How to solder large cross-section wires - Metals and their processing

Technology of soldering wires and cable cores

Soldering wires is a method that allows you to obtain good contact conductivity results. Reliable connection of wires when installing electrical wiring requires special attention, because the conductivity of the contact and, as a consequence, the fire safety of the building as a whole depends on this. There are different ways to connect wires. Welding is the most reliable method, but it requires certain equipment and is quite labor-intensive.

Types of twisting wires for soldering.

Required tools and materials

To perform soldering work you will need the following tools:

an ordinary household soldering iron with a power of 40-100 Watts (you can use a soldering station on which it is easy to adjust the temperature of the soldering iron tip, which is very convenient when soldering);
knife for stripping insulation;
rosin for tinning surfaces;
solder for soldering various metals; you can also use various acid-free fluxes;
pliers for twisting;
a small file for cleaning the soldering iron tip.

Solder materials.

Soldering copper and aluminum wires with a soldering iron or gas torch is somewhat different, with a special difference in the solders used for these purposes. For soldering copper wires, lead and tin compounds are used:

For soldering aluminum wires use:

TsO-12 (zinc-tin);
A (zinc-tin-copper);
P250A (zinc-tin);
TsA-15 (zinc-aluminum).

Return

Work order

Let's take a closer look at the soldering process for these types of materials. Different methods of connecting wires involve the use of different fluxes and soldering compounds, depending on the material.

The soldering method is usually used when connecting copper wires up to 10 mm2; cross-sections up to 6 mm2 are usually twisted together before soldering.

Connecting single-wire aluminum conductors by soldering double twist with a groove: 1 - double twist; 2 - solder stick; 3 - propane-butane burner.

Here's what you need to do to ensure quality work in this case:

the conductors are stripped of insulation to a length of 5-6 cm;
using a heated soldering iron, cover the surface with a layer of flux or rosin (rosin does not work well on an oxidized surface; when penetrating deeply into the twist, it is necessary to achieve complete replacement of rosin with tin);
by heating the wire with a soldering iron with solder on the tip, achieve a uniform coating of the surface with a layer of solder;
when soldering twists, ensure that all irregularities are filled with solder and the surface of the twist is covered with it;
After soldering is completed, all twists are insulated using special nozzles, heat-shrink tubing or electrical tape.

The main difference between aluminum soldering is the high rate of surface oxidation upon contact with ambient air. The oxide film prevents reliable adhesion of the solder to the metal. When soldering aluminum, the oxide should be mechanically removed and the surface should be tinned at the same time. The technology for connecting aluminum wires depends on the cross-section of the wires and the type of flux used; a gas burner is usually used for heating.

Let's consider the procedure for performing soldering work on cores with a cross section of 4-10 mm2:

the ends of the cores are cleared of insulation to a length of 5-6 cm;
the conductors are cleaned with a knife, sandpaper or a file until a metallic shine is obtained;
the cores are overlapped using the double twist method, making a groove in the middle, at the point of contact;
heat the joint to a temperature close to the melting point of the solder;
Without removing the flame, rub the groove with a stick of special solder;
under the influence of friction, the oxide film is removed and the groove is tinned with solder;
all sides of the twist are treated in the same way, filling it with tin;
after soldering, clean the joint by wiping the surface with gasoline;
the cleaned surface is covered with asphalt varnish and a layer of electrical tape.

Soldering wires is not particularly fast in installation, but the high quality of the contacts obtained, the durability and reliability of the connections have allowed this method to become widespread in electrical installation work.

Everyone has had to deal with the problem of broken wires in equipment. It’s unreasonable to take such a small thing to a workshop; it’s easier to master the soldering technique, which will help you repair household equipment at home.

The essence of technology

There are several methods for soldering wires, but for beginners, the manual method is recommended. This option is suitable for connecting metal conductors; for propylene and other plastics, a different technology is used.

The soldering process is absolutely accessible and understandable. The connected ends are treated with a special substance and then fixed with solder. The melting point of the solder should be lower than that of the metals used in the conductors. High-quality soldering can withstand a weight exceeding the material of the conductors.

Soldering time is considered to be the period from the heating of the solder until it completely hardens. The total duration of creating one connection is 4-5 minutes.

What you need for soldering

To solder the wires you will need a soldering iron, solder and flux. It is better to carry out work on a wooden stand. For a soldering iron, you need to prepare a stand in advance so that the hot tip does not damage the surface of the table.

Any scraper is suitable for cleaning; you cannot use sandpaper with coarse stones. Before carrying out work, the surfaces need to be degreased, so it is worth preparing another alcohol solution and cotton pads or swabs.

For convenience, you should also prepare tweezers and safety glasses. The first tool will help connect thin elements, and glasses will prevent eye injury. During the soldering process, hot springs or wires may jump off, which will lead to various problems. Protection will ensure the master's safety.

