Is it possible to solder aluminum wires?

How to solder aluminum at home: solder for soldering, methods, features

The procedure for soldering aluminum elements at home is a very problematic process, which is facilitated by the use of special materials.

The work is complicated by the immediate appearance of a thin oxide film at the stripping site, which interferes with soldering. An additional difficulty is created by the material itself, which has a low melting point (+660 °C).

Using solder for soldering aluminum, special strong fluxes and following technology, you can independently solder almost any aluminum object.

Features and principles of soldering

The low temperature value of metal melting complicates the technological process of soldering, as well as repairing products with your own hands.

Parts very quickly lose strength when heated, and structures reduce stability when the temperature reaches 300 degrees.

Low-melting solders consisting of bismuth, cadmium, indium, and tin come into difficult contact with aluminum and do not provide sufficient strength. Excellent solubility is observed in the metal in combination with zinc, which makes the soldered areas highly reliable.

Before soldering begins, aluminum elements are well cleaned of oxides and dirt. To do this, you can use mechanical force with brushes or use special fluxes made from a potent composition. Before the procedure itself, be sure to tin the areas to be treated.

The tin coating will protect the part from the formation of oxides. In order to reliably solder aluminum products, it is necessary to choose the right heating tool, taking into account the volume of metal being processed.

In addition, the reliability of the connection depends on the alloy chosen, as well as the flux for soldering aluminum.

Soldering methods

Soldering of aluminum products is carried out with an electric soldering iron, a blowtorch or a gas torch. There are three ways to solder various aluminum objects:

• with rosin;
• using solders;
• electrochemical method.

With rosin

This option for soldering aluminum objects, wires, cables is used for small parts. To do this, the cleaned section of the electrical wire is covered with rosin and placed on a piece of sandpaper with a medium grain size. The wire is pressed from above with the tinned tip of a heated soldering iron. This action is carried out several times, after which the procedure of soldering the electrical wires itself is performed. You can use a rosin solution in diethyl ether.

In this case, the end of the soldering iron is not removed from the end being tinned, but rosin is added on top. An electric soldering iron with a power of about 50 W is suitable for twisting thin aluminum wires. With an aluminum thickness of about 1 mm, a 100 W soldering iron is required, and parts larger than 2 mm require preheating of the joint.

Using solders

This method is the most common and is used in electrical engineering, in the repair of automobile parts, as well as other products. Before soldering aluminum, the area to be soldered is pre-coated with an alloy and the tin-plated elements are subsequently connected. Pre-tinned parts are connected to each other, as well as to other alloys and metals.

Soldering of elements can be carried out using light alloy solders containing tin, zinc, and cadmium. In addition, refractory materials based on aluminum are actively used.

Why are light alloy compounds used? Because they allow you to solder an aluminum product at temperatures up to 400 degrees. This does not produce qualitative changes in the properties of the metal and maintains its strength.

Compositions with cadmium and tin do not create sufficient contact reliability and are susceptible to corrosive effects. Refractory materials containing zinc, copper, and aluminum-based silicon do not have these disadvantages.

Electrochemical method

This procedure requires a plating facility. With its help, copper plating is carried out on the surface of a product or wire. In its absence, independent processing of the part is used. To do this, apply a few drops of a saturated solution of copper sulfate to the area cleaned with sandpaper. After this, the negative pole of an independent power supply is connected to the workpiece.

They can be a battery, an accumulator, or any electrical rectifier. A cleaned copper wire with a diameter of about 1 mm, located in an insulated stand, is connected to the positive terminal. During the electrolysis process, copper will gradually deposit on the part, after which the area is tinning and dried using an electric soldering iron. After this, you can easily solder the tinned area.

Solders, materials, fluxes

Soldering of aluminum with tin is carried out subject to the use of highly active fluxes, as well as good cleaning of parts of the parts. Such tin compounds require additional coating with special compounds, since they have low strength and poor protection against corrosion processes.

How to solder aluminum elements? High-quality solder joints are obtained by using solders with silicon, aluminum, zinc, and copper. These materials are produced by both domestic and many foreign manufacturers.

Domestic brands of rods are represented by the most used solders TsOP40, which according to GOST contain 60% tin and 40% zinc, as well as 34A (aluminum - 66%, silicon - 6%, copper - 28%). The zinc used gives high strength to the contact area and provides good corrosion resistance.

Imported low-temperature alloys with excellent characteristics include HTS-2000, which provides maximum ease of use.

These alloys are used to work with large-sized parts (radiators, pipes) with high heat dissipation using a heating pad or objects made of aluminum alloys that have a fairly high melting temperature. Novice repairmen can familiarize themselves with the soldering process by watching an instructional video. This will help to avoid many unpleasant nuances during the work process.

In addition to solders, aluminum soldering requires the use of special fluxes containing ammonium fluoroborate, zinc fluoroborate, as well as triethanolamine and other elements. The most popular is the domestic F64, which has increased chemical activity. It can be used even without first removing the oxide film from products. In addition to it, 34A is used, containing lithium, potassium and zinc chlorides, as well as sodium fluoride.

Preparation of products

Reliability, as well as excellent quality of connections, is ensured not only by using the right technology, but also by preparatory work. These include the treatment of sealed surfaces. It is necessary to remove contaminants and thin oxide films.

Mechanical processing is carried out using sandpaper, a metal brush, stainless steel wire mesh or a grinding machine. In addition, various acid solutions are used for cleaning.

Surface degreasing is carried out using solvents, as well as gasoline or acetone. On the cleaned aluminum area, an oxide film appears almost immediately, but its thickness is significantly lower than the original one, which facilitates the soldering process.

Heating tools

How to solder aluminum at home? Electric soldering irons are used to solder small-sized aluminum products at home. They are a universal tool, quite convenient for soldering wires, repairing small tubes and other elements.

They require a minimum of working space, as well as the presence of an electrical network. Repair of large-sized products and welding are performed with a gas torch that uses argon, butane, and propane.

To solder aluminum objects at home, you can use a standard blowtorch.

When using gas burners, it is necessary to constantly monitor their flame, which characterizes a balanced supply of oxygen and gases. With the correct gas mixture, the fiery tongue has a bright blue color. A dim hue, as well as a small flame, indicate an excess of oxygen.

Technological process

The technology for soldering aluminum objects is similar to the process of joining parts of other metal materials. The first step is to clean and degrease the areas of future adhesion. Then the connected elements are installed in working position for ease of processing.

Flux is applied to the prepared area, and the initially cold product begins to heat up using an electric soldering iron or a torch. As the temperature rises, the solder bar begins to melt, which must constantly touch the surface of the elements, controlling the heating process.

