Soldering iron

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Electric soldering iron Soldering gun.jpg
Electric soldering iron
A gas-fired soldering iron Gas soldering iron.jpeg
A gas-fired soldering iron
Spool of solder. 1.6mm. Solder on spool.jpeg
Spool of solder. 1.6mm.

A soldering iron is a hand tool used in soldering. It supplies heat to melt solder so that it can flow into the joint between two workpieces.

Hand tool tool equipment powered manually

A hand tool is any tool that is powered by hand rather than a motor. Categories of hand tools include wrenches, pliers, cutters, files, striking tools, struck or hammered tools, screwdrivers, vises, clamps, snips, saws, drills and knives.

Soldering process of joining metal pieces with heated filler metal

Soldering is a process in which two or more items 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. Unlike welding, 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 alloys for electronics and plumbing purposes.

Contents

A soldering iron is composed of a heated metal tip and an insulated handle. Heating is often achieved electrically, by passing an electric current (supplied through an electrical cord or battery cables) through a resistive heating element. Cordless irons can be heated by combustion of gas stored in a small tank, often using a catalytic heater rather than a flame. Simple irons less commonly used today than in the past were simply a large copper bit on a handle, heated in a flame.

Heating element converts electricity into heat through the process of resistive or Joule heating (electric current passing through the element encounters resistance, resulting in heating of the element; this process is independent of the direction of current flow)

A heating element converts electrical energy into heat through the process of Joule heating. Electric current passing through the element encounters resistance, resulting in heating of the element. Unlike the Peltier effect, this process is independent of the direction of current flow.

A catalytic heater is a type of heater which relies on catalyzed chemical reactions to break down molecules and produce heat.

Soldering irons are most often used for installation, repairs, and limited production work in electronics assembly. High-volume production lines use other soldering methods. [1] Large irons may be used for soldering joints in sheet metal objects. Less common uses include pyrography (burning designs into wood) and plastic welding.

Pyrography

Pyrography or pyrogravure is the art of decorating wood or other materials with burn marks resulting from the controlled application of a heated object such as a poker. It is also known as pokerwork or wood burning.

Plastic welding welding of semi-finished plastic materials

Plastic welding is welding for semi-finished plastic materials, and is described in ISO 472 as a process of uniting softened surfaces of materials, generally with the aid of heat. Welding of thermoplastics is accomplished in three sequential stages, namely surface preparation, application of heat and pressure, and cooling. Numerous welding methods have been developed for the joining of semi-finished plastic materials. Based on the mechanism of heat generation at the welding interface, welding methods for thermoplastics can be classified as external and internal heating methods, as shown in Fig 1.

Types

Soldering iron in use Soldering-PCB-b.jpg
Soldering iron in use

Simple iron

For electrical and electronics work, a low-power iron, a power rating between 15 and 35  watts, is used. Higher ratings are available, but do not run at higher temperature; instead there is more heat available for making soldered connections to things with large thermal capacity, for example, a metal chassis. [2] Some irons are temperature-controlled, running at a fixed temperature in the same way as a soldering station, with higher power available for joints with large heat capacity. Simple irons run at an uncontrolled temperature determined by thermal equilibrium; when heating something large their temperature drops a little, possibly too much to melt solder.

The watt is a unit of power. In the International System of Units (SI) it is defined as a derived unit of 1 joule per second, and is used to quantify the rate of energy transfer. In dimensional analysis, power is described by .

Two physical systems are in thermal equilibrium if there is no net flow of thermal energy between them when they are connected by a path permeable to heat. Thermal equilibrium obeys the zeroth law of thermodynamics. A system is said to be in thermal equilibrium with itself if the temperature within the system is spatially uniform and temporally constant.