Sequence of soldering wires

The technological process of soldering two thin metal conductors consists of the following steps.

1. Cleaning the surfaces of conductors, removing corrosion and other contaminants. The process is carried out carefully until the metal shines. Any third-party attack will make the connection unreliable.

2. The stripped ends of the conductors are coated with flux. This is a special substance that removes oxide fragments well and also prevents oxidation of wires during operation. When choosing a flux, preference should be given to solid and paste-like substances; liquid is of little use in this matter.

3. Using a soldering iron, the solder is melted and an even thin layer is applied to the ends of the conductors. The solder should bond well to the metal.

4. Connect the wires using temporary twist or tweezers. An alternative is to use a vice.

5. Applying flux to the joint to prevent the formation of rust under the solder.

6. Melt the solder with a soldering iron and distribute the substance around the joined ends of the conductors. If the fixation turns out to be weak, it is recommended to choose a different type of solder.

The work is completed by cleaning the soldering iron tip and treating it with inactive flux (if it is tinned). Fluxed tools will help you perform high-quality soldering in the future. It is recommended to store the soldering iron in a closed box.

Watch the video “How to solder with a soldering iron”

Source: https://otoplenie-help.ru/tehnologiya-payki-provodov-i-zhil-kabeley.html

How to solder copper wires with a soldering iron

Soldering wires with a soldering iron is not difficult, so even an inexperienced electrician can handle this method of connecting copper wires. Next, we will tell you how to properly solder wires in a distribution box - the place where electrical wiring is carried out in rooms.

The technology will be provided step by step, with pictures and video examples, so that you can more clearly understand how to solder two wires together. We immediately draw your attention to the fact that we will tell you how to solder copper wires. This is due to the fact that aluminum conductors are practically no longer used at home.

GOST standards recommend avoiding the connection of different non-ferrous metals (aluminum and copper conductors), so the only safe option for a private house and apartment is to solder the copper cable cores.

Step 1 – Prepare the tool

First, you need to prepare a soldering iron for soldering wires with your own hands. All that is required is to thoroughly clean the tip from solder residues or other possible contaminants.

For this you can use a regular file. In addition, you must prepare solder and flux, without which you will not be able to solder wires with a soldering iron. As for solder, in order to solder the wires, you can use either an alloy of tin and lead, or a special thread, as shown in the photo below.

Flux is necessary so that during soldering the solder evenly covers the materials being soldered. In addition, flux removes the oxide film from copper conductors, which significantly impairs the reliability of the connection. As a flux, you can use either rosin or special soldering acid. Both options are popular among craftsmen.

Another important stage of preparation is creating a suitable workplace. You should have an outlet and a stand for a soldering iron nearby so that the technology of soldering wires with your own hands is safe.

By the way, you can make a soldering iron with your own hands, which will not take much time and effort. A homemade device will serve you for quite a long time, as you can see for yourself!

Step 2 – Tinning

So, if you need to solder two power wires together, then first of all you must remove the polyethylene insulation and tin the exposed wires, especially if they are very thin.

Before soldering, the stranded conductor is first twisted and then treated with flux, on top of which a thin layer of heated solder is applied.

Before soldering, be sure to prepare the tip of the soldering iron - dip it in flux (in the same rosin as shown in the photo), and then in tin so that the tip is covered with a small layer of solder.

Tinning wires for soldering is quite simple - first you must place the bare wire on the rosin, then heat this place with a soldering iron so that the wires are immersed in the flux. After this, you need to take it out and treat it evenly on all sides with solder.

To properly apply the heated tin-lead alloy to the surface, twist the wire in your hands while tinning. If you need to connect the wires in a junction box, for convenience, you can use acid instead of rosin.

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It is enough to simply apply it with a brush to the surface that you need to solder.

If the conductors have a large cross-section (thick), tinning is performed in a similar way. The only difference is that you do not need to pre-twist the cores, like a stranded conductor.

After you have completed the tinning, you can move on to the soldering process. We immediately draw your attention to the fact that it is necessary to carry out work only when the electricity is turned off. Soldering live wires is strictly prohibited!

Step 3 – Solder the wires

Well, the last thing left is to solder the two prepared wires in the junction box. All you need to do is twist or overlap the wires and heat the joint with a soldering iron. The solder will melt and after it hardens, it will reliably connect the electrical conductors. We discussed tips for connecting wires by soldering in a junction box separately.

An important point - do not move the wires during soldering, otherwise the connection will not be reliable enough.

It should also be noted that preliminary tinning does not need to be done, but simply twist the wires together in a junction box, treat them with flux and solder them properly. However, we do not recommend you soldering this way, because in this case the connection will be much worse.