Soldering aluminum elements at home with an electric soldering iron is done in a well-ventilated room, as hazardous compounds are released during operation.

Using flux-free solder requires compliance with some nuances. To prevent the oxide film from interfering with the alloy getting onto the parts, the end of the rod makes scratching movements along the area where the elements are soldered. This breaks the oxide integrity and the solder comes into contact with the metal being processed.

Destruction of the oxide layer during soldering can be done using another method. To do this, the area to be treated is scratched with a metal brush or a stainless steel rod.

To ensure maximum strength of aluminum parts in the soldered area, the treated areas are pre-tinned. Compliance with the technology of soldering aluminum elements guarantees excellent quality of the connection, as well as its protection against corrosion.

Source: https://oxmetall.ru/pajka/kak-payat-alyuminij

Rod for soldering aluminum at home / Tools / iXBT Live

Hi all! Many people know that aluminum is soldered mainly in an argon atmosphere with a special welding machine, but there is also an option for working with a gas torch, and even a turbo lighter can be used on a small scale.

In general, this is not my first acquaintance with this wire, but the shopping experience is not very good, so I will share not only the test result, but also trusted places to buy so as not to get sample No. 2 , but let’s start in order.

• Characteristics
• Unboxing and appearance
• Testing
• Results

Characteristics

Diameter: 2.0 mm
Length: 500 mm
Soft solder ISO 3677: ~B-Zn98Al 381-400
Approximate composition (weight%): 2.4 Al – rest Zn
Melting point ºС: 360
Tensile strength (MPa): Up to 100 (Al)
Density (g/cm3): 7.0

Unboxing and appearance

The last and most profitable purchase was sample No. 3 from banggood.

Came in a small gray package

The rod is additionally packaged in a transparent zip bag.

5 meters cost me $8 with points, that is $1.6 per meter - go to the store

White powdery flux is visible in the center, the rod is moderately hard, looks like aluminum without oxidation

Comparison

The first one I bought was the leftmost sample No. 1 from Ali. Its properties are absolutely identical to sample No. 3 , but 3 meters cost me $12 , that is, $4 per meter , which is almost three times more expensive. check current price

In the center is sample No. 2 . It costs $5 for 3 meters or $1.7 per meter , like sample No. 3

But as soon as you take the bag in your hand, you realize that this is a POS with not very thick flux inside.

don't buy here

Two more samples at $8 for 3 meters were never delivered, they were probably not even sent.

Testing

Over time, aluminum becomes covered with an oxide film, due to which the surface becomes dull, so, before soldering, the surfaces must be cleaned to a shine, otherwise the solder will simply roll off in balls on the surface, regardless of the degree of its heating. Sample No. 1

 In general, it is correct to heat the part to a temperature of about 400 degrees, and then simply move the rod, which will melt and fill the cracks, but I have little experience, so in order not to overheat the surface, I periodically bring the rod into the burner flame. If the temperature is low, the solder will roll down the surface like a ball; if it is sufficiently high, it will tin it.

 The fracture test shows a good result - the break does not occur along the seam

Sample No. 2 . It melts very well, emits a lot of smoke, and smells like burnt “aspirin.” It sticks to aluminum, but if you overheat it, it burns out pretty quickly.

It is inconvenient to work due to the stench and the need to control the temperature.

Sample No. 3 . I decided to solder the tubes with the outer walls

We try to break the seam. After the tube came out of the vice, I clamped it higher, bringing it out of focus and only noticed this at the stage of creating GIFs

But there is a photo of the result which shows that the seam was not damaged.

And finally, let’s splice the aluminum tube with a piece of duralumin.

 The tear test was also successful.

Results

An interesting wire - aluminum solders perfectly, filling even small gaps, the main thing is that the joints are not dirty. It also sticks well to copper, but experienced people say that it is better to use other alloys to work with it, although this rod is quite suitable for emergency field repairs.

The melting point of aluminum is about 660ºC, it would seem that you can use rods at 450-500 degrees, but you may encounter two problems:
1. A massive part needs to be heated up to 500 degrees with something else
2. You can overheat the soldering area and ruin the part

Sample No. 3 seemed to me the most optimal .
It corresponds to the declared characteristics and costs at least half as much as the others. There are also lots of different lengths to choose from: 1 meter - $2.89
2 meters - $4.39
3 meters - $6.39
5 meters - $9.89

go to the store

Source: https://www.ixbt.com/live/instruments/prutok-dlya-payki-alyuminiya-v-domashnih-usloviyah.html

How to solder aluminum with tin yourself

Soldering wire connections with solder is considered the most reliable method of connecting wires and cable cores. It’s good if you only need to solder copper wires, which are easily tinned with solder. It’s not for nothing that in electronics all terminals of elements are copper and tinned.

Soldering aluminum at home

Once solid wires and stranded cable strands are tinned, they are fairly easy to connect by soldering. How to solder aluminum with tin if the solder is rejected by aluminum oxide. As you know, aluminum is coated with a thin layer of oxide, which instantly forms on aluminum upon contact with oxygen. In order for the solder to adhere well to the aluminum wire, you need to remove the aluminum oxide and then tin it.

For this purpose, the following fluxes exist: soldering acid, special fluxes for aluminum, and a mixture of rosin and acetone. All these advantages destroy or hinder the formation of an oxide film on aluminum. After using this type of flux, the process of tinning aluminum is simplified.

The necessary tools for soldering aluminum with tin are: an electric soldering iron, a sharp knife, pliers for twisting wires, a small file for preparing the soldering iron tip. The materials you will need are: POS 61 or POS 50 solder, flux for soldering aluminum F-64 or similar, sponge.

Soldering aluminum with tin and flux F 64

Flux F 64 is intended for soldering aluminum. The soldering technique is not complicated. First of all, you need to remove 5 cm of insulation from the wires. The insulation is removed with a sharp knife at an angle to the wire so as not to cut it. Notched aluminum breaks off easily.

Tools and materials for soldering aluminum wire

Next, you need to thoroughly clean the wire with fine sandpaper or a sharp knife. Having stripped the wire, it is moistened with a brush with a plus and with a sharp knife they continue to strip the wire, but now under flux. In this way, the oxide film of the aluminum wire is removed, preventing it from oxidizing again in air. Next, using a heated soldering iron with solder, begin tinning the wire from its end.

If you start tinning the wire near the insulation, then you can burn it. In this case, the insulating properties of the wire will be lost. The wire is tinned with a soldering iron, moving back and forth, while the oxide film is removed from the aluminum. It is not possible to tin the wire straight away. Therefore, flux is again applied to the non-tinned sections of the wire and sections of the remaining oxide film are removed with a hot soldering iron with solder and movements back and forth and serviced.

