knob, it will start blinking green.
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# Before you begin using the soldering iron, wet the sponge! Take it to a sink and drench that boi. This is used to clean the soldering iron continually during use. If you don't make it wet, it will burn up the sponge and smell/look gross, and it won't clean the soldering iron.
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# Now you're ready to use the soldering iron! Refer to the videos in times of doubt.  
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# Don't forget to complete that video checking off your board!
  
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Each type of solder offers advantages and disadvantages. Soft solder is so called because of the soft lead that is its primary ingredient. Soft soldering uses the lowest temperatures (and so thermally stresses components the least) but does not make a strong joint and is unsuitable for mechanical load-bearing applications. It is also unsuitable for high-temperature applications as it loses strength, and eventually melts. Silver soldering, as used by jewelers, machinists and in some plumbing applications, requires the use of a torch or other high-temperature source, and is much stronger than soft soldering. Brazing provides the strongest of the non-welded joints but also requires the hottest temperatures to melt the filler metal, requiring a torch or other high temperature source and darkened goggles to protect the eyes from the bright light produced by the white-hot work. It is often used to repair cast-iron objects, wrought-iron furniture, etc.
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==Safety==
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# Always wear safety glasses when you are cutting wires or anything else at the electronics workstation. If other people are nearby, ask them to wear safety glasses or step away briefly.
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# Angle your wire cuts down into the table or cover them with your free hand to block the projectile.
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# Soldering irons can get up to 1000 °F. Do not touch the tip of the soldering iron; it is extremely hot. If you get burned, run cold water over the burned area for several minutes to reduce inflammation and the potential for blistering.
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# Wires and components can also become extremely hot from soldering. Use the available helping hands, and allow the wires/components to cool before touching.
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# Always return the soldering iron to its stand when not in use. Never lay it directly on the workbench.
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# Ensure you have adequate ventilation when soldering. Use the available fume extractors.
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# Turn off the soldering iron when it is not in use.
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# If you start an electrical fire, use a fire extinguisher to put it out. NEVER use water to put out an electrical fire.
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# Keep liquids away from the electronics workstation.
  
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Soldering operations can be performed with hand tools, one joint at a time, or ''en masse'' on a production line. Hand soldering is typically performed with a [[soldering iron]], [[soldering gun]], or a torch, or occasionally a [[hot-air pencil]]. Sheetmetal work was traditionally done with "soldering coppers" directly heated by a flame, with sufficient stored heat in the mass of the soldering copper to complete a joint; gas torches (eg, butane or propane) or electrically-heated soldering irons are more convenient. All soldered joints require the same elements of cleaning of the metal parts to be joined, fitting up the joint, heating the parts, applying flux, applying the filler, removing heat and holding the assembly still until the filler metal has completely solidified. Depending on the nature of flux material used and the application, cleaning of the joint may be required after it has cooled.
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==Certification==
  
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Each solder alloy has characteristics that work best for certain applications, notably strength and conductivity, and each type of solder and alloy has different melting temperatures. The term ''silver solder'' denotes the type of solder that is used. Some soft solders are "silver-bearing" alloys used to solder silver-plated items. Lead-based solders should not be used on precious metals because the lead dissolves the metal and disfigures it.
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For the soldering irons in <strong>The Hub</strong>, complete <strong>The Hub - {{PAGENAME}} Module</strong> at the link below to gain access to the {{PAGENAME}}.
  
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===Soldering and brazing===
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For the soldering irons in the <strong>PCB Lab</strong>, complete the <strong>PCB Lab - {{PAGENAME}} Module</strong> at the link below to gain access to the {{PAGENAME}}.
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The distinction between soldering and brazing is based on the melting temperature of the filler alloy. A temperature of 450&nbsp;°C is usually used as a practical demarcation between soldering and brazing. Soft soldering can be done with a heated iron whereas the other methods typically require a higher temperature torch or a furnace to melt the filler metal.
 
  
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Different equipment is usually required since a [[soldering iron]] cannot achieve high enough temperatures for hard soldering or brazing. Brazing filler metal is stronger than silver solder, which is stronger than lead-based soft solder. Brazing solders are formulated primarily for strength, silver solder is used by jewelers to protect the precious metal and by machinists and refrigeration technicians for its tensile strength but lower melting temperature than brazing, and the primary benefit of soft solder is the low temperature used (to prevent heat damage to electronic components and insulation).
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The Maker Hub Canvas course pertains to all facilities and equipment contained in the Maker Hub; simply complete the quizzes for the facilities/equipment you wish to use in the Maker Hub. Please email <span style="color:blue">makerhub@georgefox.edu</span> if you have any questions.
  
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Since the joint is produced using a metal with a lower melting temperature than the workpiece, the joint will weaken as the ambient temperature approaches the melting point of the filler metal. For that reason, the higher temperature processes produce joints which are effective at higher temperatures. Brazed connections can be as strong or nearly as strong as the parts they connect,<ref name=Bellman-MelcorInc>[http://www.bellmanmelcor.com/brazing_tips1.htm Brazing tips]</ref><ref name=WallColmonoy>[http://www.wallcolmonoy.com/TechServices/NicrobrazNewsArchives/WCC_Article_Joint_Strength.htm Factors that affect joint strength]</ref> even at elevated temperatures.<ref name=goldbulletin>[http://www.goldbulletin.org/assets/file/goldbulletin/downloads/Colbus_2_7.pdf Properties of Gold-Nickel Alloy Brazed Joints in High Temperature Materials; Prof. Jakob Colbus & Karl Zimmermann.]</ref>
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[https://georgefox.instructure.com/enroll/GH36RT Maker Hub Canvas Course]
  
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===Silver soldering===
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==Troubleshooting==
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"Hard soldering" or "silver soldering" is used to join precious and semi-precious metals such as gold, silver, brass, and copper. The solder is usually described as easy, medium, or hard in reference to its melting temperature, not the strength of the joint. Extra-easy solder contains 56% silver and has a melting point of {{convert|1145|F}}. Extra-hard solder has 80% silver and melts at {{convert|1370|F}}. If multiple joints are needed, then the jeweler will start with hard or extra-hard solder and switch to lower-temperature solders for later joints.
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There are two things in particular that could keep you from successfully soldering: an untinned tip and a loose tip. If the tip is not shiny silver, then place a little solder on the tip and wipe it on the sponge. Some soldering irons allow there tips to be replaced for the sake of having different shapes. If the iron is not heating up and you are using this type of iron, it is possible that the tip is not inserted into the iron fully. To fix this, grab some pliers (so you don't burn your hands), grip the shaft and push it in fully. After you have finished soldering, you might check the electrical continuity of your solder joint with a [[Electronics Workstation | DVM]].
  