Source: https://respect-kovka.com/kak-spayat-mednye-provoda-payalnikom/

How to solder twisted copper wires

Electrical wiring in the room must be safe and convenient to use.

If you strictly follow this rule, then each energy consumer (chandelier, TV, computer, refrigerator) must have its own protection device against short circuits or overheating of the wiring.

You can run a separate cable from the personal circuit breaker for each outlet and switch. Two more criteria oppose this: rationality and economy.

What are distribution boxes for?

Rational wiring looks like this:

That is, the total energy consumption of the facility is evenly distributed among the circuit breakers. In addition, consumers should be divided into groups, for example:

Living room and bedroom lighting
Kitchen lighting
Lighting for bathroom and hallway
Socket group (in each room)
Power socket group (for powerful consumers, such as an air conditioner or an electric oven)

But with such a scheme, there may be many connections on one wiring line.

It is not safe to make overhead connections and hide them in the wall.

At a minimum, this does not make it possible to disable a faulty branch while leaving the rest of the circuit operational.

For normal distribution of lines, there are distribution boxes.

They are an insulated container, inside which switching (permanent) of electrical wiring lines occurs.

The connection of wires in a junction box can be done in various ways, the main thing is to ensure reliable insulation between phases and a contact that can withstand the load.

The wiring diagram in the junction box allows you to save money when purchasing electrical cables, as well as avoid uncontrolled interweaving of wires in the walls. The so-called radial wires diverge from the shield with protective circuit breakers. On each of them there are connecting nodes: those same distribution boxes.

Important: The wire cross-section may be the same or different. The main condition: the power of the main cable cannot be lower than the power of the final wiring to the consumer (socket, light fixture).

In addition, there are certain methods and rules for connecting wires in a junction box. Let's talk about this in more detail.

General rules for switching electrical cables in distribution boxes

Of course, all requirements for energy supply are set out in the PUE.

This is an electrician's reference book. Moreover, there are fines for violating the Electrical Installation Rules. However, in practice, all these strictures apply only to institutions and organizations.

In private households, responsibility ends with the wire coming out of the meter (electricity meter). The rest is up to the homeowner.

To prevent an incorrect connection from leading to a fire or electric shock, you must follow simple rules:

The connection of wires in the junction box is made during a complete power outage. Even if the electrician is wearing dielectric gloves and is familiar with safety rules, accidental contact of the phase wire with structural elements of the building or grounding is possible.
The type of connection must be the same for each line within the same box. This will protect your line from loosening under load.
Physical contact of conductors made of different materials (copper with aluminum) is not allowed. When electric current flows, active electrocorrosion occurs. Metals are coated with an oxide film, which impairs contact. The result is sparking, overheating, and complete burnout of the contact connection. If such a need arises, it is necessary to tin the wires using solder. After twisting, the connection must be soldered for at least 50% of the length. The rest of the strand will not corrode because no current flows through it under load.
It is necessary to exclude the possibility of exposed conductors leaving the box. Even if the cable is completely laid in the wall.
When connecting without contact devices, that is, using soldering, twisting or welding, an insulating cap must be placed on the exposed conductor. The insulator must be firmly fixed; non-combustible materials are used in its manufacture.
The ends of the wires inside the box must have at least a 200% margin along the length of the connecting ends. In the event of a break or burnout, it will be possible to re-install without laying a new wire.

In addition, inexperienced electricians often make mistakes and break off wires when stripping the insulation. If the wire is inserted into the box under tension, reconnection will be impossible.

Methods for connecting conductors in a box

There is no single possible method. When choosing a way to connect wires in a junction box, an electrician weighs all factors: from the cost of materials to the expected load.

Terminals. There is an opinion that this method is the most reliable, but this is a false statement. Most often, terminals are used on boxes with ready-made contact pads.

This connection of wires in the box allows you to disconnect one of the lines at any time (for example, for repairs) without causing damage to the entire power system.

There are two ways to connect, directly to the block (by making a ring from a wire core), or using a terminal.

With the ring everything is simple, you just need to ensure that the wire is laid in such a way that when tightening the threaded connection, the contact does not loosen.

But with terminals everything is more complicated.

It is irrational to crimp a single-core wire: you can mechanically damage the conductor, and the core will break off at any moment.

And when laid in a box, a single-core cable with terminals takes up a lot of space, and it is difficult to separate different phases at a sufficient distance.

An excellent result is obtained when crimping a multi-core soft cable; the contact terminal fits comfortably. But stationary installation of multi-core cable is nonsense.

Bottom line: Terminal blocks in the distribution box are convenient, but it is better to make the connection directly to the conductor under the screw, without using crimp terminals.

There are modern boxes with quick-installation contact blocks. This solution is really convenient, but is designed for light load.

Thus, the use of contact blocks is justified only if it is necessary to periodically disconnect one of the lines. And even then, sooner or later the conductor will break off.

