Soldering
Materials
Solder
Solder
Alloys
There
are a wide variety of solder alloys for varying uses as shown by this
table below, which also gives the solidification and liquifaction points together with their uses.
Ag
= Silver
Cd
= Cadmium
Cu
=Copper
PB
= Lead
Sn
= Tin
Sb
= Antimony
2%Sn/2%Sb/96%Pb
Solidus 305°C Liquidus 315 °C Uses: High Temperature, High
Creep Strength
5%Sn/93.5%Sb/1.5%Pb
Solidus 296 °C Liquidus 301°C Uses: High Melting Point
95/5%Sn/4.5%Pb
Solidus 236°C Liquidus 243°C Uses: High Melting Point
100%Sn
Solidus 232°C Liquidus 232°C Uses: Lead Free
15%Sn/85%Pb
Solidus 225°C Liquidus 290°C Uses: Lamps
96%
Sn/4%Ag Solidus 221°C Liquidus 221°C Uses: Stainless Steel,
Bright, Strong Non Toxic
20%Sn/80%Pb
Solidus 183°C Liquidus 275°C Uses: Lamps
30%Sn/70%Pb
Solidus 183°C Liquidus 255°C Uses: Lamps, Motors
31.2%Sn/67Pb/1.8%Sb
Solidus 185°C Liquidus 243°C Uses: Radiators, General Purpose
Non Electrical
40%Sn/60%Pb
Solidus 183°C Liquidus 234°C Uses: General Purpose
45%Sn/55%/Pb
Solidus 183°C Liquidus 224°C General Purpose
50%Sn/48.5%Pb/1.5%Cu
Solidus 183°C Liquidus 215°C Uses: Saves Copper Erosion
50%Sn/49.7%Pb/0.3%Sb
Solidus 183°C Liquidus 212°C Uses: General Purpose
50%Sn/50%Pb
Solidus 183°C Liquidus 212°C Uses: General Purpose
60%Sn/39.7%Pb/0.3%Sb
Solidus 183°C Liquidus 188°C Uses: General Purpose
60%Sn/40%Pb
Solidus 183°C Liquidus 188°C Uses: Electrical
63%Sn/36.7%Pb/0.3%Sb
Solidus 183°C Liquidus 183°C Uses: Electrical
62%Sn/35.7%Pb/2%Sb/0.3%Ag
Solidus 179°C Liquidus 179°C Uses: Silver - Plated Surfaces
62%Sn/36%Pb/2%Ag
Solidus 179°C Liquidus 179°C Uses: Silver - Plated Surfaces
18%Sn/80.1%Pb/1.9%Ag
Solidus 178°C Liquidus 270°C Uses: Aluminium
50%Sn/32%Pb/18%Cd
Solidus 145°C Liquidus 145°C Uses: Low melting point,
Soldering on Gold
70%Sn/30%Zn
Solidus 196°C Liquidus 307°C Uses: Spray Wire for Metal Film
capacitors
80%Sn/20%Zn
Solidus 196°C Liquidus 268°C Uses: Spray Wire for Metal Film
capacitors
30%Sn/70%Cd
Solidus 176°C Liquidus 240°C Uses: Low Thermal EMF Solder
Common
Solder Compositions for Stained Glass
The
table above shows what a large variety of compositions there are for
various soldering purposes.
The
common solders for stained glass are mixtures of tin and lead,
respectively:
63/37:
melts at 183°C (362°F)
60/40:
melts between 183°C (362°F) and 188°C (376°F)
50/50:
melts between 183°C (362°F) and 212°C (421°F)
40/60:
melts between 183°C (362°F) and 234°C (454°F)
lead-free
solder (useful in jewellery, eating containers, and other
environmental uses): melts between 118°C (245°F) and 220°C
(428°F), depending on composition.
The
63/37 and 60/40 solders are most often used in copper foil work
because of their narrower melting range. This allows the solder to
set more quickly than the solders with higher lead content. They tend
to give smoother beads also.
50/50 and 40/60 solders are more
often used in leaded panel work. Their wider range of melting
temperatures allows the solder to spread and become flat.
Hard
Solder
As
used for brazing, hard solder is generally a copper/zinc or
copper/silver alloy, and melts at higher temperatures than tin/lead
compositions.
In
silversmithing or jewellery making, special hard solders are used
that will pass assay. They contain a high proportion of the metal
being soldered and lead is not used in these alloys. These solders
also come in a variety of hardnesses, known as 'enamelling', 'hard',
'medium' and 'easy'. Enamelling solder has a high melting point,
close to that of the material itself, to prevent the joint
de-soldering during firing in the enamelling process. The remaining
solder types are used in decreasing order of hardness during the
process of making an item, to prevent a previously soldered seam or
joint de-soldering while soldering a new joint. Easy solder is also
often used for repair work for the same reason. Flux or rouge is also
used to prevent joints de-soldering
Flux
Core Solder
A
tube of multi-core electronics solder is used for manual soldering in
the electronics industry - the flux is contained in cores within the
solder itself.