Cordless iron

Small irons heated by a battery, or by combustion of a gas such as butane in a small self-contained tank, can be used when electricity is unavailable or cordless operation is required. The operating temperature of these irons is not regulated directly; gas irons may change power by adjusting gas flow. Gas-powered irons may have interchangeable tips including different size soldering tips, hot knife for cutting plastics, miniature blow-torch with a hot flame, and small hot air blower for such applications as shrinking heat shrink tubing.

Butane organic compound

Butane is an organic compound with the formula C4H10 that is an alkane with four carbon atoms. Butane is a gas at room temperature and atmospheric pressure. The term may refer to either of two structural isomers, n-butane or isobutane (also called "methylpropane"), or to a mixture of these isomers. In the IUPAC nomenclature, however, "butane" refers only to the n-butane isomer (which is the isomer with the unbranched structure). Butanes are highly flammable, colorless, easily liquefied gases that quickly vaporize at room temperature. The name butane comes from the roots but- (from butyric acid, named after the Greek word for butter) and -ane. It was discovered by the chemist Edward Frankland in 1849.

An operating temperature is the temperature at which an electrical or mechanical device operates. The device will operate effectively within a specified temperature range which varies based on the device function and application context, and ranges from the minimum operating temperature to the maximum operating temperature. Outside this range of safe operating temperatures the device may fail. Aerospace and military-grade devices generally operate over a broader temperature range than industrial devices; commercial-grade devices generally have the narrowest operating temperature range.

Heat gun type of home appliance

A heat gun is a device used to emit a stream of hot air, usually at temperatures between 100 °C and 550 °C (200-1000 °F), with some hotter models running around 760 °C (1400 °F), which can be held by hand. Heat guns usually have the form of an elongated body pointing at what is to be heated, with a handle fixed to it at right angles and a trigger, in the same general layout as a handgun, hence the name. A lighter duty heat gun is similar to a portable Hair dryer.

Temperature-controlled soldering iron

Simple soldering irons reach a temperature determined by thermal equilibrium, dependent upon power input and cooling by the environment and the materials it comes into contact with. The iron temperature will drop when in contact with a large mass of metal such as a chassis; a small iron will lose too much temperature to solder a large connection. More advanced irons for use in electronics have a mechanism with a temperature sensor and method of temperature control to keep the tip temperature steady; more power is available if a connection is large. Temperature-controlled irons may be free-standing, or may comprise a head with heating element and tip, controlled by a base called a soldering station, with control circuitry and temperature adjustment and sometimes display.

A variety of means are used to control temperature. The simplest of these is a variable power control, much like a light dimmer, which changes the equilibrium temperature of the iron without automatically measuring or regulating the temperature. Another type of system uses a thermostat, often inside the iron's tip, which automatically switches power on and off to the element. A thermal sensor such as a thermocouple may be used in conjunction with circuitry to monitor the temperature of the tip and adjust power delivered to the heating element to maintain a desired temperature. [2] [3] In some models, the firmware for the control circuitry is free software that can be modified by the end-user. [4] [5] [6]

Thermostat component which maintains a setpoint temperature

A thermostat is a component which senses the temperature of a physical system and performs actions so that the system's temperature is maintained near a desired setpoint.

Thermocouple thermoelectric device

A thermocouple is an electrical device consisting of two dissimilar electrical conductors forming electrical junctions at differing temperatures. A thermocouple produces a temperature-dependent voltage as a result of the thermoelectric effect, and this voltage can be interpreted to measure temperature. Thermocouples are a widely used type of temperature sensor.

Electronic circuit electrical circuit with active components such as transistors, valves and integrated circuits; electrical network that contains active electronic components, generally nonlinear and require complex design and analysis tools

An electronic circuit is composed of individual electronic components, such as resistors, transistors, capacitors, inductors and diodes, connected by conductive wires or traces through which electric current can flow. To be referred to as electronic, rather than electrical, generally at least one active component must be present. The combination of components and wires allows various simple and complex operations to be performed: signals can be amplified, computations can be performed, and data can be moved from one place to another.

