How to solder with a copper soldering iron

How to solder copper wires with a soldering iron - Metals, equipment, instructions

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.

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://spb-metalloobrabotka.com/kak-spayat-mednye-provoda-payalnikom/

Soldering with soldering acid

Every craftsman has a variety of general and special-purpose tools in his arsenal, which he uses during his work. Such devices include a soldering iron.

With its help, you can solve many problems, so the scope of application of the device is very wide, ranging from tinning and soldering the joint of electrical wires to welding radiators.

This article discusses how to solder aluminum, types of soldering irons and soldering methods, as well as what solder paste is and the correct algorithm for using acid.

Soldering methods

In general, the soldering process, regardless of the method used, boils down to one thing: it is heating the tin and the mating metal pad to the required melting temperature and joining these materials to form a single structure. There are several soldering methods that are most often used in industry and everyday life:

1. Soldering with a device powered by current. Electric soldering irons have a heating element inside their body, which, when voltage is applied to it, raises the temperature of the sleeve to the maximum value. Many of them are equipped with a heat control device to allow you to set the desired heating;
2. Soldering using a gas torch. This method is applicable in conditions where it is necessary to cover a large area with solder, for example, to solder an aluminum radiator or perform tinning. In this case, an open gas flame acts as a heat source, and special metal rods are used to apply tin, which, after heating, maintain the set temperature for some time;

1. Joining two materials or wires without a soldering iron. This technology appeared relatively recently. Its advantage is that to seal the surface of the radiators, no additional equipment or electricity is needed; for restoration, a ready-made soldering paste is used, which contains tin and binding components. It is applied to the material in a dense layer, after which it is heated with an open fire or an industrial hair dryer. After cooling, the tin melts over the entire contact, forming a single structure. It is very convenient to use it for emergency repairs of radiators made of aluminum or copper, when it is not possible to remove the part from its seat. Recently, on the market you can find paste in the form of a tape, which is wound into a cylinder and looks like PVC electrical tape. This product is comfortable to store and convenient to apply to the surface. Soldering without a soldering iron is used only for small jobs, for example, when you need to solder wires at a joint.

The listed soldering methods are the most common and are used in many areas of industry, installation of electrical equipment or in everyday life. Separately, it is worth noting the classification of soldering according to the type of insulating material, which is rosin or acid. In the first case, wood resin envelops the surface of the heating element or soldering iron, creating a thin layer that prevents the tin from sticking to the rod.

The use of acid allows you to save on material, since its consumption is much less than that of rosin, moreover, the liquid better envelops the coating and additionally degreases the material.

Important! When working with acid, it is necessary to observe safety precautions, protect the respiratory system and avoid contact of the substance with mucous membranes and skin. If this happens, you should rinse the area with plenty of water and consult a doctor.

The concentration of acid varies, the most common is a 10 percent solution. Of course, it is safe for human skin, but during the heating process it can emit harmful fumes. Depending on the problem being solved and the coverage area, the composition of the reagent can be changed by adding acid to the liquid.

Acid soldering process

Methods for soldering LED strips

How to solder without a soldering iron? In order to properly perform this type of work, which can be used for tying copper wires, as well as for soldering brass, you will need an open flame source, a metal tip and tin solder. The action algorithm will be as follows:

1. At the first stage, it is necessary to clean the surface of visible dirt, old paint and oxidation. Most often, a metal brush is used for this, which is mounted on a drill and, when rotated, tears off old pieces. You need to clean both materials that are planned to be joined;
2. A metal tip is heated over an open fire and dipped into an acidic composition. The surface to be coated must also be lubricated with a reagent to degrease the material. If you plan to seal the hole, then the elements are heated simultaneously, for which a gas burner is used with oxygen supplied through a special gun;
3. When the surface has reached the desired temperature, tin solder or copper wire is applied to it. Then the burner forces one layer onto another by bringing the nozzle closer to any area. You can also use a copper rod for this, which will melt during the straightening process and create an additional layer;
4. Finally, you need to remove the heat source and wait for the coating to cool. Acid has a side effect: after cooling, salt deposits form on the material, so when the structure turns black, you need to clean the joint with a wire brush.