For standard wiring in an apartment (or household), the classics are still more suitable:

Welding wires in a junction box has been used since time immemorial. Anyone who repaired their Khrushchev or Brezhnev cars probably noticed a drop of solidified melt at the end of the aluminum strands in the boxes.

Today, the use of aluminum wiring is prohibited by the PUE, and the welding connection method is still popular.

The point is this: after carefully twisting the stripped wires, the contact of the welding machine is briefly applied to the end point.

Usually this is a compact device of low power. It is used by almost all professional electricians. Works on the principle of a spot welding spotter.

It will not be possible to light an arc, but the metal at the point of application melts properly. The figure shows the simplest circuit that can be assembled at home.

The connection quality is more than sufficient.

In addition to the total twist length (40–50 mm), the ball at the end forms a point with minimal resistance.

An additional plus is that this twist will not unwind even when moving the wires inside the box.

If a welding machine is not available, we limit ourselves to ordinary twisting.

Of course, we make the connection not with our fingers, but with the help of pliers.

Twisting is done after the wires are finally secured in the box. If the cable moves, the connection may become weak. The result is sparking, overheating, and contact breakage. It will be good if there is no fire.

As an option, after twisting, the wires are soldered in the junction box.

Important! There is a widespread opinion among amateurs: under load, the twist will heat up and the solder will melt.

Firstly: a load capable of heating a conductor to the melting temperature of solder is unrealistic at home. Of course, provided that the circuit breakers are in working order.

Secondly: heating during twisting occurs due to loose contact, and this can be solved by soldering.

The reliability is not much worse than with welding. In this case, there is no need to purchase (do it yourself) a welding machine, a fairly powerful soldering iron, or even a hair dryer.

Tip: Use the most powerful soldering tool possible. It is better to expose the contacts to high temperatures for a short time than to heat the contacts slowly and for a long time with a weak heater.

During heating, monitor the condition of the insulation. If it starts to melt, take a break until it cools completely. Immediately after soldering, do not move the wire; allow both the solder and the insulation to cool.

Use refractory solders; these alloys have higher strength characteristics.

Crimping. From the point of view of electrical conductivity, the quality of contact is no better than that of conventional twisting. But the strength of the connection increases significantly. If it is not possible to weld or solder the twist, crimp it using a special sleeve.

You can get by with pliers, but a special tool is still more reliable.

There are bushings for parallel splicing of wires, and there are for fixing twists. There is no fundamental difference.

If there are two or three conductors, parallel crimping is suitable. For larger quantities - crimping after twisting.

In fact, the methods discussed above are a modernization of the good old twisting. You should not be skeptical about the issue.

Due to poor contact in the junction box, many fires occurred and damage to household appliances was caused.

Therefore, when repairing electrical wiring in your home, use technical means to improve contact in the twist to the maximum.

Modern methods of connecting wiring in a box

The so-called quick fix pads. These products are widely offered in online stores and building materials markets.

Indeed, such devices make installation quick and convenient. The appearance of the connection is also pleasant. Therefore, such “electric clips” are loved by electricians who perform custom work.

However, this method has serious drawbacks. Let's make a reservation right away: the manufacturer does not promise high connection power: the characteristics are on the case.

For an LED lamp, connecting a computer or TV - just right.

But a refrigerator, electric stove, boiler cannot be connected through such a distribution box.

The contact area in such “quick releases” is small; the pad is connected to the conductor tangentially.

With a light load, the current does not heat the surface too much.

And when a serious consumer is connected, sparking, heating, and burning out of the connection will begin.

Conclusion

With all the variety of ways to connect wires in a box, traditional twisting remains the most reliable. Welding or soldering significantly improves contact.

No serious equipment is required; all work can be completed with basic electrical engineering skills.

on this topic

Source: https://steelfactoryrus.com/kak-payat-skrutku-mednyh-provodov/

How to solder copper wires with a soldering iron - Metalworker's Guide

How to solder with a soldering iron?

This article will help you learn how to solder correctly with a soldering iron if you have not held one in your hands before. A soldering iron is a really necessary thing if you are a radio amateur, a system administrator, want to repair home electronics yourself, or if you want to learn something new and useful.

It is important to understand that if today you need to resolder wires in household appliances or solder the motherboard in a computer, reading one article will clearly not be enough. Despite its apparent simplicity, working with a soldering iron is almost an art that requires care, experience and a steady hand. Before you solder anything for a wire that has value, you should practice a fair amount on the consumable material.

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Soldering iron operating principle

Understanding how a soldering iron works is not difficult. The heating element heats up to a high temperature ( 300 degrees and above ). Soldering is the process of absorbing a special substance (solder). It has a melting point lower than that of soldering wire.

The soldering iron melts the solder, which fills all the micropores of the metal, interacting with them at the molecular level. When cooled, it “sticks” and forms a stable connection between the two parts of the wire.