Another approach is to use magnetized soldering tips which lose their magnetic properties at a specific temperature, the Curie point. As long as the tip is magnetic, it closes a switch to supply power to the heating element. When it exceeds the design temperature it opens the contacts, cooling until the temperature drops enough to restore magnetisation. More complex Curie-point irons circulate a high-frequency AC current through the tip, using magnetic physics to direct heating only where the surface of the tip drops below the Curie point. [7]

Soldering station

Temperature-controlled soldering station Soldering Station Weller 2.jpeg
Temperature-controlled soldering station

A soldering station, invariably temperature-controlled, consists of an electrical power supply, control circuitry with provision for user adjustment of temperature and display, and a soldering iron or soldering head with a tip temperature sensor. The station will normally have a stand for the hot iron when not in use, and a wet sponge for cleaning. It is most commonly used for soldering electronic components. Other functions may be combined; for example a rework station, mainly for surface-mount components may have a hot air gun, vacuum pickup tool, and a soldering head; a desoldering station will have a desoldering head with vacuum pump for desoldering through-hole components, and a soldering iron head.

Soldering tweezers

Soldering tweezers in use Soldering a 0805.jpg
Soldering tweezers in use

For soldering and desoldering small surface-mount components with two terminals, such as some links, resistors, capacitors, and diodes, soldering tweezers can be used; they can be either free-standing or controlled from a soldering station. The tweezers have two heated tips mounted on arms whose separation can be manually varied by squeezing gently against spring force, like simple tweezers; the tips are applied to the two ends of the component. The main purpose of the soldering tweezers is to melt solder in the correct place; components are usually moved by simple tweezers or vacuum pickup.

Hot knife

A hot knife is a form of soldering iron equipped with a double-edged blade that is situated on a heating element. These tools can reach temperatures of up to 1,000 degrees Fahrenheit (538 degrees Celsius) allowing for cuts of fabric and foam materials without worry of fraying or beading. Hot knives can be utilized in automotive, marine, and carpeting applications, as well as other industrial and personal uses. [8]

Stands

Soldering iron stand Soldering iron in holder.jpg
Soldering iron stand

A soldering iron stand keeps the iron away from flammable materials, and often also comes with a cellulose sponge and flux pot for cleaning the tip. Some soldering irons for continuous and professional use come as part of a soldering station, which allows the exact temperature of the tip to be adjusted, kept constant, and sometimes displayed.

Tips

Wikibooks-logo-en-noslogan.svg Choosing a soldering tip at Wikibooks

Used plated tip with remains of solder flux Loetspitze IMGP9290.jpg
Used plated tip with remains of solder flux

Most soldering irons for electronics have interchangeable tips, also known as bits, that vary in size and shape for different types of work. [9] [10] [2] Common tip shapes include: bevel (aka "hoof", especially if featuring concavity [11] ), [12] [13] chisel, [12] [13] and conical. [12] [13]

Pyramid tips with a triangular flat face and chisel tips with a wide flat face are useful for soldering sheet metal. Fine conical or tapered chisel tips are typically used for electronics work. Tips may be straight or have a bend. Concave or wicking tips with a chisel face with a concave well in the flat face to hold a small amount of solder are available. [14] [15] Tip selection depends upon the type of work and access to the joint; soldering of 0.5mm pitch surface-mount ICs, for example, is quite different from soldering a through-hole connection to a large area. A concave tip well is said to help prevent bridging of closely spaced leads; different shapes are recommended to correct bridging that has occurred. [16] Due to patent restrictions not all manufacturers offer concave tips everywhere; in particular there are restrictions in the USA. [16]