This process is universal, so it is applicable for soldering wires of different sections made of copper or aluminum. Some craftsmen use another acid soldering method, when soldered copper conductors are dipped into a container of molten tin, after which a thin metal film is formed on the material; this process is also called tinning.

Soldering aluminum

How to choose the right socket

Brass and copper can be soldered using the same technology, but this approach is not entirely applicable for aluminum, since it quickly oxidizes, which prevents normal contact of the solder with the surface.

For example, to restore batteries from this material, both parts must be heated simultaneously so that their oxidation does not interfere with fusing and the formation of a protective layer.

In this case, acid acts as an excellent remedy for grease: it dissolves it completely and forms a film for smooth spreading of solder.

Important! Aluminum soldering should be carried out in a well-ventilated area, with artificial ventilation, to remove smoke and harmful impurities.

Soldering brass

How to solder brass and copper? An ordinary soldering iron powered by current is not suitable for this, since its temperature is not so high and the structure will be fragile. The most appropriate method is to use a torch and wire, which, when melted, fills the hole or other defects, forming an airtight coating.

How to solder copper

For this, any method can be used, since this material is not fussy, has a low oxidation coefficient and melting temperature.

How to solder metal of different composition? If you need to join brass and copper elements, then they can be soldered by heating with an open fire, for which a gas burner and a rod are used.

Important! When heating, do not touch the soldered element with open areas of the body, since the overall temperature of the part will be high; to hold it, use a remote clamp or thick gloves.

Thus, before replacing the soldering iron with a torch and using the listed metal processing methods, you need to carefully understand the issue of how to properly solder with a soldering iron using acid, take into account the characteristics of the materials and other indicators.

Source: https://rem-serv.com/payka-s-payalnoy-kislotoy/

How to solder copper with hard and soft solder

Copper products are found everywhere in different areas of life. For example, it is used to create strong and durable heating and water supply systems. But to connect the two elements, experts resort to a special technology - soldering copper pipes. The procedure requires suitable tools and materials, as well as knowledge. Since it has certain features that a beginner may not know about.

To solder copper, the master needs to have with him a composition such as solder. This thermoplastic substance seals the surface of the product and, under the influence of high temperature, melts, spreading over the entire joint. But as soon as it cools, it hardens and securely holds the products together.

The result is one item that has a long service life, withstands high loads, pressure and temperature changes, and is not afraid of ultraviolet radiation.

What tools and materials are needed

Soldering is carried out not only at industrial facilities, but also at home. To do this, you need to prepare the following tools and materials:

• electric soldering iron or gas burner;
• pipe cutter;
• solder;
• flux;
• brush and steel brush.

How exactly to connect the products depends on the convenience and preference of the master. But the power of the device is selected in accordance with the melting temperature of the solder.

Flux can be liquid or solid; each type has individual differences that should be taken into account. If the material is used in the form of a thickened mixture, then it is applied to the joint, both before and after the connection.

Flux is needed to protect the surface from oxidation, promote solder flow and improve adhesion.

Types of fluxes and solders, features of working with them

Craftsmen know a variety of hard and soft substances that ensure high-quality soldering of metal products. 95% use tin, which is a low-temperature composition with slightly worse technical parameters. But it is valued for the fact that work can be carried out at any temperature without reducing the strength of the products being joined.

Connecting elements also include silver, which has excellent technological properties. Craftsmen often use three-component compositions of silver, tin and copper. Often, materials used in low-temperature soldering contain zinc chloride.

The advantage of soft solders is that they cover a larger area when applied to the surface of the part. They provide high strength and reliability.

Soft solders

Soft solder is used in the installation of water supply and heating networks, where the pipe diameter reaches 10 cm and the water temperature does not exceed 130 degrees. These types include:

• lead-tin type;
• with low tin content;
• special and fusible.

Lead-free flux is most often chosen as solder. The tin-copper type is the most common due to its affordable price. But its advantage lies elsewhere. All mixtures containing tin in the composition are economical in consumption.

It is enough to apply a little solder to half the surface being treated and it will spread over the entire area. This property is explained by the fact that tin easily penetrates and spreads throughout any structure.