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Silver solder is somewhat absorbed by the surrounding metal, resulting in a joint that is actually stronger than the metal being joined. The metal being joined must be perfectly flush, as silver solder cannot normally be used as a filler and will not fill gaps.
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==Maintenance==
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====General maintenance====
  
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Another difference between brazing and soldering is how the solder is applied. In brazing, one generally uses rods that are touched to the joint while being heated. With silver soldering, small pieces of solder wire are placed onto the metal prior to heating. A flux, often made of boric acid and denatured alcohol, is used to keep the metal and solder clean and to prevent the solder from moving before it melts.
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The maintenance for the soldering iron generally consists of keeping the soldering station cleaned, stocked, and the iron tinned.
  
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When silver solder melts, it tends to flow towards the area of greatest heat. Jewelers can somewhat control the direction the solder moves by leading it with a torch; it will even sometimes run straight up along a seam.
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====Specific Maintenance Tasks====
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{| class="wikitable"
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===Induction soldering===
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!Maintenance Procedure
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Induction soldering uses [[induction heating]] by high-frequency AC current in a surrounding copper coil. This induces currents in the part being soldered, which generates heat because of the higher resistance of a joint versus its surrounding metal ([[resistive heating]]). These copper coils can be shaped to fit the joint more precisely. A filler metal (solder) is placed between the facing surfaces, and this solder melts at a fairly low temperature. Fluxes are commonly used in induction soldering. This technique is particularly suited to continuously soldering, in which case these coils wrap around a cylinder or a pipe that needs to be soldered.
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!Frequency
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!Done By
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Some metals are easier to solder than others. Copper, silver, and gold are easy. Iron, [[mild steel]] and [[nickel]] are next in difficulty. Because of their thin, strong oxide films, [[stainless steel]] and some aluminium alloys are even more difficult to solder. [[Titanium]], [[magnesium]], [[cast iron]]s, some high-carbon [[steel]]s, [[ceramic]]s, and [[graphite]] can be soldered but it involves a process similar to joining carbides: they are first plated with a suitable metallic element that induces interfacial bonding.
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|-
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|General Cleaning
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==={{anchor|REBALLING|Cold joint}}Electronic components (PCBs)===
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|After each use
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[[File:Soldering a 0805.jpg|thumb|right|Soldering of an SMD capacitor]]
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|Student
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[[File:Ersin Multicore Solder Tube.jpg|thumb|right|A tube of multicore electronics solder used for manual soldering]]
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|-
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[[File:Cold solder joint2.jpg|thumb|An improperly soldered 'cold' joint]]
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|Tin Soldering Iron
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[[File:Gebrochene loetstellen.jpg|thumb|Broken solder joints on a [[circuit board]]]]
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|As needed
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|Student
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Currently, mass-production printed circuit boards (PCBs) are mostly [[wave soldering|wave soldered]] or [[reflow soldering|reflow soldered]], though hand soldering of production electronics is also still widely used.
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|-
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|Stock solder, solder wick, sponge
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In wave soldering, components are prepped (trimmed or modified) and installed on the PCB. Sometimes, to prevent movement they are temporarily kept in place with small dabs of adhesive or secured with a fixture, then the assembly is passed over flowing solder in a bulk container.  This solder flow is forced to produce a standing wave so the whole PCB is not submerged in solder, but rather just touched. The end result is that solder stays on pins and pads, but not on the PCB itself.
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|As needed
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|Ace
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Reflow soldering is a process in which a [[solder paste]] (a mixture of prealloyed solder powder and a flux-vehicle that has a peanut butter-like consistency<ref name="indiumcorporation"/>) is used to stick the components to their attachment pads, after which the assembly is heated by an infrared lamp, a hot air pencil, or, more commonly, by passing it through a carefully controlled oven.
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|}__TOC__
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Since different components can be best assembled by different techniques, it is common to use two or more processes for a given PCB. For example, [[Surface-mount technology|surface mounted]] parts may be reflow soldered first, with a wave soldering process for the [[Through-hole technology|through-hole]] mounted components coming next, and bulkier parts hand-soldered last.
 
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For hand soldering, the heat source tool should be selected to provide adequate heat for the size of joint to be completed. A 100 watt soldering iron may provide too much heat for printed circuit boards, while a 25 watt iron will not provide enough heat for large electrical connectors, joining copper roof flashing, or large stained-glass lead came. Using a tool with too high a temperature can damage sensitive components, but protracted heating by a tool that is too cool or under powered can also cause heat damage, perhaps even detaching PCB traces from the substrate.
 
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Hand-soldering techniques require a great deal of skill for the fine-pitch soldering of surface mount [[integrated circuit|chip]] packages. In particular [[ball grid array|ball grid array (BGA)]] devices are notoriously difficult, if not impossible, to rework by hand.
 
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For attachment of electronic components to a PCB, proper selection and use of flux helps prevent oxidation during soldering;  it is essential for good wetting and heat transfer. The soldering iron tip must be clean and pre-tinned with solder to ensure rapid heat transfer. Components which dissipate large amounts of heat during operation are sometimes elevated above the PCB to avoid PCB overheating. After inserting a through-hole mounted component, the excess lead is cut off, leaving a length of about the radius of the pad. Plastic or metal mounting clips or holders may be used with large devices to aid heat dissipation and reduce joint stresses.
 