In this way, the aluminum wire is completely covered with solder. After tinning, the aluminum wire is dipped in a soda solution (5 tablespoons per 200 grams of water) and the remaining flux is washed off with a toothbrush. The flux contains active acids that not only corrode the film, but also the wire itself. Therefore, the remaining flux must be washed off. It will not be possible to wash it off completely, since it partially remains under the solder and eats into the wire.

But at least partially it needs to be washed off. Copper wire is not treated with F 64 flux; it is better to use a solution of rosin and alcohol (50% to 50%). Using a brush, apply liquid rosin to the copper wire (having previously stripped it) and use a hot soldering iron to service the wire, starting from the end. The soldering iron tip should be smooth and clean. The shells at the end of the soldering iron tip are removed with a fine file.

And the remains of burnt solder (slag) are wiped off with a sponge or rag. Once the aluminum and copper wires are tinned, they are twisted with pliers, liquid rosin is applied with a brush and the connection is soldered, also starting from the end. If you connect aluminum without tinning with solder, the connection may break down over time. The aluminum-copper connection is a galvanic couple, and when current passes through it, it heats up and destroys the connection.

Table of temperature conditions of solder brands

As a result, the twisted area becomes very hot and charred, which increases the fire hazard. Tin solder is neutral to aluminum, so aluminum wires must be tinned before connecting to copper. POS 61 and POS 50 solders with a low melting point of 190 - 210C are well suited for soldering aluminum wires.

Soldering aluminum with copper, tin and rosin

Soldering electrical wires using soldering acid is prohibited in the PUE. This is due to the fact that this acid does not burn completely during soldering. As a result, the junction of the wires is corroded by acid over time, oxides are formed, which heat up when current passes and can cause the insulation to catch fire. These acid-containing fluxes include special fluxes for soldering aluminum, including F 64.

So how to solder aluminum with copper so that the connection is high-quality and durable. In terms of complexity, the method of tinning aluminum with tin and rosin is even easier than tinning aluminum with F 64 flux. But the quality and reliability when tinning with rosin will be high. When tinning aluminum in rosin, you need to make or select a low bath for liquid rosin (rosin 60% and alcohol 40%).

Fluxes for aluminum soldering

Fill the bath with liquid rosin so that the wire is buried in it with 5-10 mm of insulation. The wire, stripped of insulation, is placed in rosin and with a sharp knife (conveniently a scalpel) the oxide film is removed from the aluminum wire without removing it from the bath. That is, under rosin they protect the wire along its entire length from all sides. Under the rosin, a film does not form on the cleaned areas of the aluminum wire, since there is no contact with oxygen.

Now take a heated soldering iron with solder with a power of at least 60 W and lower it onto the bare and free of oxide wire, right at the surface of the rosin, little by little scroll and pull out the already tinned sections of the wire. The essence of the method is that the wire is tinned at the very surface of the liquid rosin. So that the stripped sections of the wire from oxide cannot come into contact with air.

The soldering iron can be immersed 2-3 mm in rosin at times. After tinning the wire a little, lift the soldering iron so that it heats up again. Yes, at the beginning, there will be a lot of smoke, so it is better to learn to solder outdoors or in a room with good ventilation. After several attempts, you will develop your own tinning technique and gain a little experience.

You will decide on the position of the soldering iron, the speed of tinning the wire will increase, that is, skill will appear, and the amount of smoke will decrease. But the wire will be perfectly tinned. Next, as usual, twist the wires and solder them with a small amount of solder.

The remaining rosin on the soldered twisted wires is washed off with a brush and alcohol. The disadvantage of this method is the impossibility of soldering in hard-to-reach places. For such cases, it is better to use other methods for safely connecting aluminum to copper.

Source: http://electricavdome.ru/kak-payat-alyuminij-olovom-svoimi-rukami.html

How to solder aluminum at home with a soldering iron

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Aluminum is highly durable and a good conductor of heat and electricity. It has a low specific gravity, is easy to process, and is environmentally friendly. However, all these positive qualities create almost insurmountable obstacles when solving the problem of how to solder aluminum at home with a soldering iron. This cannot be done using traditional methods, so you have to use special welding methods and optimally selected materials.

Technical difficulties in soldering aluminum products and parts

Soldering aluminum structures and other elements is always quite difficult, especially if it is done at home by novice craftsmen who have not fully studied the process. Basically, such soldering is performed industrially using special equipment. However, it is quite possible to create the most suitable conditions for welding parts made of aluminum.

To achieve this goal, it is necessary to resolve several technical problems:

• The biggest problem when soldering is caused by oxidation in the form of a film that appears on the surface as a result of contact between aluminum and air. Even if the metal is prepared, a coating forms on it almost immediately afterward. Such a film coating interferes with the joining process and adds many problems during the tinning and soldering process. In this situation, conventional types of solders and fluxes are completely unsuitable, since they do not guarantee a high-quality connection. The film is removed either by physical-mechanical means or with the help of strong chemicals.
• One should also take into account the high temperatures at which aluminum begins to melt. It reaches a maximum of 6000C. A temperature difference arises between the metal being soldered and its film, causing difficulties in the soldering process.
• Due to the temperature regime, aluminum begins to noticeably lose its strength during the heating process. This moment occurs when the material being welded is heated to 250-300 degrees. Some aluminum alloys contain components whose melting point differs from the base metal.
• Weak interaction of aluminum with traditional types of solders, consisting mainly of tin, cadmium and other elements. This leads to insufficient strength characteristics and reliability of the created seams. The problem of how to solder is solved using special solders containing zinc, which, in turn, has excellent contact with aluminum and penetrates into it. Adhesion occurs at the molecular level, providing the necessary strength of the connection.

Preparation for soldering aluminum parts

Great importance is attached to preparing aluminum for upcoming soldering.

There are several ways to do this to ensure connection reliability:

• The connection area is pre-degreased and treated with rosin. After the substance is applied to the surface, sandpaper is placed here. Next, you need to turn on a powerful soldering iron and press the sandpaper firmly against the surface.
• After this, the surface is rubbed and polished, and the joint itself is simultaneously tinning. An aluminum part is installed on the prepared surface, which can be soldered according to the usual scheme. If necessary, rosin can be replaced with oil used in sewing machines.
• In the second option, metal shavings are added to the rosin, after which the resulting mixture is applied to the surface of the future joint. The soldering iron tip needs to be well heated and tinned, and then rub it over the entire working surface of the parts to be soldered until the chips melt. At the same time, solder is added here. In this case, the oxide is removed mechanically, and the solder immediately falls on the surface and protects it from the reappearance of the oxide film.
• The third method is to pre-clean the surface. For this purpose, copper is used, through which the oxide film is removed. This method is one of the most difficult, since copper plating of the surface must be carried out in a special bath.