Soldering iron and tools needed for work

Answering the question “how to solder with a soldering iron”, it is necessary to touch upon the topic of the tools and consumables necessary for soldering. So, in order to solder correctly and efficiently, you will need:

The soldering iron itself
Special stand
Solder
Flux
Additional tools

Soldering iron

There are many different models needed to solve a wide range of technical problems. But the main criterion is power. Based on power, they are divided into several types:

3-10 W. These are the lowest power models. They are designed for soldering the smallest and most sensitive microcircuits
20-40 W. They belong to the category of “household” or amateur radio. With their help you can solder a wire, a transistor or other part
60-100 W. If the wires requiring soldering are very thick, this type will do. It is often used by car enthusiasts or professional mechanics
100 W or more. With this soldering iron you can solder a thick wire, a pan or even a car radiator. They are used only by professionals, and for obvious reasons are not applicable in everyday life.

If you plan to solder radio components, a 25-watt tool will be sufficient. To solder a regular wire, the power should be enough, but for everyday use you should choose a model with 35 W or higher.

Stands are often sold as a set. They not only keep your workbench free of solder stains, but also allow you to always control the position of the tool. When working, it should be on the edge of the table. It is important to monitor the power cord.

Solder

This special low-melting alloy typically uses the following substances:

Or any other metal with a suitable melting point. The most fusible ones have a melting point of up to 80 degrees, and the most stable ones have a melting point of over 900.

POS 61 brand solder. The most convenient type is a thin wire.

Flux

This is the name of a special substance that acts as a connecting link between the solder and the metal of the wire. It helps solder adhesion, and successfully protects it from oxidation and helps degrease. The most popular brand is LTI 120.

If necessary, it can be done independently. To do this, just dissolve rosin in alcohol (about 60 to 40% ) and shake thoroughly.

Additional tool

To solder conveniently and safely with a soldering iron, you should acquire the following items:

Wire cutters. They bite off the wire, remove the insulation, and support the part during operation.
File – for cleaning the heating part of the soldering iron
Scalpel with tweezers. They will help you avoid burning your fingers when working with small parts.

Getting Started

The new soldering iron must be cleaned and tinned. You should plug it into the network for 15-20 minutes. In this case, the factory lubricant often begins to burn out, and the tool itself may smoke a little, this is not a big deal.

After warming up, you should carefully clean the work surface with a file, and then immediately dip it in solder. It is important not to let it oxidize. The tool is now ready for use.

It is important if the tip of your tool is made of metal ceramics. It cannot be processed with a file. There is a special damp cloth for this, and you need to gently wipe the surface with it.

How to solder a wire: process

It is very important to prepare the surface. There should be no foreign substances on it, such as grease, paint, varnish, or insulation residues. The success of all work depends on cleanliness. If there is anything, you should carefully clean it with a scalpel and wipe it so that no dust remains.

Next, you take a little solder with the tip and carefully solder it in the right place. This is not a very complicated process, but it requires a “tough” hand, and the very first time you are unlikely to get a beautiful and neat solder.

While working, it is worth remembering a number of rules:

Soldering must be fast
If you can't solder the wires right away, you should let them cool before the second attempt. This applies doubly to radio components or microcircuits
The end of the tool should be applied with the entire surface, the process will be most effective

How to solder wires more securely? You should twist them before starting the procedure. After cooling, they are insulated with electrical tape to avoid short circuits during operation.

A good solder is shiny, even, and free of any cracks. Then it will last as long as possible, and you will not have problems with the device.

Safety precautions

How to solder with a soldering iron without getting burned? Safety precautions must be observed. Working with a soldering iron is not the best time to try your luck with violating safety rules. There are some simple tips:

Clear the work surface of foreign objects
Remove overly curious children and animals from the room
Watch the cord - if you touch it with your foot or hand, there is a risk of burns
If there are strangers in the room, warn them that you are working with a soldering iron on.
Flux - just a little. If you use too much, it can splatter on your hand, or in the worst case, directly into your eyes.
Each time you should take no more solder than 2 solderings . If you overdo it, it can drip onto the table, hand, or even worse, onto the soldered chip.

By following these simple rules, you will protect yourself from extremely unpleasant consequences. If you take your work seriously and don't leave your soldering machine unattended, there shouldn't be any problems.

Solder the wires properly

The further operation of the entire device depends on how the wire is soldered. Experienced craftsmen give a number of tips for high-quality and reliable soldering:

If there is not enough solder, it will not be able to properly hold the parts together and fill all the gaps
If there is insufficient amount of flux on the tip, the soldering site turns out to be heterogeneous and uneven, which negatively affects the result. This can happen when the instrument is heated, then the rosin evaporates before soldering is completed.
When there is too much rosin, it can splash out and touch adjacent contacts or wires, and in the worst case, get on your hand

With experience comes the ability to heat the soldering iron to the desired temperature and use exactly as much solder as needed. Maintaining perfect balance, the solder independently takes the desired shape and flows correctly around the contacts. This is exactly what we need to strive for.