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A heat sink may be used on the leads of heat sensitive components to reduce heat transfer to the component. This is especially applicable to germanium parts. (Note the heat sink will mean the use of more heat to complete the joint since heat taken up by the heat sink will not heat the workpieces.) If all metal surfaces have not been properly cleaned (ie, "fluxed") or brought entirely above the melting temperature of the solder used, the result will be an unreliable ("cold solder") joint, even though its appearance may suggest otherwise.
 
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To simplify soldering, beginners are usually advised to apply the soldering iron and the solder separately to the joint, rather than the solder being applied direcly to the iron. When sufficient solder is applied, the solder wire is removed. When the surfaces are adequately heated, the solder will flow around the workpieces. The iron is then removed from the joint.
 
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Since non-eutectic solder alloys have a small plastic range, the joint must not be moved until the solder has cooled down through both the liquidus and solidus temperatures. When visually inspected, a good solder joint will appear smooth and shiny, with the outline of the soldered wire clearly visible. A matte gray surface is a good indicator of a joint that was moved during soldering.  The boundary between the solder and the workpiece in a good joint will have a low angle.
 
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Other solder defects can be detected visually as well. Too little solder will result in a "dry" and unreliable joint; too much solder (the familiar 'solder blob' to beginners) is not necessarily unsound, but tends to mean poor wetting. With some fluxes, flux residue remaining on the joint may need to be removed, using water, alcohol or other solvents compatible with the parts involved.
 
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Excess solder and unconsumed flux and residue is sometimes wiped from the soldering iron tip between joints. The tip of the bit (commonly iron plated to reduce erosion) is kept wetted with solder ("tinned") when hot to assist soldering, and to minimize oxidation and corrosion of the tip itself.
 
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Environmental legislation in many countries, and the whole of the [[European Community]] area (see [[Restriction of Hazardous Substances Directive|RoHS]]), has led to a change in formulation of both solders and fluxes. Water-soluble non-rosin-based fluxes have been increasingly used since the 1980s so that soldered boards can be cleaned with water or water-based cleaners. This eliminates hazardous solvents from the production environment, and from factory effluents.  Those regulations have also reduced the use of lead based solders, and caused the melting temperatures of solders in use to increase by up to a hundred degrees F.
 
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====Hot-bar reflow====
 
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''Hot-bar reflow'' is a selective soldering process where two pre-fluxed, solder coated parts are heated with heating element (called a thermode) to a sufficient temperature to melt the solder.
 
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Pressure is applied through the whole process (usually 15 s) to ensure that components stay in place during cooling. The heating element is heated and cooled for each connection. Up to 4000 [[Watt|W]] can be used in the heating element allowing fast soldering, good results with connections requiring high energy.<ref>{{cite web|title=Unitek Eapro: Electronic Assembly Products|url=http://www.unitekeapro.com/pages.php?id=85|archiveurl=https://web.archive.org/web/20080506083947/http://www.unitekeapro.com/pages.php?id=85 |archivedate = 2008-05-06}}</ref>
 
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====Laser====
 
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''Laser soldering'' is a technique where a ~30-50 [[Watt|W]] [[laser]] is used to melt and solder an electrical connection joint. [[Diode]] laser systems based on semiconductor junctions are used for this purpose.<ref>{{cite web|title=Laser Solutions for Soldering|url=http://www.coherent.com/Downloads/circuitsassembly0204Rev2.pdf}} 0204 www.coherent.com</ref>  [[Suzanne Jenniches]] patented laser soldering in 1980.<ref name=swe>{{cite web|title=SWE Women - Jenniches|url=http://societyofwomenengineers.swe.org/index.php/swe-blog-swe-blog-189/45-swe-women-jenniches|publisher=Society of Women Engineers|accessdate=20 May 2014}}</ref>
 
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[[Wavelength]]s are typically 808&nbsp;nm through 980&nbsp;nm. The beam is delivered via an optical fiber to the workpiece, with fiber diameters 800&nbsp;µm and smaller. Since the beam out of the end of the fiber diverges rapidly, [[lens (optics)|lens]]es are used to create a suitable spot size on the workpiece at a suitable working distance. A wire feeder is used to supply solder.<ref>{{cite web|title=Laser Soldering|url=http://www.ma-info.de/html/laser_soldering.html}} 070927 ma-info.de</ref>
 
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Both lead-tin and silver-tin material can be soldered. Process recipes will differ depending on the [[alloy]] composition. For soldering 44-pin chip carriers to a board using soldering preforms, power levels were on the order of 10 Watts and solder times approximately 1 second. Low power levels can lead to incomplete wetting and the formation of voids, both of which can weaken the joint.
 
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===Fiber focus infrared soldering===
 
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Fiber focus infrared soldering is technique where many [[infrared]] sources are led through [[optical fiber|fibers]], then focused onto a single spot at which the connection is soldered.<ref name="nofiss">{{cite web|title=NovaBrite RGB Full Color High Power LED Application Note|url=http://www.vincenc.com.tw/download/Full%20color%20%20Hi%20POWER%20LED%20Application%20Note.pdf}} 070927 vincenc.com.tw (mentioned as a technique)</ref>{{Failed verification|date=November 2010}}
 
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===Pipe soldering===<!-- [[Sweat fitting]] redirects here -->
 
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[[File:Fitting1537.JPG|thumb|210px|Soldered copper pipes]]
 
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[[File:Weichlot.jpg|thumb|210px|Solder]]
 
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[[File:Leadfree Cadmium solder.jpg|thumb|210px|Lead-free solder]]
 
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Copper pipe, or 'tube', is commonly joined by soldering. When applied in a plumbing trade context in the United  States, soldering is often referred to as ''sweating'', and a tubing connection so made is referred to as a ''sweated joint''.
 