Brazing alloys

When it comes to considering the environmental conditions in which soldering is performed, it is better to use hard solders. The use of such substances ensures high strength of the seam. The most common compounds are the following compounds:

• copper and zinc;
• phosphorus and copper;
• pure copper;
• no-clean flux.

Solid compounds are classified as refractory and low-melting. Each type is characterized by certain properties. For example, copper-phosphorus replaces expensive silver flux. It is moderately expensive, but has one drawback - it cannot be used at low temperatures.

The strongest of the solid compounds are copper-zinc and multicomponent ones. They are expensive, but the price is justified by the reliability of the connection. When soldering is performed with copper itself, it is necessary to use flux. In this case, it will be possible to firmly connect the two parts.

Why do you need solder paste?

Solder paste is a pasty mass consisting of small particles of solder, flux and special additives. Flux paste is used in industry when soldering elements on printed circuit boards. The paste is selected according to certain conditions:

• after application there should be easily removable particles;
• the substance must maintain viscosity and stickiness;
• do not have a negative impact on the surface being treated;
• do not leak onto clothing during melting.

How to work with the paste depends on the type and size of solder contained in its composition. The material also differs in the type of flux (rosin, water-washable, no-clean). It is necessary to hold small parts in place and facilitate the joining process.

Soldering technology

The process is quite simple, therefore, when it is necessary to connect something at home, the owner does the soldering with his own hands and without the involvement of specialists. But still, you can’t do without the preparatory stage.

It determines how high-quality and reliable the connection will be. First of all, you should pay attention to the cut of the part, which should be strictly vertical, without burrs, with even and smooth edges. If you find the slightest defects, you should take sandpaper and rub it over the surface until the defects disappear.

If two copper pipes are connected, then, having brought the cut to an ideal state, it is necessary to insert it into the fitting and then remove it. The part that came into contact with the fitting must be cleaned of oxidation. The next step is applying flux. There is nothing complicated about this, you just need to run the brush over the entire part, paying special attention to the joint.

Then the elements are connected to each other and firmly fixed. Further actions depend on what is being used for soldering - a gas torch or a soldering iron. Considering that the parts must be stationary, an assistant will be required. He will be the one to hold them, but if one is not found, you need to manage and do it yourself.

When something needs to be soldered at home, a solid compound is most often used. But the master can purchase special pastes. With the correct choice of compositions, it is possible to connect two pipelines or radio components as accurately and firmly as possible.

Soldering is performed at either high or low temperature. In the first case, the process is distinguished by high strength of the seam, and the connected area also gains heat resistance. Which is very important if it later serves as part of various communications. But high-temperature soldering is not allowed on threaded connections. Most often this process is performed with a propane-filled torch.

When low-temperature soldering is used, a soft compound, paste or gel is used. It is most suitable for a beginner master because it is simple and easy. In this type of process, the temperature does not rise above 425 degrees, so it is even possible to use a soldering iron, which is found in almost every home.

Working with a soldering iron

Every person has seen a soldering iron at least once in their life, and many constantly work with it. Therefore, they will not see anything complicated in soldering copper products with this tool. The whole essence of the process is that the solder located between the two parts is heated with a soldering iron until it begins to melt.

When it hardens, the two parts will be securely fastened into one. To solder efficiently, it is necessary to distribute the substance evenly over the entire surface, filling every gap. It is important to choose exactly the material that can withstand the high temperature of the soldering iron.

Working with the burner

The tool is turned on when the two parts are already connected to each other. You should not hold it near the joint for too long, since the combustion temperature is several thousand degrees. While you only need to heat a certain place to 250-300 degrees.

This will take 20-30 seconds. As soon as the flux changes color to dark, the compound to be joined is introduced. Important! The burner or hair dryer should be placed in the middle to cover the entire joint area.

Is it possible to solder copper with tin?

Many novice craftsmen are interested in whether it is possible to solder copper with tin. In fact, it’s not just possible, but necessary. Because this composition provides good bonding. Most often, tin is used when holding food items together.

There is only one thing to remember - this metal requires a higher temperature than other solders. It is better to use a powerful electric soldering iron as a tool.