Older and very cheap irons typically use a bare copper tip, which is shaped with a file or sandpaper.[ citation needed ] This dissolves gradually into the solder, suffering pitting and erosion of the shape.[ citation needed ] Copper tips are sometimes filed when worn down. Iron-plated copper tips have become increasingly popular since the 1980s.[ citation needed ] Because iron is not readily dissolved by molten solder, the plated tip is more durable than a bare copper one, though it will eventually wear out and need replacing.[ citation needed ] This is especially important when working at the higher temperatures needed for modern lead-free solders.[ citation needed ] Solid iron and steel tips are seldom used because they store less heat, conduct it poorly, and rusting can break the heating element.[ citation needed ]

Iron-plated tips may feature a layer of nickel between the copper core and the iron surface. [9] A nickel-chrome outer plating may be used further back from the very tip, as solder does not stick well to this material: this avoids solder wetting parts of the tip where it would be unwanted. [9]

Some tips have a heater and a thermocouple-based temperature sensor embedded to facilitate a more precise temperature control (TS100 and T12, for instance).

Cleaning

When the iron tip oxidises and burnt flux accumulates on it, solder no longer wets the tip, impeding heat transfer and making soldering difficult or impossible; tips must be periodically cleaned in use. Such problems happen with all kinds of solder, but are much more severe with the lead-free solders which have become widespread in electronics work, which require higher temperatures than solders containing lead. Exposed iron plating oxidises; if the tip is kept tinned with molten solder oxidation is inhibited. A clean unoxidised tip is tinned by applying a little solder and flux.

A wet small sponge, often supplied with soldering equipment, can be used to wipe the tip. For lead-free solder a slightly more aggressive cleaning, with brass shavings, can be used. Soldering flux will help to remove oxide; the more active the flux the better the cleaning, although acidic flux used on circuit boards that is not carefully cleaned off will cause corrosion. A tip which is cleaned but not retinned is susceptible to oxidation.

Soldering iron tips are made of a copper core plated with iron. The copper is used for heat transfer and the iron plating is used for durability. Copper is very easily corroded, eating away the tip, particularly in lead-free work; iron is not. Cleaning tips requires the removal of oxide without damaging the iron plating and exposing the copper to rapid corrosion. The use of solder already containing a small amount of copper can slow corrosion of copper tips.

In cases of severe oxidation not removable by gentler methods, abrasion with something hard enough to remove oxide but not so hard as to scratch the iron plating can be used. A brass wire scourer, brush, or wheel on a bench grinder, can be used with care. Sandpaper and other tools may be used but are likely to damage the plating.

Electro-static discharge

Not all soldering irons are ESD-safe.

Although some manufacturers' mains-powered models are built with the element shaft (and hence the tip) electrically connected to ground via the iron's mains lead, [17] other models' tips may float at arbitrary voltages unless an additional grounding wire is used. [4]

See also

Related Research Articles

Printed circuit board board to support and connect electronic components

A printed circuit board (PCB) mechanically supports and electrically connects electronic components or electrical components using conductive tracks, pads and other features etched from one or more sheet layers of copper laminated onto and/or between sheet layers of a non-conductive substrate. Components are generally soldered onto the PCB to both electrically connect and mechanically fasten them to it.

Surface-mount technology method for producing electronic circuits

Surface-mount technology (SMT) is a method for producing electronic circuits in which the components are mounted or placed directly onto the surface of printed circuit boards (PCBs). An electronic device so made is called a surface-mount device (SMD). In industry, it has largely replaced the through-hole technology construction method of fitting components with wire leads into holes in the circuit board. Both technologies can be used on the same board, with the through-hole technology used for components not suitable for surface mounting such as large transformers and heat-sinked power semiconductors.

Brazing metal-joining technique by high-temperature molten metal filling

Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, the filler metal having a lower melting point than the adjoining metal.

Clothes iron tool or appliance for smoothing cloth using heat and pressure

A clothes iron is a device that, when heated, is used to press clothes to remove creases. It is named for the metal of which the device was historically commonly made, and the use of it is generally called ironing. Ironing works by loosening the ties between the long chains of molecules that exist in polymer fiber materials. With the heat and the weight of the ironing plate, the fibers are stretched and the fabric maintains its new shape when cool. Some materials, such as cotton, require the use of water to loosen the intermolecular bonds.