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Copper tubing conducts heat away much faster than a conventional hand-held soldering iron or gun can provide, so a [[propane torch]] is most commonly used to deliver the necessary power; for large tubing sizes and fittings a [[MAPP gas|MAPP]]-fueled, [[acetylene]]-fueled, or [[propylene]]-fueled torch is used with atmospheric air as the oxidizer; MAPP/oxygen or acetylene/oxygen are rarely used because the flame temperature is much higher than the melting point of copper. Too much heat destroys the temper of hard-tempered copper tubing, and can burn the flux out of a joint before the solder is added, resulting in a faulty joint. For larger tubing sizes, a torch fitted with various sizes of interchangeable ''swirl tips'' is employed to deliver the needed heating power. In the hands of a skilled [[tradesman]], the hotter flame of acetylene, MAPP, or propylene allows more joints to be completed per hour without damage to copper tempering.
 
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However, it is possible to use an electrical tool to solder joints in copper pipe sized from 8mm to 22mm.  For example, the Antex Pipemaster is recommended for use in tight spaces, when [[open flame]]s are hazardous, or by [[do-it-yourself]] users.  The [[pliers]]-like tool uses heated fitted jaws that completely encircle the pipe, allowing a joint to be melted in as little as 10 seconds.<ref name=SPP>{{cite web|title=Pipemaster Soldering Tool|url=http://smartplumbingproducts.com/product/pipemaster-soldering-tool|work=Smart Plumbing Products|publisher=Smart Contractor Products|accessdate=2014-05-20}}</ref>
 
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Solder fittings, also known as ''capillary fittings'', are short sections of smooth pipe designed to slide over the outside of the mating tube, are usually used for copper joints. Commonly used fittings include for straight connectors, reducers, bends, and tees. There are two types of solder fittings: ''end feed fittings'' which contain no solder, and ''[[solder ring fitting]]s'' (also known as Yorkshire fittings), in which there is a ring of solder in a small circular recess inside the fitting.
 
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As with all solder joints, all parts to be joined must be clean and oxide free. Internal and external wire brushes are available for the common pipe and fitting sizes; [[emery cloth]] and wire-wool are frequently used as well, although metal wool products are discouraged, as they can contain oil, which would contaminate the joint.
 
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Because of the size of the parts involved, and the high activity and contaminating tendency of the flame, plumbing fluxes are typically much more chemically active, and often more acidic, than electronic fluxes. Because plumbing joints may be done at any angle, even upside down, plumbing fluxes are generally formulated as pastes which stay in place better than liquids. Flux should be applied to all surfaces of the joint, inside and out. Flux residues should be removed after the joint is complete or they can, eventually, erode through the copper substrates and cause failure of the joint.
 
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Many plumbing solder formulations are available, with different characteristics, such as higher or lower melting temperature, depending on the specific requirements of the job. Building codes currently almost universally require the use of lead-free solder for potable water piping, though traditional tin-lead solder is still available. Studies have shown that lead-soldered plumbing pipes can result in elevated levels of lead in drinking water.<ref>[http://www.plumbingpages.com/featurepages/Pipeworkfluxsolder.cfm]</ref><ref>http://www.askdrsears.com/html/10/T110211.asp</ref>
 
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Since copper pipe quickly conducts heat away from a joint, great care must be taken to ensure that the joint is properly heated through to obtain a good bond. After the joint is properly cleaned, fluxed and fitted, the torch flame is applied to the thickest part of the joint, typically the fitting with the pipe inside it, with the solder applied at the gap between the tube and the fitting. When all the parts are heated through, the solder will melt and flow into the joint by capillary action. The torch may need to be moved around the joint to ensure all areas are wetted out. However, the installer must take care to not overheat the areas being soldered. If the tube begins to discolor it means that the tube has been over-heated and is beginning to oxidize, stopping the flow of the solder and causing the soldered joint not to seal properly. Before oxidation the molten solder will follow the heat of the torch around the joint. When the joint is properly wetted out, the solder and then the heat are removed, and while the joint is still very hot, it is usually wiped with a dry rag. This removes excess solder as well as flux residue before it cools down and hardens. With a solder ring joint, the joint is heated until a ring of molten solder is visible around the edge of the fitting and allowed to cool.
 
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Of the three methods of connecting copper tubing, solder connections require the most skill, but soldering copper is a very reliable process, provided some basic conditions are met:
 
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* The tubing and fittings must be cleaned to bare metal with no tarnish
 
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* Any pressure which is formed by heating of the tubing must have an outlet
 
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* The joint must be dry (which can be challenging when repairing water pipes)
 
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Copper is only one material that is joined in this manner. Brass fittings are often used for valves or as a connection fitting between copper and other metals. Brass piping is soldered in this manner in the making of [[brass instruments]] and some [[woodwind]] (saxophone and flute) musical instruments
 
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===Mechanical and aluminium soldering===
 
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A number of solder materials, primarily [[zinc]] alloys, are used for soldering aluminium metal and alloys and to a lesser extent steel and zinc. This mechanical soldering is similar to a low temperature brazing operation, in that the mechanical characteristics of the joint are reasonably good and it can be used for structural repairs of those materials.
 
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The [[American welding society]] defines brazing as using filler metals with melting points over {{convert|450|°C|°F|abbr=on}} — or, by the traditional definition in the United States, above {{convert|800|°F|°C|abbr=on}}. Aluminium soldering alloys generally have melting temperatures around {{convert|730|°F|°C|abbr=on}}.<ref name="alumaloy">[http://www.alumaloy.net/alumaloy1.htm Alumaloy], accessed 2009-04-03</ref> This soldering / brazing operation can use a propane torch heat source.<ref name="alumiweld">[http://www.alumiweld.com/faq.html Alumiweld FAQ], accessed 2009-04-03</ref>
 
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These materials are often advertised as "aluminium welding", but the process does not involve melting the base metal, and therefore is not properly a weld.
 