Soldering with silver solder

When you need to solder parts at home, silver solder is often used. It is beneficial because you can create it yourself. But it should not be used alone, in combination with zinc and copper.

Treated with this solder, the seam will be very strong and neat. The percentage of components is controlled by GOST 19746 74. But you can find out exactly what types of substances to use from the instructions of experienced craftsmen or those included with the products being connected.

How to solder copper and stainless steel

If you need to solder copper to another metal, such as steel, you will have to work hard. This process is not easy, but it is quite feasible. This is explained by the fact that stainless steel interacts poorly with other metals and is difficult to heat treat.

When two different products are combined, you need to find an average composition that suits both at the same time. In such cases, you have to sacrifice quality and it is not even necessary to use flux. But it is important to carry out preparation, tinning and other soldering steps.

The need for a connection often arises at home. Joining stainless steel and copper requires little time and a conventional gas torch is sufficient. Therefore, having decided on the tool and solder, you should clean the surface of both joints and prepare flux. Then tinning the bonding area and applying flux. After which the two parts are connected, and the resulting seam is coated with solder.

The next stage is its uniform heating with a burner. Once the solder has spread, the product is left to cool naturally.

How to solder copper to iron

Soldering copper products to iron ones or vice versa is also a common task, for which the connecting compound is selected correctly. The instructions in this matter will be of significant help.

Useful information can be found in the thematic video, where the entire soldering process is shown in detail. If all conditions are met, it is possible to obtain an even and durable seam.

Basic mistakes when soldering yourself

Most often, it is haste that leads to the fact that the connection of two elements is unsuccessful. Because they forget to inspect the surface of the parts being connected. The first action aimed at correcting an error is checking for the absence of defects. They could appear when cutting parts.

How reliable the seam will be depends on the cleanliness of the surface. Therefore, it is still worth brushing off even invisible specks of dust. One of the most basic mistakes is made when applying flux. The master may forget to process a small area of ​​the product. And it will cause the proper connection to fail.

It is also important to monitor the temperature of the torch or soldering iron, since overheating of the element being processed leads to combustion of the flux. But insufficient melting point is also harmful. In this case, the connecting compounds do not soften or stick.

Safety precautions

Soldering copper products is a rather dangerous process, so it is very important to comply with all standards and regulations for safety. The process involves open flames and hazardous substances, so DIYers and professionals alike must wear protective equipment. We are talking about mittens, glasses and special clothing.

Before you take up the tool, you need to carefully study the rules of technology.

Source: https://oxmetall.ru/pajka/medi-tverdym-i-myagkim-pripoem

Soldering wires: welding machine, cold soldering and thin wires

Soldering wires is a mandatory set of measures, the task of which is to install electrical wiring in the room. High-quality connection of wires by soldering, connection of wires in the distribution panel, correct twisting - these are the factors on which the durability and performance of electrical wiring depends.

Advantages and disadvantages of soldering electrical wiring

The solder connection is considered one of the best in terms of reliability

To properly solder the wires, you need to familiarize yourself with the advantages and disadvantages of the method. Despite existing analogues, this method is considered the most widespread and in demand, especially in electronics.

Advantages:

• Reliability. An important parameter is the presence and magnitude of the contact resistance. The lower it is, the better. For soldering, this parameter is extremely small. In terms of reliability, soldering is inferior to welding only in one case - if the work had to be performed in extreme conditions, for example, in an environment with extremely high or low temperatures, or exposure to aggressive environments. If we are talking about apartment wiring or a country house, such factors are excluded.
• The connection does not require maintenance.
• Versatility of use. With the help of soldering, it is possible to connect single-core and stranded wires with different cross-sectional areas, in any combination. This versatility allows you to solve many non-standard and difficult tasks. In addition, the use of fluxes ensures a reliable connection of copper and aluminum conductors.
• Low connection cost. To carry out the work you will need a soldering iron, solder and flux. The cost is low and the consumption is economical.

Flaws:

• Low technology. To carry out the work, it is necessary to carry out many preparatory measures, hence the high labor intensity.
• The need for performer qualifications.