It is best to use soldering irons that have a thermostat. Then it is easy to maintain the desired temperature, which has a positive effect on the process and result of the work. A soldering iron without a regulator can quickly overheat, and its tip can turn black from oxidation. Then you have to turn it off periodically. Maintaining the required temperature is very difficult, and the soldering is not of sufficient quality.

How to solder efficiently with a soldering iron?

The best way to learn how to do something is to practice. Soldering is no exception. There are a number of exercises to help you master this undoubtedly complex but useful instrument.

You should take a bare or insulated wire (to practice stripping) and cut it into 12 equal pieces. To ensure that they are not too small, the optimal length is 30-40 centimeters (before cutting).

After cutting, you should take a soldering iron and form a cube from these blanks, using only a soldering iron and pliers. This will allow you to feel the instrument and get used to using it. Then the finished cooled cube should be taken in the palm of your hand and squeezed into a fist. The work is satisfactory if the adhesions remain intact. This can be practiced to keep your skills at a high level, even if you are an experienced professional and confident in yourself.

How to Solder Copper to Brass

The second method of training to work with a soldering iron requires thin wire and a stripped cable. It needs to be wrapped around a wire, and then carefully soldered using a soldering iron and pliers. You should practice until you can solder the wires well the first time. After this, you should begin normal responsible work.

Regular practice will allow you to achieve significant progress in soldering very quickly. In no time, you will be able to repair your radio, wiring (with caution), or other home appliances yourself. But before that, you should entrust this matter to specialists so as not to risk expensive items.

Source: https://ssk2121.com/kak-spayat-mednye-provoda-payalnikom/

A quick way to solder large diameter conductors

I will show you an easy and quick way to solder two different conductors using the example of a copper wire with a diameter of 2 mm, a copper plate, or an ordinary metal nail. The problem with soldering such conductors is the difficulty of uniformly heating the contact point.

It is almost impossible to ensure high-quality soldering using a household soldering iron, so we will not use this tool. The method is based on the use of a simple burner made from cheap materials that can be purchased in regular stores.

To make a compact burner we will need:

Cheap lighter with flint and wheel.
Plastic gel pen refill.
Syringe needle.
Hot glue gun.
Super glue.
Baking soda, used in baking.

Preparing to assemble the burner

Disassemble the gel pen, remove the refill, remove the metal writing element from it and get rid of the ink.
You should have a clean plastic tube in your hands. You can replace it with any plastic tube of the same diameter. For convenience, I recommend bending the plastic tube at a right angle.

Bring it to the flame of a lighter for a few seconds and gently bend it in the middle.
Take a lighter. Using pliers, remove the metal guard, remove the wheel, silicon and feed spring. Be careful not to damage the plastic gas lever.

We will need it to control the burner fire.

Gas burner assembly

Take a regular syringe needle. Do not throw away the cap, as it will be useful when storing the burner. Using a hot glue gun, connect one end of the plastic tube to the needle. Check the reliability and tightness of the fastening.

To connect the opposite end of the tube and the lighter you will need baking soda and superglue.

The tube must be secured to a plastic lever, which opens the gas supply valve. The tube must be fixed in such a way that the lever can move freely within the limits specified by the manufacturer to start and stop the gas supply. Gently sprinkle the mounting area with baking soda and apply superglue on top.

Check the operation of the compact gas burner by pressing the gas supply valve and applying a spark to the sharp end of the needle.
The quick soldering tool is ready.

Examples of soldering two conductors

For high-quality soldering of the twisted copper cables, we will use solder, rosin with alcohol and a manufactured torch.

Quick soldering process:

The twisting area must be cleaned and treated with a solution of rosin and alcohol.
We screw a piece of solder, made in the form of a thin wire, onto the joint.
We light a compact burner and bring the flame to the junction of the conductors.
We wait for uniform heating of the material and complete melting of the solder.
Let's wait until the solder cools down. To remove traces of soot, wipe the soldering area with a rag moistened with alcohol.
Check the connection quality.

Combining copper plate with copper wire

We proceed in the same way. We fix the conductors in a position convenient for soldering. We treat the joint with a solution of rosin and alcohol. Place a small piece of solder as close to the copper wire as possible. We take a torch and heat the contact area until the solder completely melts. If necessary, add the required amount of fixing material.

Soldering of different metals

Let's try the method using a metal nail and a piece of copper wire as an example. We wrap the stripped copper cable around a metal nail. Treat with rosin and alcohol. We wind solder between the turns of copper wire. We bring the flame of the burner to the joint and heat the material until the solder completely melts. To remove traces of burning, use a rag soaked in alcohol.

