Otis Singleton
Soldering is a useful skill for DIY enthusiasts and professionals alike, enabling the repair of electrical items and the creation of new electronics projects. While it may sound intimidating, it is a straightforward process that involves melting solder to create a connection or melting down an existing solder joint to break a connection. Before soldering, it is important to ensure that devices are powered off and unplugged, and to wear safety goggles to protect against solder spatter. This guide will cover the basics of how to solder over old connections, including the tools required and the steps to take for a successful solder joint.
Characteristics and Values Table
| Characteristics | Values |
|---|---|
| Soldering Connections | Through-hole soldering, surface-mount soldering, soldering wires |
| Tools | Soldering iron, vise, clamp, soldering splint, safety glasses, fume extractor, soldering gun, solder pump, desoldering iron, heat shrink tube sleeve, wire stripper, sponge, rosin flux, dielectric silicone paste, heat gun |
| Safety | Never solder devices that are powered on or plugged in, avoid soldering directly to lithium-ion batteries, be careful with lithium-polymer battery wires, prevent oxidation, wear safety goggles |
| Solder Types | Lead-free solder, lead solder, solder with rosin core |
| Pros of Soldering | Longevity, increased reliability, strong connection |
| Cons of Soldering | Requires skill, can be time-consuming, lead solder is toxic and bad for the environment |
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What You'll Learn
Safety precautions
Soldering is a useful skill for creating strong, durable, and long-lasting connections. However, it is important to take safety precautions to ensure your safety and the quality of your work. Here are some detailed safety instructions to follow when soldering over old connections:
Prepare Your Workspace:
- Ensure your workspace is well-ventilated and fireproof.
- Keep a fire extinguisher nearby and know how to use it.
- Use a soldering stand to hold your soldering iron when not in use.
- Keep the workbench free of electrical cables to prevent damage from the heated soldering iron tip.
- Use a grounded outlet and grounding prong to prevent short circuits.
Personal Protective Equipment (PPE):
- Wear safety glasses or eye protection to shield your eyes from solder "spitting".
- Put on fire-resistant clothing, such as 100% cotton, to cover your arms and legs, protecting against accidental burns.
- Wear gloves to protect your hands and prevent lead exposure through skin contact.
Tool and Material Safety:
- Inspect your soldering iron for any damage. Do not use irons with damaged bodies, cables, or plugs. Ensure they have been electrically safety tested (PAT) within the last year.
- Match the solder wire diameter to the size of the connectors—use thinner wire for electronics and thicker wire for plumbing.
- Choose between lead or lead-free solder. Lead-free solder is recommended due to health and environmental concerns, but lead solder is easier to work with and forms more reliable joints.
- Use rosin-containing solders only in controlled conditions and with fume extraction, such as through an enclosed hood or tip extraction.
- Keep a log of filter changes for extraction systems.
Working with Solder:
- Wash your hands with soap and water after soldering to remove any residue.
- Never touch the hot element of the soldering iron.
- Hold wires with tweezers or clamps when heating.
- Keep the cleaning sponge wet during use, and clean the soldering iron tip on it between uses.
- Always turn off and unplug the soldering iron when you're finished.
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Soldering tools
Soldering is the process of joining two or more electronic parts by melting solder around the connection. The solder is a metal alloy that creates a strong electrical bond between the parts. Soldering requires a set of tools that help in the process. The most important tool is the soldering iron. This is a hand tool that plugs into a standard 120v AC outlet and heats up to melt the solder around electrical connections. Soldering irons come in different variations, such as pen or gun form. The tip of the soldering iron is interchangeable, with different shapes and sizes available. The conical tip is commonly used in precision electronics soldering due to its fine tip, which allows for targeted heat application. The chisel tip, on the other hand, is broader and flatter, making it suitable for soldering wires or larger components.
To ensure a smooth soldering process, it is essential to have a clean soldering iron tip. A sponge can be used to wipe the tip and remove any oxidation. Brass wire can also be used to keep the tip clean by stabbing the tip into the wire a few times. Additionally, soldering irons with temperature control settings are available. When using leaded solder, the temperature should be set to around 300-350 °C, while lead-free solder requires a higher temperature of about 400 °C.
Other tools that can be used in the soldering process include a vise or "helping hands" tool to secure the circuit board and hold it steady. A fume extractor is also important to capture the solder fumes, and safety goggles should be worn to protect the eyes. When working with wires, a wire stripper is used to remove the plastic coating from the wires, and heat shrink tubing is applied to cover the joint after soldering. Rosin flux can be applied to the spliced wire to improve the adhesion of the solder, creating a better bond.
For more complex soldering projects, a soldering station can be used. This includes the soldering iron, a stand, a tip cleaner, and sometimes basic starter materials. Soldering stations provide greater control over temperature and offer features such as set-temperature memory.
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Preparing the surface
To prepare the surface for soldering over old connections, you need to begin by removing the old solder. This process is called desoldering and involves melting down an existing solder joint to break the connection, and then clearing away the old solder.
There are various tools you can use to remove the old solder. One option is a solder pump, also known as a solder vacuum or "solder sucker". This is a handheld suction device that vacuums up small amounts of liquefied solder as you melt the joints. There are manual and electrically powered versions available. With the manual type, you use the release of a compressed spring to generate a strong suction that rapidly removes the melted solder. With the powered type, you simply hold the solder pump close to the solder as it melts and it will be automatically suctioned away.