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[[United States Military Standard]] or MIL-SPEC specification MIL-R-4208 defines one standard for these zinc-based brazing/soldering alloys.<ref name="MIL-R-4208">[http://www.tpub.com/content/logistics/34/39/10/00-580-0585.htm MIL-R-4208], accessed 2009-04-03</ref> A number of products meet this specification.<ref name="alumiweld"/><ref name="3in1">[http://www.aladdin3in1.com/catalog.htm Aladdin 3-in-1], accessed 2009-04-03</ref><ref name="HTS-2000">[http://www.aluminumrepair.com/more_info.asp HTS-2000], accessed 2009-03-09</ref> or very similar performance standards.<ref name="alumaloy"/>
 
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'''Resistance soldering''' is soldering in which the heat required to flow the solder is created by passing an electric current through the solder. When current is conducted through a resistive material a certain level of heat is generated. By regulating the amount of current conducted and the level of resistance encountered, the amount of heat produced can be predetermined and controlled.
 
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Electrical resistance (usually described as a material's opposition to the flow of an electric current) is used to convert electric energy into thermal energy as an electric current (I) conducted through a material with resistance (R) releases power (P) equal to: P = I² R, where P is the power measured in watts, I is the current measured in amps and R is the resistance measured in ohms.
 
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===Resistance soldering===
 
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Resistance soldering is unlike using a conduction iron, where heat is produced within an element and then passed through a thermally conductive tip into the joint area. A cold soldering iron requires time to reach working temperature and must be kept hot between solder joints. Thermal transfer may be inhibited if the tip is not kept properly wetted during use. With resistance soldering an intense heat can be rapidly developed directly within the joint area and in a tightly controlled manner. This allows a faster ramp up to the required solder melt temperature and minimizes thermal travel away from the solder joint, which helps to minimize the potential for thermal damage to materials or components in the surrounding area. Heat is only produced while each joint is being made, making resistance soldering more energy efficient. Resistance soldering equipment, unlike conduction irons, can be used for difficult soldering and brazing applications where significantly higher temperatures may be required. This makes resistance comparable to flame soldering in some situations. When the required temperature can be achieved by either flame or resistance methods the resistance heat is more localized because of direct contact, whereas the flame will spread thus heating a potentially larger area.
 
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===Stained glass soldering===
 
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Historically, [[stained glass]] soldering tips were copper, heated by being placed in a [[charcoal]]-burning [[brazier]]. Multiple tips were used; when one tip cooled down from use, it was placed back in the brazier of charcoal and the next tip was used.
 
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More recently, electrically heated soldering irons are used. These are heated by a coil or ceramic heating element inside the tip of the iron. Different power ratings are available, and temperature can be controlled electronically. These characteristics allow longer beads to be run without interrupting the work to change tips. Soldering irons designed for electronic use are often effective though they are sometimes underpowered for the heavy copper and lead came used in stained glass work.
 
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Oleic acid is the classic flux material that has been used to improve solderability.
 
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Tiffany-type stained glass is made by gluing copper foil around the edges of the pieces of glass and then soldering them together. This method makes it possible to create three-dimensional stained glass pieces.
 
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===Active soldering===
 
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Flux-less soldering with aid of conventional [[soldering iron]], [[ultrasonic soldering]] iron or specialized solder pot and active solder that contains an active element, most often Ti, Zr or Cr.<ref>{{cite journal|url=http://www.iaeng.org/publication/WCE2012/WCE2012_pp1727-1732.pdf|journal= World Congress on Engineering |date=Jul 2012|volume= 3|issn=2078-0966|title=Study of Active Soldering of Al2O3 Sputtering Targets on Copper Substrates |author=M. Provazník}}</ref>  The active elements, owing to mechanical activation, react with the surface of the materials generally considered difficult to solder without premetallization. The active solders can be protected against excessive oxidation of their active element by addition of rare earth elements with higher affinity to oxygen (typically Ce, La). Another common additive is Ga – usually introduced as a wetting promoter. Mechanical activation, needed for active soldering, can be performed by brushing (for example with use of stainless wire brush or steel spatula) or ultrasonic vibration (20 – 60&nbsp;kHz). Active soldering has been shown to effectively bond ceramics,<ref>{{cite journal|url=http://www.iaeng.org/publication/WCE2012/WCE2012_pp1727-1732.pdf|journal= World Congress on Engineering |date=Jul 2012|volume= 3|issn=2078-0966|title=Study of Active Soldering of Al2O3 Sputtering Targets on Copper Substrates |author=M. Provazník}}</ref> aluminium, titanium, silicon,<ref>{{cite journal|url=http://ieeexplore.ieee.org/document/5582418/?reload=true|journal= IEEE|date=Sep 2010|volume= 61|pages=1736–1739| issn= 0569-5503|title=Die bonding of silicon and other materials with active solder|author=C. Peng}}</ref> graphite and carbon nanotube based structures <ref>{{cite journal|url=http://pubs.acs.org/doi/abs/10.1021/acsnano.5b02176|journal=ACS Nano |date=Aug 2015|volume= 9|issue=8|page=8103|title=Soldering of carbon materials using transition metal rich alloys|author=M. Burda et al}}</ref> at temperatures lower than 450&nbsp;°C or use of protective atmosphere.
 
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==Solderability==
 
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{{Main|Solderability}}
 
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The solderability of a substrate is a measure of the ease with which a soldered joint can be made to that material.
 
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==Desoldering and resoldering==
 
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{{main|Desoldering}}
 
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Used solder contains some of the dissolved base metals and is unsuitable for reuse in making new joints. Once the solder's capacity for the base metal has been achieved it will no longer properly bond with the base metal, usually resulting in a brittle cold solder joint with a crystalline appearance.
 
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It is good practice to remove solder from a joint prior to resoldering—[[desoldering braid]]s or vacuum desoldering equipment ([[solder sucker]]s) can be used. Desoldering wicks contain plenty of flux that will lift the contamination from the copper trace and any device leads that are present. This will leave a bright, shiny, clean junction to be resoldered.
 
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The lower melting point of solder means it can be melted away from the base metal, leaving it mostly intact, though the outer layer will be "tinned" with solder. Flux will remain which can easily be removed by abrasive or chemical processes. This tinned layer will allow solder to flow into a new joint, resulting in a new joint, as well as making the new solder flow very quickly and easily.
 
