Beatrice Lang
Soldered electrical connections were the norm before 1950, but today, there are many other reliable splice techniques. Soldering is a process in which two or more metal items are joined together by melting a low-temperature metal alloy over a joint or wire splice. Solder is typically a great electrical connection but not always a good mechanical connection. For example, it is not allowed in almost every application on boats. However, it is still used for some specific applications, such as high-current DC or any RF connection, where connections are permanent and internal to a piece of equipment, or where corrosion is a concern.
Characteristics of electrical connections that have to be soldered
| Characteristics | Values |
|---|---|
| Materials | Solder, wires, soldering iron |
| Solder composition | 63% tin and 37% lead |
| Solder melting point | 361 °F (183 °C) |
| Solder use case | Combining two wires |
| Safety | Safety glasses, gloves |
| Process | Strip wires, twist wires, melt solder onto wires, cover exposed wires |
| Advantages | Reliable, long-lasting, good electrical connection |
| Disadvantages | Poor mechanical connection, difficult to rework |
| Use cases | High-current DC, RF connections, PCB, connector with solder option |
| Alternatives | Crimping, wire nuts, screw-in terminal blocks, twisting and taping |
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What You'll Learn
Soldering is a reliable technique for electrical connections
Soldering has been used for decades and was the norm before 1950. It is still used today, especially in electronics manufacturing, to connect wires to printed circuit boards (PCBs). Soldering is also used in plumbing, metalwork, and jewellery making.
The reliability of soldering comes from its ability to create strong and permanent but reversible connections. The solder is melted using a soldering iron, and the process ensures that the connection will not break loose due to mechanical or thermal forces. This is especially important for high-current DC or RF connections, where crimp-on connectors may fail over time.
Additionally, soldering can be a more reliable option than other methods, such as wire nuts or twisting wires, as it provides a larger contact area and better electrical continuity. Soldering also has the advantage of being less susceptible to corrosion, which can be an issue for other types of connections.
However, it is important to note that the reliability of soldering depends on the type of solder used and the skill of the person performing the soldering. For example, lead-free solders can be more difficult to work with and may not create as reliable joints as lead-based solders.
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Solder is not always a good mechanical connection
The solder's weakness as a mechanical connection is further highlighted by the fact that it takes much longer to solder a connection than to use other methods such as wire nuts, which both connect and cover wires in a single operation. This makes solder connections much less forgiving of improper strain relief than other connection types. If wires are not clamped and someone pulls on them, the strain can be transferred to the solder joint, causing it to break.
In addition, the layers of insulation required for solder connections make the joint uninspectable. An inspector may assume that a soldered rattail splice is not properly insulated. Solder also has only about 1/10 the conductivity of copper, which is important in mains wiring where engineering is done to ensure copper is not wasted.
Despite these drawbacks, solder connections can still be suitable in certain situations. For example, if soldered connections are between wires securely clamped in a junction box that is rarely accessed, there is little to worry about. Additionally, solder can be useful when connecting wires to a PCB or connector that only has a solder option, as is often the case in electronics.
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Soldering is not suitable for high-current paths
While soldering connections can offer longevity and increased reliability, it is not always the best option for electrical connections. In fact, soldering is not suitable for high-current paths due to several factors.
Firstly, solder has a much lower conductivity than copper, with only about 1/10 the conductivity of copper wire. This means that in high-current applications, solder connections may not be able to handle the required current levels and could lead to overheating or even failure.
Secondly, modern electrical wiring is designed to operate within specific temperature ranges, typically between 60°C to 75°C, with a maximum of 90°C. In contrast, solder has a lower melting point, which can vary depending on the type of solder used. For example, lead-based solder melts at 183°C, while other types of solder can have melting points of 200°C or higher. This means that if a soldered connection is subjected to high currents and generates enough heat, it could potentially melt the solder, compromising the integrity of the connection.
Additionally, soldering can make it difficult to inspect the joint. The layers of insulation used in soldering can make it challenging for inspectors to verify the quality of the connection. This is especially important in high-current applications, where a faulty or improperly insulated connection could lead to safety hazards.
Furthermore, soldering may not be the most practical or economical choice for high-current paths. Modern electrical equipment often utilizes crimp-on connectors, screw-in terminal blocks, and other pressure-based connections. These methods provide secure and reliable connections without the need for specialized tools or skills required for soldering.