Selection of solder and flux for aluminum

Tin- and lead-based solders can be used to weld wires, elements and parts made of aluminum, provided they are thoroughly cleaned. Such soldering must be carried out using special flux solutions consisting of highly active substances.

However, such connections have insufficient strength due to the weak interaction of aluminum products with tin and lead, and the tendency to form corrosion. Therefore, special compounds are used in the form of anti-corrosion coating for surfaces made of this metal.

These compounds include solders containing copper, zinc, aluminum and silicon. They are produced both in our country and abroad. Among domestic brands, the most widely used is TsOP-40, which contains 40% zinc and 60% tin, as well as compound 34A with aluminum (66%), copper (28%) and silicon (6%). zinc affects not only the strength of aluminum contacts, but also their resistance to corrosion.

Of all the known solders, the minimum temperature at which they begin to melt is those based on tin and lead. The highest melting point belongs to compounds with an aluminum-silicon structure, as well as with aluminum, copper and silicon.

In the first case, similar types of solders melt when the temperature reaches 590-600 degrees, and in the second - at 530-550 degrees.

They are selected for each specific case, when parts with large dimensions, with good heat dissipation or refractory aluminum connections are connected.

Technological processes are inextricably linked with special types of fluxes used for better interaction of all welding components.

Selecting the most suitable material is considered a rather difficult undertaking. This is especially important when the process uses tin-lead solder. The structure of such fluxes includes elements that form its increased activity when interacting with aluminum. Among them are triethanolamine, ammonium fluoroborate, zinc fluoroborate and other similar components.

One of the most popular flux substances produced in Russia is the F64 substance, which is characterized by high activity. The quality of this connection allows you to solder metal parts made of aluminum without removing the refractory oxide coating located on the surface.

Soldering aluminum components

The procedure and technical process for welding aluminum are exactly the same as for other types of non-ferrous metals.

Among home craftsmen, the following two options are most often used:

• High-temperature soldering used for welding large-sized elements. This category includes aluminum structures with thick walls and increased mass, which require a temperature of 550-6500C to heat up.
• Soldering at low temperatures of 250-3000C, which is quite enough for installing wires of electronic equipment and welding small items used in everyday life. Aluminum wires are connected in the same mode in any electrical network.

Connections at high temperatures occur using special heating elements. One of them is a burner, which requires gas in the form of propane or butane to operate. If such a burner is not available, home craftsmen use various types of blowtorches.

Welding at high temperatures requires constant control over the degree of heating of the surfaces of the parts being joined. To do this, take one of the refractory solders in a small amount, and after it begins to melt, we can talk about reaching the desired temperature.

In this case, the heating of the part stops, otherwise it will simply melt and collapse.

Soldering at low temperatures is carried out with a 100-200 W electric soldering iron. The power of a soldering iron depends on the size of the components being connected: the larger the part, the more powerful a soldering iron will be required to heat it up. The conductors are easily connected with a 50 W soldering iron.

Regardless of the temperature conditions, connections are made in the same way, and all actions are performed in the following order:

• The place of future connection of parts or cables is processed mechanically. For this purpose, any cleaning agents are used that weaken oxidative deposits, providing more complete interaction with the flux substance.
• The joint must be degreased with acetone, gasoline, alcohol and other organic solvents.
• Before soldering aluminum with a soldering iron or torch at home, the parts are firmly fixed in the most convenient position.
• Flux is applied to the prepared surface. If the substance is used in liquid form, it is applied with a brush.
• The connection point is heated using an electric soldering iron of sufficient power or a gas burner. Next, molten solder is applied here and distributed in an even layer.
• Metal surfaces are connected and fixed in the desired position.
• After the solder has cooled and the parts have set, the joint is washed with running water. Flux residues are washed away and do not cause corrosion in the future.

Source: https://electric-220.ru/news/kak_pajat_aljuminij_v_domashnikh_uslovijakh_pajalnikom/2018-11-20-1605

Soldering aluminum at home: instructions

There is a widespread belief that it is impossible to solder or tin aluminum (as well as alloys based on it) without special equipment for this.

Two factors are cited as an argument:

1. upon contact with air, a chemically resistant and refractory oxide film (AL2O3) is formed on the surface of the aluminum part, resulting in an obstacle to the tinning process;
2. The soldering process is significantly complicated by the fact that aluminum melts at a temperature of 660°C (for alloys this ranges from 500 to 640°C). In addition, the metal loses strength when, during the heating process, its temperature rises to 300°C (for alloys up to 250°C), which can cause a violation of the stability of aluminum structures.

Considering the above factors, it is truly impossible to solder aluminum using conventional means. The use of strong fluxes in combination with the use of special solders will help solve the problem. Let us consider these materials in detail.

Solder

Commonly used low-melting solder bases are tin (Sn), lead (Pb), cadmium (Cd), bismuth (Bi) and zinc (Zn). The problem is that aluminum is practically insoluble in these metals (with the exception of zinc), which makes the connection unreliable.

By using a flux with high activity and properly treating the joints, you can use tin-lead solder, but it is better to avoid such a solution. Moreover, a solder joint based on the Sn-Pb system has low corrosion resistance. Applying a paint coating to the soldering area allows you to get rid of this drawback.

For soldering aluminum parts, it is advisable to use solder based on silicon, copper, aluminum, silver or zinc. For example 34A, which consists of aluminum (66%), copper (28%) and silicon (6%), or the more common TsOP-40 (Sn - 60%, Zn - 40%).

Domestic solder – TsOP-40

Note that the higher the percentage of zinc in the solder, the stronger the connection and the higher its resistance to corrosion.

High-temperature solder is considered to be solder consisting of metals such as copper, silicon and aluminum. For example, like the above-mentioned domestic solder 34A, or its foreign analogue “Aluminium-13”, which contains 87% aluminum and 13% silicon, which allows soldering at temperatures from 590 to 600°C.

"Aluminum-13" produced by Chemet

Flux

When choosing a flux, it is necessary to take into account that not all of them can be active towards aluminum. We can recommend using products from a domestic manufacturer for such purposes - F-59A, F-61A, F-64, they consist of ammonium fluoroborates with the addition of triethanolamine. As a rule, the bottle is marked “for aluminum” or “for aluminum soldering.”

Domestic flux

For high-temperature soldering, you should purchase flux produced under the brand 34A. It consists of potassium chloride (50%), lithium chloride (32%), sodium fluoride (10%) and zinc chloride (8%). This composition is most optimal if high-temperature soldering is performed.