When soldering, changes in materials occur at the molecular level, so the pre-soldered parts undergo thorough preparation.

What you need to solder electrical wiring

Before soldering the wire, prepare the working tools and consumables. To complete the work you will need the following list of tools:

• An ordinary household soldering iron, the power of which ranges from 40-100 W. As an analogue, a welding machine is used, on which it is possible to control the temperature of the tip, which simplifies the soldering process.
• A small file for cleaning the soldering iron tip.
• Knife for removing the insulating layer.
• Twisting pliers.
• Rosin intended for tinning surfaces.
• Solder for soldering different materials; acid-free fluxes are used as an analogue.

Gas torch Solder Pine rosin for soldering

Soldering aluminum and copper wires differs somewhat in the types of solders used.

Copper	Aluminum
Tin and lead compounds are used. The markings are as follows:	Tin and zinc alloy – TsO-12 Alloy of copper, tin and zinc - A Tin and zinc alloy type P250A Aluminum and zinc alloy – TsA-15

How to solder wires correctly

An example of universal sharpening of a soldering iron tip and proper maintenance of its working area

The soldering process may vary slightly depending on the materials used. Different methods involve the use of different soldering compounds and fluxes. Most often, soldering of wires is carried out when connecting copper wires with a cross-sectional area of ​​up to 6 mm2.

https://www.youtube.com/watch?v=n1mQng5Okk8

When performing work, follow the following algorithm:

1. An insulating layer of approximately 5-6 cm in length is removed from the wires.
2. Heat up the working tool and cover the surface with a layer of rosin or flux. The first one does not work well on oxidized surfaces; when penetrating deeply into the twist, it is important to thoroughly pre-treat the materials.
3. When heating the wire using a heated tool with solder on the tip, it is important to achieve uniform distribution of solder over the entire surface being processed.
4. When soldering twists, specialists must fill all irregularities with solder.
5. Upon completion of the work, all twists are carefully insulated using special nozzles, electrical tape and heat-shrink tubing.

If you need to work with aluminum, it is important to take into account its high oxidation rate when in contact with oxygen. The resulting film does not allow for reliable adhesion of the metal to the solder.

Stripping wires from insulation

The oxide is removed mechanically, then the surface is serviced. The algorithm for connecting aluminum cores depends on the type of flux used and the cross-sectional area. A gas burner is usually used for heating.

The procedure for soldering cores with an area of ​​4-10 mm2:

1. At the ends of cores 5-6 cm long, the insulating layer is removed.
2. To obtain a metallic shine, the wires are cleaned with a file, sandpaper or a knife.

   Tinning of stranded wires

3. The cores are connected to each other overlapping using a double twist method, and a groove is made at the point of contact in the middle.
4. The joint is heated to a temperature that is close to the melting point of the solder joint.
5. Each side of the twist is processed in a similar way, all cavities are filled with tin.
6. At the end of the work, clean the connection area with gasoline.
7. The cleaned surface is covered with asphalt varnish and carefully insulated.

The work is not fast, but the high quality and durability of the connections is worth the time and effort.

How to solder copper and aluminum wires

Soldering wires by twisting method

The copper wire is thoroughly cleaned, then immersed in rosin. A specialist melts a few drops of solder and, for tinning, the wire is immersed in the molten mass. The procedure is performed with careful and uniform movements.

Solder for soldering should cover the surface of the wire as little as possible. Excess is removed with a hot soldering iron. As the work progresses, the red tint of the copper wire should change to silver.

If the work is to be done with multi-core soldering irons, each wire should be untwisted and only then tinned. Then everything returns to its original position.

Before soldering electrical wires, the aluminum wire must be cleaned, and then the previously prepared flux must be evenly distributed over its surface. Next, the aluminum wire is thoroughly rubbed with a small piece of tinol and heated with the flame of a gas burner. Such manipulations will allow you to effectively get rid of the oxide film.

To increase the quality of connection of single-wire wires, twisting of tinned wires of small sizes is used. All resulting cavities are filled with tinol.

The next stage is connecting copper and aluminum wires. To do this, restore the insulating layer. For dry rooms, only cotton tape can be used.