Flux (metallurgy) type of chemicals used in metallurgy

In metallurgy, a flux is a chemical cleaning agent, flowing agent, or purifying agent. Fluxes may have more than one function at a time. They are used in both extractive metallurgy and metal joining.

Tweezers are small tools used for picking up objects too small to be easily handled with the human fingers. The word is most likely derived from tongs, pincers, or scissors-like pliers used to grab or hold hot objects since the dawn of recorded history. In a scientific or medical context they are normally referred to as forceps.

Desoldering

In electronics, desoldering is the removal of solder and components from a circuit board for troubleshooting, repair, replacement, and salvage.

Wave soldering

Wave soldering is a bulk soldering process used in the manufacture of printed circuit boards. The circuit board is passed over a pan of molten solder in which a pump produces an upwelling of solder that looks like a standing wave. As the circuit board makes contact with this wave, the components become soldered to the board. Wave soldering is used for both through-hole printed circuit assemblies, and surface mount. In the latter case, the components are glued onto the surface of a printed circuit board (PCB) by placement equipment, before being run through the molten solder wave. Wave soldering is mainly used in soldering of through hole components.

Plating is a surface covering in which a metal is deposited on a conductive surface. Plating has been done for hundreds of years; it is also critical for modern technology. Plating is used to decorate objects, for corrosion inhibition, to improve solderability, to harden, to improve wearability, to reduce friction, to improve paint adhesion, to alter conductivity, to improve IR reflectivity, for radiation shielding, and for other purposes. Jewelry typically uses plating to give a silver or gold finish.

Reflow soldering

Reflow soldering is a process in which a solder paste is used to temporarily attach one or thousands of tiny electrical components to their contact pads, after which the entire assembly is subjected to controlled heat. The solder paste reflows in a molten state, creating permanent solder joints. Heating may be accomplished by passing the assembly through a reflow oven or under an infrared lamp or by soldering individual joints [unconventionally] with a desoldering hot air pencil.

Rework (electronics) term for the refinishing operation or repair of an electronic printed circuit board (PCB) assembly

Rework is the term for the refinishing operation or repair of an electronic printed circuit board (PCB) assembly, usually involving desoldering and re-soldering of surface-mounted electronic components (SMD). Mass processing techniques are not applicable to single device repair or replacement, and specialized manual techniques by expert personnel using appropriate equipment are required to replace defective components; area array packages such as ball grid array (BGA) devices particularly require expertise and appropriate tools. A hot air gun or hot air station is used to heat devices and melt solder, and specialised tools are used to pick up and position often tiny components.

ColdHeat

ColdHeat was an American company founded to develop and market products using the proprietary graphite-like compound Athalite. The composite material is claimed by the manufacturer to have the unusual ability to conduct large amounts of heat and return to room temperature in a short amount of time.

Soldering gun

A soldering gun is an approximately pistol-shaped, electrically powered tool for soldering metals using tin-based solder to achieve a strong mechanical bond with good electrical contact. The tool has a trigger-style switch so it can be easily operated with one hand. The body of the tool contains a transformer with a primary winding connected to mains electricity when the trigger is pressed, and a single-turn secondary winding of thick copper with very low resistance. A soldering tip, made of a loop of thinner copper wire, is secured to the end of the transformer secondary by screws, completing the secondary circuit. When the primary of the transformer is energized, several hundred amperes of current flow through the secondary and very rapidly heat the copper tip. Since the tip has a much higher resistance than the rest of the tubular copper winding, the tip gets very hot while the remainder of the secondary warms much less. A tap on the primary winding is often used to power a pilot lamp which illuminates the workpiece.