Recommended flux for packing at high temperatures

Surface preparation

Before you begin tinning, you must complete the following steps:

• degrease the surface using acetone, gasoline or any other solvent;
• remove the oxide film from the place where soldering will be performed. For cleaning, use sandpaper, an abrasive wheel or a brush with steel wire bristles. As an alternative, etching can be used, but this procedure is not so common due to its specificity.

It should be taken into account that it will not be possible to completely remove the oxide film, since a new formation will immediately appear in the cleaned area. Therefore, stripping is carried out not with the goal of completely removing the film, but to reduce its thickness in order to simplify the task of the flux.

Heating the soldering area

To solder small parts, you can use a soldering iron with a power of at least 100W. Massive items will require a more powerful heating tool.

Soldering iron 300 Watt

The best option for heating is to use a gas burner or blowtorch.

Simple gas burner

When using a burner as a heating tool, the following nuances should be taken into account:

• Do not overheat the base metal, as it may melt. Therefore, it is necessary to regularly monitor the temperature during the process. This can be done by touching the solder to the heated element. Melting the solder will let you know that the required temperature has been reached;
• Oxygen should not be used to enrich the gas mixture, since it promotes strong oxidation of the metal surface.

Soldering instructions

The process of soldering aluminum parts does not have its own distinctive features; it is carried out in the same way as with steel or copper.

The algorithm of actions is as follows:

• the soldering area is degreased and cleaned;
• the parts are fixed in the desired position;
• the connection area heats up;
• touch the solder rod (containing active flux) to the joint. If flux-free solder is used, then flux is applied to destroy the oxide film, after which a solid piece of solder is rubbed over the soldering area.

A brush with steel wire bristles is also used to break down the aluminum oxide film. This simple tool is used to rub molten solder over an aluminum surface.

Soldering aluminum - complete video instructions

Source: https://www.asutpp.ru/pajka-alyuminiya.html

How to solder aluminum at home, features of aluminum soldering

Soldering aluminum is a difficult process to do at home. The complexity is explained by the properties of the metal, which make it difficult to connect individual aluminum parts with other substances. Aluminum must be joined in compliance with specially developed technologies that ensure the quality of soldering. What matters is the experience of the craftsman who joins aluminum parts by soldering.

Why is aluminum difficult to solder?

Many people have tried to solder aluminum at home and understand well: the solder does not want to stick to the surface of the parts. This occurs due to the formation of a stable oxide film on the metal, which has low adhesion to the solder material. Methods for soldering aluminum at home come down to fighting the protective film.

In mineralogy, aluminum oxide is called corundum. It consists of transparent crystals, which are gemstones. Corundum has different colors depending on the impurities: chromium gives a reddish tint, sapphire gives a bluish tint. The oxide film is highly durable and cannot be soldered. It must be removed from the surface and then begin to solder the parts.

How to remove oxide film

The film is removed from the metal surface in several ways, the most effective being chemical and mechanical. Both methods require an airless environment in which there is no oxygen to work.

The chemical method is based on the deposition of zinc or copper on the surface of the workpiece by electrolysis. Copper sulfate in the form of a concentrated solution is applied to the area prepared for soldering.

The negative terminal of a battery or other power source is attached to a clean area of ​​metal. One end of the copper wire is connected to the positive terminal, the other is dipped into a solution on the surface of the aluminum.

As a result of electrolysis, copper or zinc is deposited in a thin layer on the aluminum and adheres tightly to it. Now you can solder aluminum with tin.

An oil film is used to remove the oxide. For this method, it is better to use synthetic or transformer oil with a low water content. Other types of oils need to be kept at a temperature of +150+200°C, the water will evaporate. At higher temperatures, the contents will begin to splatter. Dehydrated oil is applied to the surface of the aluminum part. Use sandpaper to rub the aluminum under the applied layer to remove the oxide.

The emery cloth is replaced with a scalpel, a serrated soldering iron tip, or iron filings obtained from a nail rubbed with a file. The shavings are poured onto the oil and the soldering iron tip is rubbed over the surface, removing the oxide layer. It is advisable to heat a massive part with a hot air stream. The solder is dipped into the oil droplet with a soldering iron and rubbed over the soldering area. To improve the soldering process, rosin or other flux is added.

Source: https://odinelectric.ru/knowledgebase/kak-spayat-alyuminij-v-domashnih-usloviyah

Rules for soldering aluminum and copper wires

The most common connection method in modern electrical wiring is soldering wires. This method is characterized by a high degree of reliability of the electrical connection, which in turn ensures high fire safety and overall operational safety. We will consider below how to achieve the desired result and perform this work correctly and safely.

Let's start with preparation. Next, the theoretical and practical aspects of soldering copper and aluminum conductors will be described. We probably won’t consider in detail the choice between copper and aluminum. We only note that although copper costs more, it is significantly superior to aluminum wiring in quality and durability. So, for your attention, the order of soldering wires in the junction box.

What tools and materials will be needed?

The choice of tools and materials we need will be determined by our specific goals, as well as the soldering methods used. The main tool used is either an electric soldering iron or a gas torch. Well, then there will be, in general, a standard soldering kit. We will need:

1. Knife for cutting wire insulation - do not forget to sharpen it or use a stationery knife. You can also make an electrician's knife with your own hands.
2. Pliers for twisting conductors.
3. Solder and flux. Flux is a substance with which we remove oxidation from the surface we solder. Solder is what is used to directly solder the wires.
4. File – a fine file will do.

When soldering wires with a soldering iron or gas torch, different solders and fluxes can be used. So, for copper conductors you need solder based on a mixture of tin and lead - these are solders of the POS-40, POS-50, POS-60 brands. The following grades are suitable for soldering aluminum wires: P-250A (zinc and tin), TsO-12 (zinc and tin), TsA-15 (zinc and aluminum), A (zinc, tin, copper).

Rosin is used as a flux - an organic material containing a mixture of resin acids from coniferous trees. Rosin is the most common and inexpensive option. There are also methods of soldering with acid as a flux, but it is not recommended to use them because they are harmful. In addition, acid causes corrosion on the twist over time.

Let's solder!

When all the necessary tools and materials are ready, we get to work. Let's consider the technology of soldering copper wires in a junction box. At home, the most common connection method is soldering twists of single-core conductors. We strip them of insulation - remove 4-5 cm from each end. For good quality twists, you should twist them tightly and crimp the ends with pliers.

Just don’t overdo it, otherwise you may break off the current-carrying wire. We take a soldering iron in our hands, which should be warm enough, and begin to saturate our twist with rosin so that it penetrates between the wires as best as possible. Then solder, consisting of tin and lead, is applied to the soldering iron tip, and by gradually heating the joint, we achieve uniform application of solder. It should penetrate well between the wires.