Solder
often comes pre-mixed with, or is used with, flux, a reducing agent
designed to help remove impurities (specifically oxidised metals)
from the points of contact to improve the electrical connection. For
convenience, solder is often manufactured as a hollow tube and filled
with flux. Most cold solder is soft enough to be rolled and packaged
as a coil, making for a convenient and compact solder/flux package.
The
two principal types of flux are acid flux, used for metal mending;
and rosin flux, used in electronics, where the corrosiveness of the
vapours that arise when acid flux is heated could damage components.
Due to concerns over atmospheric pollution and hazardous waste
disposal, the electronics industry has been gradually shifting from
rosin flux to water-soluble flux, which can be removed with
de-ionised water and detergent, instead of hydrocarbon solvents.
Lead-Free
Solder
Most
of the advice in the stained glass community about lead free solder
is to avoid using it. However, lead-free solder is essential for
making jewellery (which may have skin contact) or any project that
may be in contact with food.
Lead-free
solder does require a hotter iron than lead bearing solders, plus it
does not flow easily. It has a pasty state between solid and liquid
that is prone to lumps and spikes. If this is not bad enough, it also
does not take patina designed for lead bearing solders well.
Those
using rheostats with their soldering irons, should get rid of the
rheostat, as they limit the ability of the iron to recover the
soldering temperature. The best iron to use with lead free solders is
a temperature controlled iron of 100W or 200W. You can get tips that
run at 800F to replace the standard 700F tips. This helps with the
higher temperatures needed for the lead free solder. But you should
not be vaporizing the solder as the fumes are a health hazard.
Consider
the effects of the flux that you are using. Experimenting with
various kinds (see below) can lead you to one that works better than
the others.
As
always, good hygiene and good ventilation are required when
soldering. Also you should wash your hands well and frequently, and
eat in a separate room.
Flux
An
Introduction
Flux
is a key contributor to most soldering applications. It is a compound
that is used to lift tarnish films from a metal's surface, keep the
surface clean during the soldering process, and aid in the wetting
and spreading action of the solder. There are many different types
and brands of flux available on the market; check with the
manufacturer or reseller of your flux to ensure that it is
appropriate for your application, taking into consideration both the
solder being used and the two metals involved in the process.
Although there are many types of flux available, each will include
two basic parts, chemicals and solvents.
The
chemical part includes the active portion, while the solvent is the
carrying agent. The flux does not become a part of the soldered
joint, but retains the captured oxides and lies inert on the joint's
finished surface until properly removed. It is usually the solvent
that determines the cleaning method required to remove the remaining
residue after the soldering is completed. It should be noted that
while flux is used to remove the tarnish film from a metal's surface,
it will not (and should not be expected to) remove paint, grease,
varnish, dirt or other types of inert matter. A thorough cleaning of
the metal's surface is necessary to remove these types of
contaminates. This will greatly improve the fluxing efficiency and
also aid in the soldering methods and techniques being used.
Courtesy
of American
Beauty Tools
The
Action of Fluxes
All
common untreated metals and metal alloys (including solders) are
subject to an environmental attack in which their bare surfaces
become covered with a non-metallic film, commonly referred to as
tarnish. This tarnish layer consists of oxides, sulphides,
carbonates, or other corrosion products and is an effective
insulating barrier that will prevent any direct contact with the
clean metal surface which lies beneath. When metal parts are joined
together by soldering, a metallic continuity is established as a
result of the interface between the solder and the surfaces of the
two metals. As long as the tarnish layer remains, the solder and
metal interface cannot take place, because without being able to make
direct contact it is impossible to effectively wet the metal's
surface with solder.
The
surface tarnishes that form on metal are generally not soluble in -
and cannot be removed by - most conventional cleaning solvents.
They must, therefore be acted upon chemically, or mechanically, in
order to be removed. The required chemical reaction is most often
accomplished by the use of soldering fluxes. These soldering fluxes
will displace the atmospheric gas layer on the metal’s surface and
upon heating will chemically react to remove the tarnish layer from
the fluxed metals and maintain the clean metal surface throughout the
soldering process.
Chemical
reactions
The
chemical reaction that is required to remove the tarnish layer will
usually be one of two basic types.
It
can be a reaction where the tarnish and flux combine forming a third
compound that is soluble in either the flux or its carrier.