Recommendations, precautions

Professional soldering iron DANIU 110V/220V 60W with temperature control and a set of tools

You should familiarize yourself with the recommendations that will allow you to perform your tasks efficiently:

• When choosing a soldering iron, you need to pay attention to models equipped with additional cones, needles and a set of replaceable tips.
• Before you begin soldering, you need to pay special attention to cleaning the tip. If the tip is too dirty, remove all dirt using a soldering iron. You can use pieces of wood or cardboard as an aid.
• When changing the length of the soldering iron, the heating temperature of the tool also changes.
• It is not recommended to leave the soldering iron “dry” while heating the working element. The tip needs to be dipped into rosin regularly.

It is important to take precautions. You need to work in personal protective equipment: special clothing (overalls), goggles and gloves. Do not leave exposed areas of the body, otherwise severe burns may occur.

Source: https://StrojDvor.ru/elektrosnabzhenie/kak-pravilno-spayat-provoda-mezhdu-soboj-mednye-provoda-i-skrutka/

How to solder aluminum and copper?

Despite the fact that in modern construction, during electrical work, aluminum cables are increasingly being replaced by copper cables, aluminum remains an indispensable material in the manufacture of large-section wires and cables.

The reasons for this lie on the surface - the electrical resistivity of aluminum is approximately one and a half times greater than that of copper, and the volumetric weight is three times less.

With a large conductor cross-section, when weight is more important than strength, the choice in favor of aluminum is obvious. The cross-sectional area of ​​an aluminum conductor will be one and a half times greater than that of a copper conductor, and at the same time, aluminum will still be two times lighter than copper. Soldering, among other methods, is used to connect wires.

Soldering methods

The problem with using aluminum conductors is their rapid oxidation. The oxide film significantly impedes the passage of electric current during connections. To do this, twisted aluminum wires are soldered.

You can solder aluminum wires in a junction box using a soldering iron or a gas torch. It is more difficult to use a soldering iron due to the inability to accurately heat to the required temperature. And for aluminum, overheating is just as unacceptable as underheating.

Metal has high thermal conductivity, and the insulation over a large area from the soldering point can simply melt.

It is easier to regulate the heating temperature with a gas burner, but it takes a long time to prepare the surface. However, it is the torch that will need to be used if it is necessary to solder any massive parts to each other. In any case, when soldering aluminum wires, they need to be prepared.

Preliminary processing

The difficulty with soldering is that aluminum itself is a very low-melting material (660 ℃) and if heated carelessly it can melt.

Another factor that makes soldering aluminum wires difficult is rapid oxidation in air.

The oxide film on the surface of the material reliably protects aluminum from the effects of all kinds of external factors, but it also prevents the adhesion of solder to the material and must be removed.

It is almost impossible to mechanically remove the oxide film under normal conditions. The material is instantly oxidized and covered with a new film. You can mechanically remove the oxide film under the oil layer.

But before this, the oil must be heated to 200 ℃ in order to remove any active oxygen that may be present there. This method is very inconvenient at home and labor-intensive.

Therefore, the ends of aluminum conductors must be tinned before soldering. Using rosin or most other fluxes will not work due to the high chemical resistance of the oxide film. It does not dissolve even with organic acids.

To tin the wires, you must use both a special flux and a mechanical method.

Of course, this must be done before the wires are twisted, otherwise it will not be possible to mechanically clean the entire surface of the wire. Only the tinned ends can be twisted together and soldered.

Working with a soldering iron

In order to solder aluminum with a soldering iron, there are several methods, the essence of which is to clean immediately under the flux layer in direct contact with the molten solder.

The first method is that aluminum conductors, before soldering, are cleaned with a hot tinned soldering iron using a mixture of rosin and steel filings.

Sawdust has an abrasive effect, rosin removes all impurities and immediately the cleaned areas are covered with solder, which should be on the soldering iron tip.

The second method involves stripping the aluminum wire on medium-grit sandpaper directly under the influence of a hot soldering iron with solder and flux.

Gas burner

Processing with a gas burner is carried out when the parts are in the position relative to each other in which they will be used. The processing smoothly transitions into the soldering process itself.