When they “paint” silver, they can be considered tinned.

To tin a stranded copper conductor, you need to twist all the small strands well into one strand and tighten them with pliers. Then apply rosin with a soldering iron first, and then the desired solder.

A distinctive feature of soldering aluminum wires is the high degree of oxidation of aluminum in air. And if the wires oxidize, then applying solder to them during electrical installation will be problematic. Therefore, you will have to constantly mechanically clean the surface from oxidation and at the same time perform tinning. A gas burner is used for heating, and the flux is selected based on the soldering method and the cross-section of the wire.

Using a knife, carefully cut off the insulation from the cores by about 5 cm. Clean the surface until a characteristic shine appears using the same knife or use sandpaper.

Next, you need to connect the cores in the form of a groove, which is formed as a result of overlapping cores, using the double twist method. We take a torch and begin to heat the twist to approximately the melting temperature of the solder. We continue to heat the connection and rub the soldering area with a special solder stick.

The groove will fill with solder. The entire surface is treated in the same way until it is completely covered with tin.

Some features of the process

We also recommend paying attention to several rules that will help you do high-quality soldering of wires with your own hands.

Check the soldering iron tip before starting work. It must be clean. If there are irregularities, cavities, and black carbon deposits on it, then such a tip must be cleaned, otherwise it will not be able to take solder normally.

Take a small file, place the tip on it at an angle and clean it so that the shine of the copper is visible. Then re-tin the end. While working, sometimes pay attention to its condition and try to keep it clean.

You can also use fine sandpaper to clean the soldering iron tip.

We always start soldering from the side of the core farthest from the insulation, since it can melt and its properties will be impaired, which is unacceptable. Carefully twist the connections with pliers, without unnecessary effort, so as not to break the wires, especially for aluminum electrical wiring, which is especially brittle.

Before applying solder, even to connecting copper wires, try cleaning the surface of the wire with a knife until it shines; you will see that the solder is applied much easier. This applies to both copper, single-core and stranded, and aluminum conductors.

Do not forget to carefully insulate the joints at the end of the work. Cotton or polyvinyl chloride insulation should be used for these purposes. Wrap them around the twists so that the insulation extends a few centimeters from the bare area.

Despite the fact that soldering is not a super fast method, it provides a good quality connection. And everything that is described, taken together, will help you increase the safety of your work, as well as increase the service life and reliability of electrical wiring.

Finally, we recommend that you watch a video that discusses in detail the technologies for soldering electrical wiring in junction boxes:

Using a gas burner

Using a special soldering iron for pipes

So we looked at how to solder wires in a junction box. We hope the instructions provided were useful and understandable for you!

Source: https://www.remontostroitel.ru/pravila-pajki-alyuminievyh-i-mednyh-provodov.html

Soldering aluminum wires

Due to its physical and mechanical properties, aluminum is very often used to create various products. In addition to its lightness and relatively high strength, the metal has good conductivity, so wires are made from it for various electrical installations.

Soldering aluminum wires is a thin and delicate process, since the thickness of the metal in them is low, which complicates the soldering process, and the properties of the metal itself do not contribute to obtaining a high-quality connection unless additional devices and tools are used.

Most movements have to be done quickly and clearly so as not to burn the wires themselves.

Soldering aluminum wires

Like welding aluminum, this process is complicated by the fight against oxides and other things. But, due to frequent use, people have to deal with it, both in industrial and at home conditions. Due to the thinness of the wires themselves, soldering aluminum contacts does not require particularly powerful equipment.

Also, there are no high requirements for the strength of the future connection, because high mechanical loads are not expected here. This simplifies the process of choosing solder for soldering aluminum.

The main thing here is to observe the principle of maintaining high electrical conductivity so that the contacts do not overheat due to increased resistance.

Soldering aluminum wires

Solderability of aluminum wires

Soldering aluminum wires is complicated by a number of several factors that prevent a normal connection. They are caused by the properties of the metal and the characteristics of the work.

The main enemy here is the oxide film, which covers aluminum surfaces upon any contact with air, and in a relatively short period of time.

It does not melt at the temperatures at which aluminum itself melts, not to mention the melting temperature of solder, so the oxide film prevents the formation of a strong contact, enveloping the solder metal.

When heated, aluminum does not change color and it is difficult to determine whether it is warm enough for soldering. Thus, soldering an aluminum wire may result in damage to the wire itself.

Despite the fact that the solderability of metal is considered low, professionals often have to deal with it and to deal with difficult issues, they use various means, each of which helps solve the problem.

Aluminum interacts poorly with other elements, so if you have to solder two different wires, the solderability becomes even worse. Soldering of aluminum wires to each other occurs in accordance with GOST 21930-76.

Difficulties in soldering aluminum wires

In addition to the oxide film and the lack of visual control over the heating temperature of the metal, there are several other difficulties. Soldering aluminum single-core wires should be carried out in just a few seconds so as not to damage the wire itself. The temperature effect on aluminum changes the structure of the metal, as a result of which it loses its strength and flexibility.

Soldering aluminum with a soldering iron at home

Almost all procedures, regardless of what type of soldering is used, must undergo a full range of preparatory procedures, which includes tinning, fluxing and stripping.

It is precisely such procedures that help eliminate the oxide film, due to which the bulk of soldering defects are obtained. Another difficulty is the correct choice of parameters, since discounts with thin elements require a delicate approach.

At the same time, the small thickness of the products helps to easily produce everything at home without any obvious loss of quality.

Methods for soldering aluminum wires

Soldering aluminum wires at home can be done in several ways. One of the main ones is soldering aluminum wires with a soldering iron, as this is one of the simplest and most common tools that is found in every home.

It is enough to select a soldering iron of the required power to melt the solder and make the connection. Unlike other methods, it is the easiest to prepare, but requires that there be a source of electricity nearby.

Unlike a torch, a soldering iron is a more crude method, so it may not be suitable for working with materials that are too thin.

Soldering aluminum with a soldering iron

The method using a burner, which can be gas or gasoline, helps to carry out more delicate procedures, since it is easier to regulate the temperature and the gas perfectly warms up not only the wire and solder itself, but also the areas that are located next to them. Preparing the burner is a longer procedure, since it needs to be refueled, the mode selected, and so on. This is also a less safe option, but after all, you don’t need to wait until the tool cools down for a long time, as happens when working with a soldering iron.

Soldering aluminum wires with a torch

Preparation for soldering

Regardless of whether aluminum wires are soldered with copper wires, or with the same ones as them, you should take the preparation responsibly, since the success of the operation depends on this. First of all, you need to clean the surface, which helps remove the oxide film. For the wires, fine-grit sandpaper or something similar will work.