An
example of this type of reaction takes place between water-white
rosin and copper oxides. Water-white rosin, when used as a flux is
usually in an isopropyl alcohol carrier and consists mainly of
abietic acid and other isomeric diterpene acids that are soluble in
several organic solvents. When applied to an oxidized copper surface
and heated, the copper oxides will combine with the abietic acid
forming a copper abiet (which mixes easily with the un-reacted rosin)
leaving a clean metallic surface for solder wetting. The hot molten
solder displaces the rosin flux and the copper abiet, which can then
be removed by conventional cleaning methods.
Another
type of reaction is one that causes the tarnish film, or oxidized
layer to return to its original metallic state restoring the metals
clean surface.
An
example of this type of reaction takes place when soldering under a
blanket of heated hydrogen. At elevated temperatures (the temperature
that is required for the intended reaction to take place is unique to
each type of base metal) the hydrogen removes the oxides from the
surface, forming water and restoring the metallic surface, which the
solder will then wet. There are several other variations and
combinations that are based on these two types of reactions.
Flux
as a temporary protective coating
Once
the desired chemical reaction has taken place (lifting or dissolving
the tarnish layer) the fluxing agent must provide a protective
coating on the cleaned metal surface until it is displaced by the
molten solder. This is due to the elevated temperatures required for
soldering causing the increased likelihood that the metal’s surface
may rapidly re-oxidize if not properly coated. Any compound that can
be used to create one of the required types of chemical reactions,
under the operating conditions necessary for soldering, might be
considered for use as a fluxing material. However, most organic and
inorganic compounds will not hold up under the high temperature
conditions that are required for proper soldering. That is why one of
the more important considerations is a compounds thermal stability,
or its ability to withstand the high temperatures that are required
for soldering without burning, breaking down, or evaporating.
When
evaluating all of the requirements necessary for a compound to be
considered as a fluxing agent, it is important to consider the
various soldering methods, techniques and processes available and the
wide range of materials and temperatures they may require. A certain
flux may perform well on a specific surface using one method of
soldering and yet not be at all suitable for that same surface using
a different soldering method. When in doubt it never hurts to check
with the flux, or solder manufacturer for recommendations.
Courtesy
of American
Beauty Tools
Flux
Categories
A.
Rosin Fluxes
Rosin
based fluxes are made from rosin which is extracted from pine sap.
The purified product is known as "Water White Rosin". The
active ingredient is an organic acid, abietic acid and may contain
homologues such as dehydro abietic acid and leviopmaric acid.
In
addition to rosin other activators may be present at different levels
to increase the ability to clean and de oxidise. Activators are
compounds that decompose at soldering temperatures yielding ammonia
or hydrochloric acid in the process. Flux activity is categorised as
R (rosin only), RMA (rosin mildly activated) and RA (rosin
activated). A low boiling solvent such as isopropanol is used as the
vehicle so they are flammable.
Type
R
containing only rosin is the least active and is recommended for
surfaces very clean to start with. It leaves virtually no residue
behind. Thus this is the best rosin based flux for copper foil and
lead cames.
Type
RMA
contains a small amount of additional activator to enhance cleaning
and de-oxidisation leaving only a minimum amount of inert residue
behind. A characteristic of RMA fluxes is that the remaining residue
be non-corrosive, tack free, and exhibit a high degree of freedom
from ionic contamination after cleaning. These fluxes are acceptable,
but more difficult to clean. They are not acceptable for conservation
work.
Type
RA
are most active of the rosin fluxes, and leave the most residue,
however the residues can be removed with appropriate flux cleaners.
The residues are really difficult to remove in decorative glass work
circumstances and should not be used.
B.
Water Soluble Fluxes
These
are called water-soluble, as the residue left after soldering is
water soluble, although the flux is not. The so-called water-soluble
fluxes are divided into two categories, organic and inorganic based
on composition. Organic fluxes are more active than RA rosin, and
inorganic are the most active of all. Both of these are the best of
all fluxes to use in decorative glass work, as the residues are water
soluble making clean-up easier, and they are more effective in
wetting and keeping the copper and lead free from oxidisation at
soldering temperatures.
Hi there. Nice blog. You have shared useful information. Keep up the good work! This blog is really interesting and gives good details. aluminium soldering flux, Water soluble flux.
ReplyDeleteHi there. Nice blog. You have shared useful information. Keep up the good work! This blog is really interesting and gives good details. aluminium soldering flux, Water soluble flux.
ReplyDeleteAn excellent article re: FLUX.
ReplyDeleteWhat can you tell me about stearine flux? Have found one US company making Stearin (candles) in small saleable quantities while most seem to come from Australia or the UK,in rather large quantities.Could not learn reason why SG users like this.LEADLIGHTING in Au uses this in block form breaking it down into manageble pieces.
I beleive most Glassers use a liquid flux here in the states.I could be mistaken.
This blog is very useful with details, sir help best surfactant for no clean flux core solder wire.
ReplyDelete