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== Lead-free electronic soldering ==
 
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More recently environmental legislation has specifically targeted the wide use of lead in the electronics industry. The RoHS directives in Europe required many new electronic circuit boards to be lead free by 1 July 2006, mostly in the consumer goods industry, but in some others as well. In Japan lead was phased out prior to legislation by manufacturers due to the additional expense in recycling products containing lead.<ref name="sol1"/> However, even without the presence of lead, soldering can release fumes that are harmful and/or toxic to humans. It is highly recommended to use a device that can remove the fumes from the work area either by ventilating outside or filtering the air.<ref name="sol2">[http://www.sentryair.com/solder-fumes.htm Hazards of Soldering Fumes]</ref>
 
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It is a common misconception that lead free soldering requires higher soldering temperatures than lead/tin solder; the wetting temperature in lead/tin solder is higher than the melting point and is the controlling factor - Wave soldering can proceed at the same temperature as previous lead/tin soldering.<ref name="sol1">[http://www.dklmetals.co.uk/PDF%20Files/Factorfiction.pdf FACT AND FICTION IN LEAD FREE SOLDERING] from ''www.dkmetals.co.uk''</ref> Nevertheless, many new technical challenges have arisen with this endeavor; to reduce the melting point of tin-based solder alloys various new alloys have had to be researched, with additives of copper, silver, bismuth as typical minor additives to reduce melting point and control other properties, additionally tin is a more corrosive metal, and can eventually lead to the failure of solder baths etc.<ref name="sol1"/>
 
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Lead-free construction has also extended to components, pins, and connectors. Most of these pins used copper frames, and either lead, tin, gold or other finishes. Tin finishes are the most popular of lead-free finishes. Nevertheless, this brings up the issue of how to deal with [[whisker (metallurgy)|tin whiskers]]. The current movement brings the electronics industry back to the problems solved in the 1960s by adding lead. [[JEDEC]] has created a classification system to help lead-free electronic manufacturers decide what provisions to take against whiskers, depending upon their application.
 
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==Soldering defects==
 
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In the joining of copper tube, failure to properly heat and fill a joint may lead to a 'void' being formed. This is usually a result of improper placement of the flame. If the heat of the flame is not directed at the back of the fitting cup, and the solder wire applied degrees{{howmany|date=September 2016}} opposite the flame, then solder will quickly fill the opening of the fitting, trapping some flux inside the joint. This bubble of trapped flux is the void; an area inside a soldered joint where solder is unable to completely fill the fittings' cup, because flux has become sealed inside the joint, preventing solder from occupying that space.
 
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===Electronics===
 
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Various problems may arise in the soldering process which lead to joints which are nonfunctional either immediately or after a period of use.
 
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The most common defect when hand-soldering results from the parts being joined not exceeding the solder's liquidus temperature, resulting in a "cold solder" joint. This is usually the result of the soldering iron being used to heat the solder directly, rather than the parts themselves. Properly done, the iron heats the parts to be connected, which in turn melt the solder, guaranteeing adequate heat in the joined parts for thorough wetting. In electronic hand soldering the flux is embedded in the solder. Therefore, heating the solder first may cause the flux to evaporate before it cleans the surfaces being soldered. A cold-soldered joint may not conduct at all, or may conduct only intermittently. Cold-soldered joints also happen in mass production, and are a common cause of equipment which passes testing, but malfunctions after sometimes years of operation.  A "dry joint" occurs when the cooling solder is moved, and often occurs because the joint moves when the soldering iron is removed from the joint.
 
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An improperly selected or applied flux can cause joint failure. If not properly cleaned, a flux may corrode the joint and cause eventual joint failure. Without flux the joint may not be clean, or may be oxidized, resulting in an unsound joint.
 
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In electronics non-corrosive fluxes are often used. Therefore, cleaning flux off may merely be a matter of aesthetics or to make visual inspection of joints easier in specialised 'mission critical' applications such as medical devices, military and aerospace. For satellites, this will also reduce weight, slightly but usefully. In high humidity, even non-corrosive flux might remain slightly active, therefore the flux may be removed to reduce corrosion over time. In some applications, the PCB might also be coated in some form of protective material such as a [[lacquer]] to protect it and exposed solder joints from the environment.
 
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Movement of metals being soldered before the solder has cooled will cause a highly unreliable cracked joint. In electronics soldering terminology this is known as a 'dry' joint. It has a characteristically dull or grainy appearance immediately after the joint is made, rather than being smooth, bright and shiny. This appearance is caused by crystallization of the liquid solder. A dry joint is weak mechanically and a poor conductor electrically.
 
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In general a good-looking soldered joint ''is'' a good joint. As mentioned, it should be smooth, bright, and shiny. If the joint has lumps or balls of otherwise shiny solder the metal has not 'wetted' properly. Not being bright and shiny suggests a weak 'dry' joint. However, technicians trying to apply this guideline when using lead-free solder formulations may experience frustration, because these types of solders readily cool to a dull surface even if the joint is good. The solder looks shiny while molten, and suddenly hazes over as it solidifies even though it has not been disturbed during cooling.
 
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In electronics a '[[wikt:concave|concave]]' fillet is ideal. This indicates good wetting and minimal use of solder (therefore minimal ''heating'' of heat sensitive components). A joint may be good, but if a large amount of unnecessary solder is used then more heating is obviously required. Excessive heating of a PCB may result in 'delamination' - the copper track may actually lift off the board, particularly on single sided PCBs without [[Through-hole technology|through hole plating]].
 
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==Tools==
 
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In principle any type of soldering tool can carry out any work using solder at temperatures it can generate. In practice different tools are more suitable for different applications.
 
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Hand-soldering tools widely used for electronics work include the electric soldering iron, which can be fitted with a variety of tips ranging from blunt to very fine, to chisel heads for hot-cutting plastics rather than soldering. The simplest irons do not have temperature regulation; small irons rapidly cool when used to solder to, say, a metal chassis, while large irons have tips too cumbersome for working on PCBs and similar fine work. Temperature-controlled irons have a reserve of power and can maintain temperature over a wide range of work. The [[soldering gun]] heats faster but has a larger and heavier body. Gas-powered irons using a catalytic tip to heat a bit, without flame, are used for portable applications. Hot-air guns and pencils allow [[rework (electronics)|rework]] of component packages which cannot easily be performed with electric irons and guns.
 
