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Soldering Wires - Here's a Different Way

 1 year ago
source link: https://www.instructables.com/Soldering-Wires-Heres-a-Better-Way/
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Soldering Wires - Here's a Different Way

Introduction: Soldering Wires - Here's a Different Way

This is a easy method of soldering wires to circuit boards. The solder feeds itself into the joint automatically so you don't need an extra hand to hold it. This method also allows exact amounts of solder on each joint. And it's quick.

Supplies

Nothing special required, just your soldering iron and solder. Oh, and your PCB and wires!

Step 1: Watch the Video

Two great tips in a couple of minutes. Subscribe to the channel for more like this.

Step 2: Why Use My Method?

Use this method where you want to avoid 'spikey' joints and achieve speed and consistency of the joints.

So many times I see people using previously applied solder on a joint where the flux has already been used up. This can lead to 'spikey' solder joints. My method feeds in flux and new solder automatically at the correct speed and the correct quantity for the joint.

Step 3: How It Works

Instead of the solder being last to the joint, I apply it first and I make sure it's not all melted. I cut off the surplus to ensure the joint will have the correct amount of solder. Now's a good time to add solder lengths to the other pads that require wires.

Step 4: The Soldering Step Is Super-quick

Offer up the wire to the joint followed by the iron. The solder melts and feeds into the joint super-quick (watch the video, even in slow-mo it's amazing).

Step 5: Multiple Wire Joints

If you have lots of wires to connect, this is a real timesaver. Each joint can have a different amount of solder depending on its size. Trimming off the length determines how much solder will be used, so it keeps you in full control here.

Not having to hold the solder gives you freedom to position each wire easily by hand.

Step 6: Avoiding Melting the Insulation

Here is the last tip. Pull the sleeving back before soldering, and ease it back after the joint cools.

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60 Comments

I love instrutables

Sometimes it's the simplest tricks. My desk is really messy with various interests and not having to find more space for a third hand or other gripper makes this one a winner.

Your technique seems to use at least three times as much solder per joint as necessary. You must get through a lot of solder.

How to not melt the insulation.
Clean your iron's tip. Apply flux and solder to the tip. Clean it again.
Slide back the insulation, apply a "Soldering Heat Sink Clip" (available on Amazon or GC Electronics or elsewhere) to the bare part of the wire between the joint and the insulation. Clean the iron's tip again. Heat the joint and solder as much as needed. Remove the clip and slide the insulation back. The clip will stop excess heat from traveling up the wire. These clips are cheap, reusable, and will save the job if you are working in a confined space or with cheap PVC-insulated wire. They also can save cheap plugs and jacks from melting if there is room to apply them.
OR: Use PTFE-insulated wire. The insulation won't melt during soldering with an iron.
Did I suggest cleaning the iron? A dirty iron can give mysterious failures with any solder or technique.

About surface mount component soldering: It is already set up for successful, strong attachments. a) The components' legs are tiny so they don't suck heat out of the joint the way a wire does. b) They are often attached with low-temperature solder paste, that has a very high flux to solder ratio. c) They are often soldered in an oven over the course of 30 seconds, with 5-10 seconds above the melting point of the solder. This is longer than the typical iron soldering time.The action of flux is not instantaneous, so taking a little longer helps assure success. I solder 0805 and TSOT-23 surface mounts (look them up) with an iron set at 425 degrees Fahrenheit and low-temp paste applied with a syringe. The tip gets cleaned before every joint, and it is obvious when a joint is successful when the appearance changes from dull paste to shiny bead. Heating time is 1-3 seconds. The excess is removed with alcohol and a tiny brush.

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Thanks Richard. I like it.

Two things to be aware of with this technique; first, there is no mechanical joint (essential for a reliable joint). Normally the mechanical joint is formed by the wire going through the hole in the plated hole.

Second, this technique doesn't allow the wire to get heated enough to take solder. In the example shown, solid wire is used, so it isn't apparent, but with stranded wire because the wire isn't heated, solder won't be wicked into the wire ... in other words, it's a cold joint. This is why the insulation doesn't melt... the wire doesn't get hot enough to take solder.

Having said all this, if your goal isn't ultimate reliability, you can get an awful lot done with this technique!

EXCELLENT!!!!!!!!!!!!!!!!!

Ok. What if I have to insert a component first will this still work?

ATTENTION -Soldering techniques are polarizing! Why? Well.. because you are either doing it correctly or you are not. If you are following and achieving success with NASA guidelines. NIIIIICE! Most professionals are there, or close, or absolutely close enough to be paid to do so in a safe manner. <<<AS LONG AS >>> your project is for yourself..have fun and learn to solder better. ..and try to avoid cold solder joints- you will need to re-flow them at some point:)

Wow! Really awesome technique! Definetely gotta use it next time! Thanks for sharing, God bless you!!

Soldering Wires - Here's a Different Way by Richard Langner

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