After this, you should tin the end of the wire that will be soldered and, if everything is done using a soldering iron, you should also tin the soldering iron tip.

Despite the problematic use of some types of flux, metal shavings of solder or some liquid options can be used as a substitute, which will improve mixability and increase the joining speed.

Step-by-step instruction

1. The first step is to prepare all available tools and consumables, which should always be at hand, and also free the workplace from unnecessary items;
2. Prepare the metal for soldering by cleaning, fluxing, tinning and other procedures;
3. After this, you need to set the equipment to the required mode so as not to spoil the workpieces during soldering and everything goes as efficiently as possible;
4. Next, with precise and quick movements you need to carry out the soldering itself, bringing a small part of the solder to the wires, and applying it to their ends, connecting them into a single product;
5. After this, you need to let the metal cool and check the strength of the connection.

Soldering mode table

Wire diameter, mm	Material consumption, grams	Soldering duration, sec
solder	petrol
2,5-4	1	5,5	25
6	1,5	7	30
10	2	11	55

Safety precautions

Work should only be carried out using proper tools. When using fluxes, it is worth ensuring normal ventilation of the room, since many of them not only emit an unpleasant odor, but also turn out to be toxic.

The soldering iron should not be left turned on and should always be in a safe place where there are no flammable objects nearby.

The same safety measures must be observed when working with a burner, only here the flame source itself must be kept as far as possible from the container with consumables so that an explosion does not occur.

Source: https://svarkaipayka.ru/tehnologia/svarka-alyuminiya/payka-alyuminievyih-provodov.html

Aluminum does not combine well with various other alloys, so when soldering two different wires, the properties of the connection will become even worse. Soldering aluminum wires to each other according to GOST 21930-76. Soldering mode table

Wire diameter, mm	Material consumption, grams	Soldering duration, sec
solder	petrol
2,5-4	1	5,5	25
6	1,5	7	30
10	2	11	55

Difficulties in soldering aluminum wires

Despite the fact that there are such difficulties as the oxide film and the effect of the required temperature on the material, there are still small difficulties. Soldering single-core aluminum wires must be done in just a few seconds to avoid damage to the wire.

When aluminum is exposed to temperature, its structure changes, causing strength and flexibility to be lost. Absolutely any procedures when soldering aluminum, regardless of what type is used, must be carried out after passing all the necessary preparatory work, which includes stripping, tinning and flux treatment.

It is thanks to such devices that poor-quality connections can be avoided due to the formation of various negative substances, such as an oxide film.

In such a soldering process, it is necessary to correctly select the adjustment parameters, since you will be faced with thin materials where a careful approach is necessary. But at home, a similar process of joining thin workpieces occurs without any problems, and there is no obvious lack of quality.

Methods for soldering aluminum wires

At home, soldering aluminum wires can be done in different ways. The main and more popular is soldering with a soldering iron, since this is considered the most convenient and popular device that many have in stock.

 You just need to select the appropriate soldering iron with the required power to melt the solder and make the connection. This method is considered much more convenient and easier to prepare, unlike other methods, but a source of electricity is required.

Unlike a torch, a soldering iron is considered a much rougher method, since it is almost impossible to connect thin materials. You can also carry out the soldering process using a burner, which can be gas or gasoline.

The soldering process follows more delicate procedures, since it is possible to regulate the temperature and gas, which contributes to good heating of not only the wire or solder, but also the necessary area that is located next to them.

The preparatory work for this method is very lengthy, because the burner must be refueled, the required correct mode must be selected, and so on.

Another similar option is considered unsafe, since working with it uses explosive consumables, which are recommended to be placed at the required distance from the place of such procedures, however, when completing the process, you do not need to wait until the device cools down, as happens with the use of a soldering iron.

Preparatory procedures for soldering

It is not particularly important when soldering aluminum wires with copper or similar wires takes place; it is necessary to carry out preparatory work, since the quality of the connection at the end of the process depends on this. First, it is necessary to carry out the necessary cleaning of the metal surface, due to which the oxide film will be removed.

Fine sandpaper or some similar option is great for working with wires. Then it is necessary to tin the end of the wire to be soldered, and also tin the end of the soldering iron, if such a device will be used for the job. There are slight difficulties in using several types of flux; metal shavings can serve as a replacement.

Step-by-step instruction

1. At the beginning, you need to prepare all the required devices and consumables, as well as remove all unnecessary items from the table for more convenient work;2.

Carry out preparatory work, preparing the metal for soldering, carrying out cleaning, tinning, flux treatment and other necessary procedures for further high-quality joining of materials;3.

Then you need to set the correct parameters and adjust the modes on the equipment, for the highest quality result, and the absence of various defects in the material;4. In the process itself, soldering should be carried out with precise and quick movements, bringing a small part of the solder to the wires, and applying it to their ends, connecting the materials into one;

5. Finally, it is necessary to give the metal time to cool and inspect the strength of the connection.

Source: https://svarkagid.com/pajka-aljuminievyh-provodov/

How to connect aluminum and aluminum wire together correctly?

When you need to connect 2 different sections of wire with each other, it is necessary, in addition to high-quality contact, to obtain sufficient strength of the section where these wires are connected to each other.

If we take into account the regulatory documents that are in force in our country, then it is permissible to connect aluminum wires to each other using various methods:

1. Welding.
2. Crimping.
3. Soldering.
4. Connection using terminals.

Despite the fact that all these connection methods specified in the regulatory documents are presented as universal, not all of them will be suitable when working with aluminum wires.

First of all, this is due to the characteristics of a material such as aluminum, in particular, its technical characteristics. As you know from a school chemistry course, there is always an oxide film on the surface of aluminum, formed as a result of direct contact with atmospheric oxygen.

It is not capable of conducting electric current through itself. In addition, the oxide film has a fairly high melting point - around 2000 degrees. This figure is significantly higher than the melting point of aluminum itself.

If you remove this film mechanically, it will appear again very quickly. It is worth noting that the presence of this film when soldering aluminum greatly interferes with the process of connecting the aluminum core to the solder. Also, it can cause difficulties when welding wires, because due to its presence various inclusions arise, due to which the quality of contact is greatly reduced.

Additional characteristics of a material such as aluminum include increased fragility and fluidity. In this regard, when connecting aluminum wires, care should be taken in advance to ensure that they are located so that the possibility of mechanical impact on this area is completely excluded.

It is worth noting that when connecting wires using a standard bolt clamp, it will have to be tightened periodically, since the metal will gradually flow out from under the bolt. As a result, the connection will become weaker.

Twist

Aluminum wires are often connected to each other using twisting. This is the simplest, but also the most dangerous method of connecting wires to each other.