Another option is a desoldering iron, which is a soldering iron with a built-in vacuuming component. This can be semi-powered or fully powered. The semi-powered option uses electricity or gas to heat the tip, and the solder is suctioned via a manually operated aspirator bulb mounted to the iron. The fully powered option has a constantly running, electrically powered solder pump that vacuums automatically while the iron is in use.
Once you have removed the old solder, you need to prepare the surface for the new solder. First, strip the wires by removing approximately one inch of plastic sheathing from each end of the two wires, using a wire stripper. Be careful not to break any strands from the wires. Then, connect the electrical wires by spreading and intermeshing the wire ends together, twisting them until completely tight, with no strands sticking up. Place the wires into a helping hands clamp and cover them completely with rosin flux, using a flux brush or your finger inside a disposable glove. Rosin flux will help to prevent oxidation, which can negatively impact the conductivity and cause the solder joint to fail.
Before soldering, it is important to ensure your soldering iron or gun is clean. To do this, dampen a sponge with water and wipe the tip of the soldering iron or gun. Apply tip tinner to prevent oxidation and ensure the tip is clean from impurities.
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Soldering techniques
Soldering is the process of joining two or more electronic parts mechanically and electrically, using a metal alloy called solder. It is used to secure the connection between two or more electronic parts, so it doesn't break due to vibration or other mechanical forces. It also provides electrical continuity, allowing an uninterrupted electronic signal to travel through the connection.
There are different types of soldering techniques, such as through-hole soldering and surface-mount soldering. Through-hole soldering involves threading components with leads through holes on a circuit board and then securing them with molten solder. Surface-mount soldering, on the other hand, involves soldering components directly onto the surface of the circuit board.
To solder effectively, it is important to choose the right type of solder and soldering iron. For electrical purposes, lead-free solder or lead solder can be used, depending on personal preference. Lead-free solder is safer and more environmentally friendly but has a higher melting point, while lead solder has a lower melting point and is quicker to use. The soldering iron should be able to reach the melting point of the chosen solder.
When soldering, it is crucial to follow safety precautions. Always unplug any devices before soldering and avoid soldering directly onto certain batteries, as the heat can damage them. It is also important to prevent oxidation, as it can negatively impact the conductivity of the solder joint. To do this, use a damp sponge to wipe the soldering iron tip before and after each use, and apply a soldering tip tinner. Additionally, wear safety goggles to protect your eyes from solder spatter.
- Prepare the wires by stripping away any insulation and ensuring that the wire strands are not broken.
- Connect the wires by spreading and intermeshing the wire ends, then twisting them tightly together.
- Apply rosin flux to the wire strands to be soldered together. This helps to clean the wires and allows the solder to stick better.
- Place the wires in a helping hands clamp and cover them with rosin flux.
- Heat up the soldering iron and wipe the tip with a damp sponge to remove any oxidation.
- Apply tip tinner to the soldering iron tip to prevent oxidation and ensure it is clean.
- Begin heating the wires by placing the soldering iron underneath them.
- Apply solder above the wires, allowing it to coat the exposed wires completely.
- Remove the heat and allow the solder to cool without touching the wires.
- Slide a heat shrink tube sleeve over the solder and heat it with a heat gun to shrink it around the soldered wires.
- Apply dielectric silicone paste to the solder with a brush and clean off any excess.
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Removing old solder
Using a Desoldering Braid or Solder Wick:
Desoldering braid, also known as a solder wick, is a great option for removing solder from flat surfaces. It is a specific copper alloy with fine-gauge strands and a special flux chemistry. Here's how to use it:
- If your solder wick does not have flux on it, apply flux to the section you plan to use. This will aid in a cleaner removal.
- Place the braid over the joint you want to rework.
- Position a hot soldering iron against the braid and the desired pin.
- Wait a few seconds. The solder will melt and flow onto the braid.
- Remove the braid carefully, as it will be very hot. You can use needle-nose pliers to avoid burns.
- Ensure you use a new section of the braid each time, as it is not reusable.
Using a Desoldering Pump:
A desoldering pump is a small, high-pressure vacuum that can be used to remove solder. Here's how to use one:
- Heat up the solder you want to remove with a soldering iron. Some desoldering pumps come with attached irons.
- Press down on the plunger to activate the vacuum and remove the molten solder.
Other Tips:
- If you're working with a Veroboard and a component with only two pins, you can melt the solder and quickly pull out one pin, then repeat for the other side.
- For components with many pins, like an IC chip holder, you can join half the pins with solder, heat it up, and then carefully remove the component with pliers. Repeat for the other side.
- You can also use a hot air station, which is a heat gun specifically designed for desoldering. However, be cautious as it can get very hot and damage the board or your fingers if you're not careful.
- Always remember to clean up any flux residue with distilled water or isopropyl alcohol after desoldering.
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Frequently asked questions
Wear safety goggles and ensure your work area is well-ventilated. Unplug any devices and remove power sources before beginning.
You will need a soldering iron or gun, a vise or clamp, a damp sponge, a solder pump or vacuum, and electrical lead-free or lead solder.
Strip the wires, then twist and intermesh them together. Secure them in a clamp and cover with rosin flux. Heat the wires from below with the soldering gun and apply solder from above, allowing it to coat the wires. Remove the heat and let the solder cool.
Use a desoldering iron, which suctions away the solder as it melts, or a separate soldering iron and solder pump. Gently touch the preheated soldering iron to the solder joint, then use the solder pump to vacuum up the liquefied solder.
For electrical purposes, use either electrical lead-free or electrical lead solder. Lead-free solder is safer and more environmentally friendly but has a higher melting point. Lead solder is quicker but is toxic.