Lastly, in high-current applications, it is crucial to consider the potential for connection failure. While soldering can provide a strong joint, it is not immune to failure. Soldering connections can fatigue over time, especially if they are subjected to repeated stress or vibration. In such cases, a crimped or screwed connection may be more suitable as they can be more easily replaced or repaired.
In conclusion, while soldering has its advantages in certain applications, it is not ideal for high-current paths due to its lower conductivity, melting point considerations, inspection challenges, and the availability of more practical and reliable alternative connection methods.
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Soldering is not always code-compliant
Soldering electrical connections is not always code-compliant. While soldering can create strong and reliable connections, modern electrical codes often have specific requirements that must be met, and soldering may not always be the best method to achieve those requirements.
Firstly, it's important to note that electrical codes can vary depending on the local area, and it's essential to refer to the specific code in your region. In some cases, electrical codes may prohibit soldering on certain types of wires, such as service wires and ground conductors. Therefore, it's crucial to consult the relevant code before making any electrical connections.
One of the main concerns with soldering electrical connections is the potential for improper insulation. The layers of insulation used in soldering can make the joint difficult to inspect, leading to uncertainty about the quality of the connection. Inadequate insulation can pose safety risks, and inspectors may have valid concerns about the integrity of soldered joints.
Additionally, soldering may not always provide the most effective electrical connection. While soldering can create a strong joint, it has lower conductivity than copper, which is commonly used in electrical wiring. Modern wiring methods often utilize techniques that maximize conductivity and minimize waste, and soldering may not align with these engineering principles.
Furthermore, soldering can be a more time-consuming and labour-intensive process compared to modern connection methods. While soldering was once a common practice, the advancement of manufacturing techniques has led to the development of more efficient and reliable splicing techniques. These modern methods, such as wire nuts and screw-in terminal blocks, offer comparable or even superior connection quality without the need for soldering.
Lastly, soldering may not always be the most suitable option for long-term reliability. While soldered connections can be strong, they can also be brittle and prone to microscopic cracks, leading to high resistance spots. In contrast, other connection methods, such as crimped connections, can provide reliable and immediate feedback on their performance, making them easier to maintain and replace when necessary.
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Soldering is not always necessary for electrical connections
Soldering is a process in which two or more metal items are joined together. It is a reliable technique for electrical connections, but it is not always necessary.
Firstly, soldering is not always feasible or the best option for electrical connections. For example, anything that requires serviceability, where the connection will need to be taken apart, soldering is usually not the best answer. In such cases, a wirenut or wago, which makes a great mechanical connection and a pretty good electrical connection, is advantageous. Additionally, soldering is not allowed in almost every application on boats.
Secondly, soldering may not be necessary for electrical connections due to the availability of alternative methods. For instance, for standard domestic power applications (100-600V), soldering is only used for limited applications, usually for permanent connections that are internal to a piece of equipment. In such cases, other methods like twisting the wires together and then using heat shrink tape/electrical tape with or without a wire connector can be used. Modern, machine-assembled electronic equipment is also built with crimp-on connectors, screw-in terminal blocks, and other pressure-based connections.
Thirdly, soldering may not be necessary for electrical connections due to the nature of the materials being joined. For example, if the connection involves high current paths (40+ amps), solder is not appropriate. Additionally, if the connection involves transistors or other heat-sensitive components, soldering can damage them. In such cases, other methods like wire wrapping or crimping may be more suitable.
Lastly, soldering may not be necessary for electrical connections due to the cost and skill required. Soldering requires more time and skill than some alternative methods, and the cost of soldering equipment and materials may be higher. In some cases, a simpler and more economical connection method may be preferred.
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Frequently asked questions
No, electrical connections do not have to be soldered. There are many other methods to connect wires, such as twisting the wires together and using heat shrink tape/electrical tape or wire connectors.
Solder is typically a great electrical connection but not always a good mechanical connection. Small amperage, DC loads, like car stereo hookups, benefit from the great electrical connection made by solder and rarely need to be reworked or reconfigured. Solder is also useful for creating permanent connections that are internal to a piece of equipment, such as where wires terminate on a PCB.
Solder is not appropriate in a high-current path (40+ amps). It is also not ideal for connections that will need to be taken apart, like household AC wiring, which is frequently reworked, replaced, and expanded.
Soldering involves melting a low-temperature metal alloy, usually a combination of metals like tin or lead, over a joint or wire splice to secure two pieces together. Both parts that are being soldered have to be hot to form a good connection. The tip of the soldering iron heats both the copper pad and the lead from the electronic component. Solder melts when placed in contact with the hot metals to be joined.