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Source: https://SdelaySam-SvoimiRukami.ru/4288-bystryy-sposob-payki-provodnikov-bolshogo-diametra.html

How to properly connect wires according to NASA standards

Friends! Today we’ll look at how to properly connect wires according to the NASA standard. Everyone knows that space technology is made as reliably as possible. And some systems and devices have double and triple redundancy.

Therefore, even for the connection of wires and harnesses inside space technology, the National Aeronautics and Space Administration NASA developed the STD 8739.4 standard in the sixth edition dated March 29, 2011. The standard itself contains 114 pages and there is no point in translating all of it. But I will give the main points.

This is so that there are no more disputes on the topic of how to most firmly and reliably connect two or more wires.

What types of wire connections does NASA use?

Let's start by connecting two wires. One of the most reliable connections is soldering wires. NASA recommends soldering two wires over an overlap length equal to 3 to 6 wire diameters.

It turns out that if the diameter of the wire is 1.6 mm, then two such wires need to be soldered to each other at a length of 4.8 to 9.6 mm without interlacing. As far as I understand, this is a general recommendation for all wire connections.

To understand how to tin wires with a soldering iron, you can watch the video below. It clearly shows how to use flux and solder for tinning wires.

You can do more overlap, but NASA doesn’t see the point in this. There is no point in increasing the weight of the spacecraft. We solder the connection of the wires so that there are no voids or places not covered with solder, then we insulate them with heat shrink. This is the easiest way to solder wires together.

A more advanced option is to connect two wires using wire and soldering. To solder two wires together with a soldering iron, NASA recommends making at least 6 turns of the wire. But so that they do not go beyond the overlap of the connection. Next, we thoroughly solder the twists of copper wires so that there are no voids or places not covered with solder and protect them with heat shrink.

The next method is soldering the wires and connecting using a crimp coupling. To ensure that the heat shrink does not fly far and expose the joint, additional sealing rings are placed on the cable braid. The metal of the crimp coupling is soft and fits the soldering area as tightly as possible. Heat shrinking provides additional protection against tearing. In my opinion, the crimp sleeve at least looks nice.

Next comes the connection, beloved by many craftsmen, using the method of wrapping on each other. Not to be confused with a connection by twisting two wires. In this connection, the wires are simultaneously tensilely bonded and a large area of electrical contact is provided. And if you also solder all this and heat-shrink it, then it turns out to be a fairy tale.

Now you can see how to properly solder wires with a soldering iron with your own hands. These methods are applicable not only on spaceships, but also at home. These methods are perfect for soldering copper or aluminum wires with a soldering iron for apartment electrical wiring.

Connecting wires without soldering

Next, we move on to a more technologically advanced method - this is a solderless crimp contact - it is a sleeve with a tail that is convenient to hold on to. The inner diameter of the contact sleeve must be selected slightly larger than the diameter of all the wires that need to be connected. After crimping with a special tool, the tail of the contact can be bitten off so as not to interfere and enclosed in heat shrink. The only drawback is the one-sided connection of the wires.

This disadvantage is eliminated using a crimp tube. You can insert more than just one cable into it on each side. But you have to select the diameter so that after crimping nothing dangles. Don't forget to put on heat shrink before crimping. Some craftsmen also solder the crimp tube for greater reliability.

How to heat shrink and knit according to NASA standards

It is better to heat shrink first from one end of the heat tube, and then from the other. This way you fix it in the right place. Next, we use a hairdryer or soldering iron along the heat shrink until it is completely compressed. Be careful not to damage the surface of the heat shrink.

How to properly connect cable harnesses is shown in the figure below. I don’t really see any philosophical meaning here, but let’s consider such weavings to be reliable space technologies.

That's all - I brought the most interesting things from the standard. I hope that the material “how to properly connect wires according to the NASA standard” will be useful to many. In the comments, share your favorite methods for connecting two wires. My favorite is wrapping wires on top of each other. Good luck to all!

Master Pike tried and translated.

P.S

Another interesting way to reliably connect two stranded wires.

Source: https://masterpaiki.ru/kak-soedinyat-provoda-po-standartu-nasa.html

Soldering strands of copper wires with a torch

Connecting wires is a necessary operation when carrying out electrical work. Each method of connecting electrical wiring (crimping, twisting, soldering) has its own conditions for use. Soldering copper wires and soldering aluminum wires is the most reliable method of contact connection; in terms of strength, it competes only with welding.

What is the process of soldering wires?

Soldering differs from welding in that during the work it is not the ends of the metal wires being connected that are melted, but only the solder. Soldering must be done with a soldering iron and flux. An alloy of metals (tin, lead, antimony, silver) that melt at a lower temperature is used as solder.