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For non-electronic applications soldering torches use a flame rather than a soldering tip to heat solder. Soldering torches are often powered by butane<ref>[http://www.toolingu.com/definition-660130-28677-soldering-torch.html What is the definition of soldering torch?<!-- Bot generated title -->]</ref> and are available in sizes ranging from very small butane/oxygen units suitable for very fine but high-temperature jewelry work, to full-size oxy-fuel torches suitable for much larger work such as copper piping. Common multipurpose propane torches, the same kind used for heat-stripping paint and thawing pipes, can be used for soldering pipes and other fairly large objects either with or without a soldering tip attachment; pipes are generally soldered with a torch by directly applying the open flame.
 
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A soldering copper is a tool with a large copper head and a long handle which is heated in a [[blacksmith]]'s forge fire and used to apply heat to [[sheet metal]] for soldering. Typical soldering coppers have heads weighing between one and four pounds. The head provides a large [[thermal mass]] to store enough heat for soldering large areas before needing re-heating in the fire; the larger the head, the longer the working time. Historically, soldering coppers were standard tools used in auto bodywork, although [[body solder]] has been mostly superseded by [[spot welding]] for mechanical connection, and non-metallic fillers for contouring.
 
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[[Toaster oven#Toaster ovens|Toaster ovens]] and hand held infrared lights have been used by hobbyists to replicate production soldering processes on a much smaller scale.
 
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Bristle brushes are usually used to apply plumbing paste flux. For electronic work, flux-core solder is generally used, but additional flux may be used from a [[flux pen]] or dispensed from a small bottle with a syringe-like needle.
 
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[[Wire brush]], [[wire wool]] and emery cloth are commonly used to prepare plumbing joints for connection. Electronic joints are usually made between surfaces that have been tinned and rarely require mechanical cleaning, though tarnished component leads and copper traces with a dark layer of oxide passivation (due to aging), as on a new prototyping board that has been on the shelf for about a year or more, may need to be mechanically cleaned.
 
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Some fluxes for electronics are designed to be stable and inactive when cool and do not need to be cleaned off, though they still can be if desired, while other fluxes are acidic and must be removed after soldering to prevent corrosion of the circuits. For PCB assembly and rework, either an alcohol or acetone is commonly used with cotton swabs or bristle brushes to remove flux residue after soldering. A heavy rag is usually used to remove flux from a plumbing joint before it cools and hardens. A fiberglass brush can also be used.
 
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A [[heat sink]], such as a crocodile clip, can be used to prevent damaging heat-sensitive components while hand-soldering. The heat sink limits the temperature of the component body by absorbing and dissipating heat (reducing the thermal resistance between the component and the air), while the thermal resistance of the leads maintains the temperature difference between the part of the leads being soldered and the component body so that the leads become hot enough to melt the solder while the component body remains cooler.
 
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==See also==
 
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*[[Desoldering]]
 
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*[[Dip soldering]]
 
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*[[Solder mask]]
 
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*[[Electronics Technician (United States Navy)|Electronics Technician]]
 
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{{clear}}
 
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==References==
 
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{{reflist|30em}}
 
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==External links==
 
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{{Wikibooks|Practical Electronics/Soldering}}
 
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{{EB1911 poster|Brazing and Soldering}}
 
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* [http://www.epemag.wimborne.co.uk/desolderpix.htm Desoldering guide]
 
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* [http://vega.org.uk/video/programme/166 A short video explanation of how solder works]
 
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* [https://web.archive.org/web/20090101042813/http://www.solderinguide.com/ Soldering 101 (Archived)]
 
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{{Metalworking navbox|formopen}}
 
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[[Category:Soldering| ]]
 
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[[Category:Electronics manufacturing]]
 
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[[Category:Laser applications]]<!-- For laser soldering -->
 
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[[Category:Metalworking]]
 

Revision as of 14:08, 22 August 2024

Soldering Iron
Soldering a component

Make: Weller

Model: WES51

Ace: Needed (Makerhub@georgefox.edu).

Location: PCB Lab, The Hub



Description

Soldering is a process in which two or more items (usually metal) are joined together by melting and putting a filler metal (solder) into the joint, the filler metal having a lower melting point than the adjoining metal. Soldering differs from welding in that soldering does not involve melting the work pieces. In brazing, the filler metal melts at a higher temperature, but the work piece metal does not melt. In the past, nearly all solders contained lead, but environmental and health concerns have increasingly dictated use of lead-free solder for electronics and plumbing purposes.

Here is an example of this piece of equipment being used.

Insert video media here.

Documentation

Terminology

  • Soldering Tip

  • Solder

  • Flux

Soldering Iron User Manual

Training

Operation

The Soldering Iron is an amazing tool that allows us to construct circuits with sturdy connections between components. The detailed steps to do this can be found in videos on the Description section.

Demonstration

Before using a Soldering Station, students will need to read some documentation, watch some videos, and pass a quiz on Canvas. Upon completion, students will be given the following PCB and components to assemble the circuit below. Upon completion, they will have the PCB Lab volunteers assess their work and confirm operation. The deliverable will include a video of the working device and a crisp "Thumbs Up" from the PCB Lab Volunteer to assure that the student successfully completed the task.