The sequence of actions when using this technology will be as follows:

1. First , remove the insulation from the wires approximately 4-5 cm on each side. It is most convenient to use a special tool designed specifically for this purpose.
2. Now the contacts should be degreased. To do this, you will have to wipe them with a cloth pre-moistened in acetone.
3. Sandpaper is used to remove the oxide film from the surface of the metal, that is, to clean it until a metallic shine is obtained.
4. The wires are crossed with each other , after which one of the wires is wound as tightly as possible onto the other using pliers.
5. The second wire is wound onto the first in the same way.
6. The twist should now be insulated using insulating tape. Professional electricians also recommend using a special heat-shrinkable tube or cambric. With its help, you can qualitatively protect the exposed area from the negative effects of the external environment.

In principle, the technology is quite simple. You just need to remember that the wires need to be exposed at least 4-5 cm, and the twisting should not be done manually, but only with the help of pliers, so that the wires fit as closely as possible to each other.

If this is not done, the result will be loose contact, which can cause the area to become very hot. In turn, this effect causes a short circuit, and in some cases even a fire.

Threaded connection

This type of connection can be very reliable if done correctly. It is worth noting that aluminum has the greatest linear expansion, and therefore a gap appears between the connected wires over time, worsening their contact with each other. To prevent short circuits, you need to tighten these screws from time to time.

To get rid of this need, special washers with cuts or groovers are installed. They select the resulting gaps and increase the reliability of the connection several times.

The wires will need to be wound around the screw so that the area of ​​its contact with the contact pad is much larger. Professional electricians often do this: they flatten this ring on an anvil to increase the contact area.

The technology for making high-quality threaded connections of wires begins with removing the insulation from them to a distance equal to 4 screw diameters. The cleaned areas are degreased.

Then you need to bend their tips so that rings are formed.

The elements are put on the screw in the following sequence:

1. Spring washer.
2. Standard washer.
3. Ring of the first wire.
4. Another standard washer.
5. Ring of the second wire.
6. Screw.

This entire system is tightened until the spring washer is in a straightened state. In principle, if both wires are made of aluminum, then there is no need to place a standard washer between them.

We use terminal blocks

If aluminum wires have a low current load, they can be connected to each other using terminal blocks. Despite the fact that the appearance of such products may vary greatly, the principle of their operation is the same.

The body of the pads is made of plastic or carbolite. It contains tubes with thick walls made of brass. There are threaded holes on the sides. The wires to be connected are inserted into opposite ends and secured with screws. It should be noted that you can insert as many wires into one brass tube as will fit there.

This is not a very reliable connection compared to soldering, but installation work takes several times less time. In addition to connecting conductors made of the same material, it is permissible to use different wires in terminal blocks.

Permanent connection

If you do not plan to disassemble the wire connection in the future, you can use the so-called one-piece methods. These methods are among the most reliable. It is advisable to use them, first of all, in hard-to-reach places.

One of the easiest methods of permanent connections is crimping. To do this, take an aluminum tube of suitable diameter, twist the wires together, insert them into this tube and clamp them with press pliers. It is best here that the conductors fit as tightly as possible.

Only in this case will the connection be the most durable. It is worth noting: if the wires fit into the tube quite tightly, then you don’t even have to twist them together. At the last stage, the connection is isolated.

Today on sale you can find special tips for making this connection, which already have an insulating cap. It shrinks together with the tip and wraps around the wires, blocking any access to them.

To obtain a high-quality permanent connection, you need to have special pliers that will not bite, but only squeeze. If they are not available, then standard pliers will do just fine.

Soldering and welding

Soldering wires allows you to get a fairly high-quality and permanent connection. However, when connecting aluminum wires, you should be aware of the presence of an oxide film on them, due to which the solder will not adhere very well.

To prevent such a defect from occurring, you need to follow a certain sequence of actions:

1. The connected sections of wires are treated with a special flux, which removes the oxide film from the surface.
2. The solder is processed as carefully as possible so that it has the largest area of ​​contact with the wires.
3. When the connection area has cooled , it is advisable to treat it with sandpaper to remove sharp edges that could damage the insulating layer.
4. Wires must be insulated.

Soldering requires certain skills.

It should be said that this method has several negative aspects:

1. He has to be isolated.
2. The method itself is quite complicated , especially if you have to solder wires under the ceiling while standing on a stepladder.
3. If an error was made during the work , then correcting it will be quite problematic.
4. A lot of time is spent on work.

Welding is somewhat reminiscent of soldering wires, but it is much faster. In order to obtain a high-quality connection, the electrode is brought to the connection area for only 1-2 seconds. Both ends of the wire are pre-treated with flux to remove the oxide film.

If you have no experience in this area, then you should initially practice on twists prepared in advance, but not connected to the system.

After completing the welding process, the twists are treated with a special solvent and varnished.

The result is a high-quality connection that can last for a long period of time, since this method helps prevent overheating. Accordingly, such an area will need to be isolated.

Alternative options

flat spring clamp

The wires can be connected to each other using a rivet. In principle, this technology is similar to screw technology, only here a rivet is used instead of a screw. The end result is a permanent connection.

This connection is made quite simply: both conductors are put on the rivet through a spring washer, then it is inserted into the rivet gun and the handles are pulled together until a click is heard.

There is also a special flat spring clamp. Such products are disposable and reusable, when the wire can be either inserted or removed. However, it should be remembered that such clamps are made of plastic, so it is not advisable to use them for currents exceeding 10 A.

Working with them is very simple: the wires are stripped and inserted into the clamp until they click. It is impossible to pull them out from there without using a special lever. It is also advisable to insulate this section of the wire.

Connection Features

Aluminum wires are best placed in special junction boxes, to which they should be approached in corrugated sleeves. This is especially important when the installation is carried out outdoors or in the case of wiring in a damp room such as a bathroom.

In general, when connecting aluminum wires that will function outdoors, care must be taken to ensure that moisture does not approach the connection areas.

Otherwise, short circuit will not be avoided. In this case, it is very convenient to use the technology of welding wires, since the subsequent use of a special varnish eliminates the impact of water on the joint, and the insulating layer will additionally protect against electric shock.

Blitz tips

1. Professional electricians do not recommend connecting aluminum and copper wires together. This is due to many reasons, the most important of which is the different resistance of metals. In addition, when interacting with each other, copper and aluminum oxidize very quickly, which causes heating of the wires and significantly worsens the contact. In addition, their rigidity is different, which significantly complicates the work.
2. You can, if necessary, combine certain methods of connecting wires. In particular, twisting goes well with soldering or welding. The result is a very reliable and permanent contact that will last for a long time.

Source: https://housetronic.ru/electro/alyuminievyj-provod-soedinenie.html