Dip soldering

Dip soldering is a small-scale soldering process by which electronic components are soldered to a printed circuit board (PCB) to form an electronic assembly. The solder wets to the exposed metallic areas of the board, creating a reliable mechanical and electrical connection.

Thermal copper pillar bump

The thermal copper pillar bump, also known as the "thermal bump", is a thermoelectric device made from thin-film thermoelectric material embedded in flip chip interconnects for use in electronics and optoelectronic packaging, including: flip chip packaging of CPU and GPU integrated circuits (chips), laser diodes, and semiconductor optical amplifiers (SOA). Unlike conventional solder bumps that provide an electrical path and a mechanical connection to the package, thermal bumps act as solid-state heat pumps and add thermal management functionality locally on the surface of a chip or to another electrical component. The diameter of a thermal bump is 238 μm and 60 μm high.

Ultrasonic soldering is a flux-less soldering process that uses ultrasonic energy, without the need for chemicals to solder materials, such as glass, ceramics, and composites, hard to solder metals and other sensitive components which cannot be soldered using conventional means. Ultrasonic (U/S) soldering, as a flux-less soldering process, is finding growing application in soldering of metals and ceramics from solar photovoltaics and medical shape memory alloys to specialized electronic and sensor packages. U/S soldering has been reported since 1955 as a method to solder aluminum and other metals without the use of flux.

Soldering station

Soldering Station – multipurpose power soldering device designed for electronic components soldering. This type of equipment is mostly used in electronics and electrical engineering. Soldering station consists of one or more soldering tools connected to the main unit, which includes the controls, means of indication, and may be equipped with an electric transformer. Soldering stations may include some accessories – holders and stands, soldering tip cleaners, etc.

References

  1. Bralla, James G. Handbook of Manufacturing Processes - How Products, Components and Materials are Made Industrial Press, 2007 page 297
  2. 1 2 3 Winstanley, Alan, The Basic Soldering Guide, archived from the original on 2010-04-14, retrieved 2010-04-14.
  3. "What is the TS100 Soldering Iron?".
  4. 1 2 "Review: TS100 Soldering Iron". 24 July 2017.
  5. "Tetris on a Soldering Iron". 7 July 2017.
  6. "Play the Tiniest Version of 'Tetris' on a Soldering Iron". 7 July 2017.
  7. "Thermaltronics Soldering: Products > TMT-9000S Soldering and Rework Station". Thermaltronics.com. Retrieved 27 August 2018.
  8. "What is a Hot Knife? - MM Newman Corporate". MM Newman Corporation. Retrieved 2016-01-14.
  9. 1 2 3 "Soldering Tips" (PDF). Userwww.sfsu.edu. Retrieved 27 August 2018.
  10. "Archived copy". Archived from the original on 2015-05-26. Retrieved 2018-12-01.CS1 maint: Archived copy as title (link)
  11. "Uses of Different Soldering Iron Tips". Instructables.com. Retrieved 27 August 2018.
  12. 1 2 3 "Understanding Different Soldering Iron Tips - Make:". Makezine.com. Retrieved 27 August 2018.
  13. 1 2 3 "How to Solder: Through-Hole Soldering". Learn.sparkfun.com. Retrieved 27 August 2018.
  14. "Hakko FX-888 Tips - Page 1". Eevblog.com. Retrieved 27 August 2018.
  15. "Soldering Tip Series 832". Ersa.com. Retrieved 27 August 2018.
  16. 1 2 "HAKKO - Select Tip Shape - Drag soldering". Hakko.com. Retrieved 27 August 2018.
  17. "FAQ's". Antex (Electronics) Limited. Retrieved 2018-08-28. [It] is appropriate to routinely test mains powered irons and stations... Guidance values for the tester settings [include:] Earth Bond Test ... pass result: < 0.1 Ohm ... A higher reading (i.e. up to 0.5 Ohm) can still be regarded as safe because the earth connection from the plug to the element shaft is welded or soldered throughout...