Solder melted with a soldering iron spreads, fills the gap between the metal wires and hardens, forming a strong, unbreakable connection. Soldering is reliable not only from a mechanical point of view, but also from an electrical point of view: the contact resistance of the conductors in the junction box depends on the contact area of the parts being connected - the larger it is, the lower the resistance.

This means that the wires heat up less and the connection is better.

Considering that a fire can be a consequence of poor contact, in hard-to-reach places it is more advisable to connect the wires by soldering, thereby eliminating the possibility of their disconnection. It is appropriate to solder conductors in the distribution box even if it is located above a suspended or suspended ceiling.

What is needed for soldering

To solder copper conductors, you will need the following devices, materials and tools:

Electric soldering iron with a power of 80 watts or more
Solder
Flux
Flux remover (neutralizer)
Pliers
Flux brush
PVC electrical tape
Heat shrink tube of suitable diameter
Hairdryer

You can solder copper wires not only with an electric soldering iron, but also with other equipment: a propane torch for soldering copper pipes, a mini gas torch, or a gas soldering iron with a torch attachment.

A burner with a small torch is convenient in that it provides local heating of the twist without damaging the conductor insulation.
Before using an electric soldering iron, its tip must be cleaned from oxides with a file or sandpaper. It is recommended to use POS-60 or analogues with a melting point of 190°C as a solder for copper.

Flux removes metal oxides, promotes better adhesion of solder and its uniform spreading over the surface. It is better to use water-based flux - it does not contain alcohol or acid, so it does not require subsequent removal. If you use orthophosphoric acid, liquid rosin or LTI-120 for this purpose, then the products must be removed from the surface after work - otherwise they will destroy copper parts over time.

Soldering procedure

Soldering copper wires is technologically simple; copper can be processed well without losing its conductive properties, while the joints are strong. Soldering of copper wires located in the junction box occurs in the following sequence.

The wires in the junction box are cut to the required length - 20–25 cm and correctly distributed by color: yellow-green is grounding, blue is zero, white (brown, red or black) is phase. Using special pullers, the insulation is removed from them, leaving bare ends 4.5–5 cm long.
Connect the wires crosswise - this is necessary to ensure that the twisting is uniform and tight. To make the twist correctly, one wire is placed on top of the other; to connect three conductors, the first is placed on top of the other two. They twist it, then crimp it using pliers, cut off the excess tails and crimp it again.
Before soldering, the twist is generously moistened with flux or placed in it.
To solder the wires correctly, the twist is heated with a soldering iron or torch until the flux begins to boil. As soon as the flux begins to boil, solder is placed on top of the twist. For soldering copper, use POS-60 solder or analogues. When using a soldering iron to connect wires, its tip is located at the bottom of the twist.
When the solder melts, it will spread under the action of tension forces and fill the twist, forming a reliable connection. The reddish copper color of the wires will take on a silver tint.
The last step is to isolate the junction. To do this, the soldered area is wrapped with PVC electrical tape, starting from the insulation that has not been removed. The adhesive layer of the electrical tape dries out over time, and the tape itself can unwind. Therefore, a heat-shrinkable tube of suitable diameter is put on top of it, which is heated with a hairdryer until it shrinks in size. It presses the electrical tape tightly and provides additional insulation.
Further soldering of wires in the distribution box - phase and neutral - is carried out in the same way.
After soldering and insulating the twists, the wires are carefully placed in the junction box and closed.

Specifics of connecting aluminum wires

The sequence of actions when working with aluminum wires is similar to that described above, but there are specific nuances that need to be taken into account.

Soldering aluminum conductors is technically more difficult due to the characteristics of the metal. The connection point is less durable than its copper counterparts.

Aluminum instantly oxidizes strongly, forming a non-conducting film. Oxides must be removed, otherwise the metal will not be able to be soldered. To remove oxides, use zinc-vaseline pastes. To solder the cores, you need aluminum solder, and it is more refractory than tin, so the heating temperature must be higher. When molten, aluminum solder is more fluid than tin solder. To work, you will need a chemically active flux F-34 or F-64, which can cope with oxides.

Since aluminum is a brittle metal, to ensure a reliable connection, it is better to solder it to a copper wire of the same cross-section. In this case, the too brittle and brittle aluminum conductor, together with flexible and durable copper wire, produces a strong connection that can withstand loads of up to 2 kW. The connection is reliable, soft and unbreakable. To solder aluminum and copper, it is better to use F-64 flux - it is stronger and even solders oxidized aluminum.

If the requirements and technical conditions are met, the soldered connection of copper or aluminum wires will last for decades without reducing contact or overheating of the soldering area.

Source: https://rem-serv.com/payka-skrutok-mednyh-provodov-gorelkoy/

Learning to solder wires - consideration of all the nuances of soldering

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