Soldering course circuit.jpg

General Procedure

  1. First things first, you need to learn how to use the soldering irons! Soldering is not difficult, but understanding some basic concepts will go a long way toward a successful experience. As part of your training, you will need to read some documentation and watch some videos.
  2. After scouring the web for examples of soldering training, we really liked the lessons captured in the PACE series, despite the fact that they were filmed in the 80's. These videos are well produced (for something possibly older than your parents) and have a lot of good information. The quizzable information is in the very first, fifth, and sixth videos, but the other videos have great examples of good and bad soldering joints. Another more modern video from Beauty and the Bolt is also insightful. This video is a little more modern, and a good resource, but not as technically interesting. It talks a bit about desoldering as well as soldering wires together and how to use heat shrink and electrical tape. A more modern series is available from Howcast. It wouldn't hurt at all to watch this series, but we will just focus on a couple for the quiz. Finally, there is an official training video from the Maker Hub that is tailored to our specific space and equipment. This video will give you the information you need to perform the live solder demonstration required for your soldering certification.
  3. This nostalgic set of videos from PACE are quite old, but surprisingly still quite relevant. The style makes you think that you will be getting ready to watch an old Disney cartoon - you aren't. Don't get disappointed.
  4. Basic Soldering Lesson 1: This is by far the longest of the videos at (20:44), but also packed with the most pertinent information. It provides great background on solder, flux, wetting, and then mechanics of the iron and the joint. We do not have the student handbook that is mentioned. We suspect that you can manage without that. Here are some key ideas that you should watch for:
    1. What is solder? What temperatures do the different solders melt at?
    2. What is flux?
    3. What is wetting?
    4. What are the different aspects of a soldering iron?
  5. Basic Soldering Lesson 2-5: These videos are worth watching, but they are not essential for this training.
    1. Basic Soldering Lesson 2 - "Soldering To PCB Terminals" (6:50)
    2. Basic Soldering Lesson 3 - "Cup Terminals" (4:19)
    3. Basic Soldering Lesson 4 - "Bifurcated Terminals" (2:45)
    4. Basic Soldering Lesson 5 - "Hook and Pierced Terminals" (1:19)
  6. Basic Soldering Lesson 6: Good explanation of a "semi-clenched" method for soldering an axial-lead component. This technique allows the component to be held in place for soldering without any extra tape or glue (or a potentially burnt finger).
  7. Basic Soldering Lesson 7: Applying the "clenching" idea to an IC. Typically, we will not use this technique, but will instead hold the part and "tack" these same leads with solder - just to hold it. The rest of the video has great examples of IC's being soldered.
  8. Basic Soldering Lesson 8-9: We don't normally see too many of these any more, but again, nice examples of good joints that are similar to components we still use. Rather than flatpack or planar components, we generally use "surface-mount" now. But, the soldering part is still useful to watch. The techniques are similar. Our PCB's will generally come "pre-tined" and the component leads are already bent, but the rest of the soldering is the same.
    1. Basic Soldering Lesson 8 - "Integrated Circuits" (1:16)
    2. Basic Soldering Lesson 9 - "Integrated Circuits: The Flatpack & Other Planar-mounted Components" (6:20)
  9. Howcast How to Solder: This set of videos from Howcast is worth watching, but we will only highlight a couple of them here that talk about removing solder.
  10. How to Remove Solder
  11. How to Remove Through-Hole Components
  12. Maker Hub Video: This video contains specific information for soldering in the Maker Hub as well as a basic overview of what will be expected in your live demonstration.
  14. Acquire a soldering station. For this procedure, this particular station will be referenced, the Weller WES51.
    ...solderingiron.png
  15. You can power it on using the switch on the left and control the temperature in °F using the temperature knob on the right. 650-750 °F is a good temperature range to keep it at. When the light is solid green, the iron is not heated up yet. When it is heated to the temperature you set on the temperature knob, it will start blinking green.
  16. Before you begin using the soldering iron, wet the sponge! Take it to a sink and drench that boi. This is used to clean the soldering iron continually during use. If you don't make it wet, it will burn up the sponge and smell/look gross, and it won't clean the soldering iron.
  17. Now you're ready to use the soldering iron! Refer to the videos in times of doubt.
  18. Don't forget to complete that video checking off your board!

Safety

  1. Always wear safety glasses when you are cutting wires or anything else at the electronics workstation. If other people are nearby, ask them to wear safety glasses or step away briefly.
  2. Angle your wire cuts down into the table or cover them with your free hand to block the projectile.
  3. Soldering irons can get up to 1000 °F. Do not touch the tip of the soldering iron; it is extremely hot. If you get burned, run cold water over the burned area for several minutes to reduce inflammation and the potential for blistering.
  4. Wires and components can also become extremely hot from soldering. Use the available helping hands, and allow the wires/components to cool before touching.
  5. Always return the soldering iron to its stand when not in use. Never lay it directly on the workbench.
  6. Ensure you have adequate ventilation when soldering. Use the available fume extractors.
  7. Turn off the soldering iron when it is not in use.
  8. If you start an electrical fire, use a fire extinguisher to put it out. NEVER use water to put out an electrical fire.
  9. Keep liquids away from the electronics workstation.

Certification

For the soldering irons in The Hub, complete The Hub - Soldering Irons Module at the link below to gain access to the Soldering Irons.

For the soldering irons in the PCB Lab, complete the PCB Lab - Soldering Irons Module at the link below to gain access to the Soldering Irons.

The Maker Hub Canvas course pertains to all facilities and equipment contained in the Maker Hub; simply complete the quizzes for the facilities/equipment you wish to use in the Maker Hub. Please email makerhub@georgefox.edu if you have any questions.

Maker Hub Canvas Course

Troubleshooting

There are two things in particular that could keep you from successfully soldering: an untinned tip and a loose tip. If the tip is not shiny silver, then place a little solder on the tip and wipe it on the sponge. Some soldering irons allow there tips to be replaced for the sake of having different shapes. If the iron is not heating up and you are using this type of iron, it is possible that the tip is not inserted into the iron fully. To fix this, grab some pliers (so you don't burn your hands), grip the shaft and push it in fully. After you have finished soldering, you might check the electrical continuity of your solder joint with a DVM.

Maintenance

General maintenance

The maintenance for the soldering iron generally consists of keeping the soldering station cleaned, stocked, and the iron tinned.

Specific Maintenance Tasks

Maintenance Procedure Frequency Done By
General Cleaning After each use Student
Tin Soldering Iron As needed Student
Stock solder, solder wick, sponge As needed Ace
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