This happens as follows:

• the burner heats the surfaces of aluminum parts;
• upon reaching the temperature at which the metal is reduced from the oxide, the film is mechanically peeled off;
• under the influence of a flame, the parts are coated with flux, and solder is introduced into the soldering area.

If the parts are thick, then their edges must be cut at an angle of 45°. Typically, heating occurs to the melting point of tin, when the solder spreads and fills the twist groove.

Differences in technology when using flux

Thanks to the achievements of modern science and technology, flux compositions for aluminum have been obtained that actively dissolve the oxide film and protect the material from further oxidation.

Examples of such drugs are formulations labeled F-59A and F-61A. The letter A means that these compounds are intended for soldering aluminum.

When using these fluxes, soldering aluminum wires is greatly facilitated. It is enough to simply treat the finished twist with flux, without even heating it, and then, after heating it with a soldering iron or torch, apply solder.

It will spread over the entire surface of the wires and adhere well, providing a strong and electrically conductive solder joint.

  Reusable Aluminum Casting Mold

Features of soldering stranded wires

Stranded wires must be soldered only using a special flux, since their mechanical processing is almost impossible. Soldering technology differs in that each wire must first be well treated with flux.

To do this, the bundle will have to be untwisted and fluffed. After processing, each thin wire conductor is covered with solder and the bundle is twisted. After this, twist the two ends and solder it.

Can it be connected to copper?

Situations often arise when it is necessary to connect an aluminum wire to a copper wire. This is perhaps the only case where soldering cannot be used.

It's all about the aluminum itself. It cannot be soldered to other metals at all due to its physical and chemical properties. When connecting directly to copper, galvanic corrosion will occur between the two active metals and will quickly destroy the connection.

And if they are soldered using solder that is neutral to both materials, then the different coefficients of thermal expansion of the metals will quickly destroy the soldered contact. After all, when current passes through a conductor, it will certainly heat up, and after switching off, it will cool down.

Difficulties in soldering aluminum wires

The main difficulty when soldering aluminum wires, as indicated above, is the presence of an oxide film on the surface of the metal. Fighting it greatly slows down the soldering process.

And if you consider that aluminum wires are now used mainly for laying external power wiring, it becomes obvious that a regular soldering iron and sandpaper will not be enough in this case. Welding is increasingly being used to connect such wires.

Source: https://varimtutru.com/kak-spayat-alyuminiy-i-med/

Rules for soldering copper wires

One of the best ways to connect copper wires is soldering. It provides high strength and electrical conductivity. At the same time, soldering is easier to carry out than welding, and it is more reliable than simple twisting. Although the wires in junction boxes are often connected using self-clamping terminals such as WAGO, soldering techniques will not hurt any electrician to know.

You can learn how to solder copper wires in a few minutes, having all the necessary materials and equipment.

The essence of the process

The essence of the soldering process is that metals are joined together using an alloy that has a melting point lower than the melting point of the substances being joined.

During soldering, materials are heated to the melting temperature of the solder. This ensures very strong adhesion (sticking) - the property of materials to adhere to each other at the molecular level.

However, the main parts do not melt and mix with the solder material, as happens when welding using filler material.

Soldering iron and solder

Soldering irons are traditionally used for soldering copper wires. There are several types of them, including electric and gas. Soldering of copper wires is carried out using an electric soldering iron with a copper tip. This tool consists of a copper rod, sometimes nickel plated, that is mounted in a heating element housing.

The heating element operates on direct or alternating current. The supply voltage can vary from 12 to 220 V. For soldering copper wires of electrical wiring in the house, the most common soldering iron with a power of 60 W is suitable. If you need to solder thin wires of an electrical appliance, then a less powerful tool will do. It is important that it heats the copper material well and melts the solder.

To ensure high soldering quality and joint strength, it is necessary to remain still while the molten solder cools. You can hold the wires with your hands, but it is more convenient to use tweezers or clamps.

Tin-lead solder is used for soldering copper wires. Most often this is POS-61, but you can also take POS-40. The marking indicates the composition - tin-lead solder with a tin content of 61%.

Solder is usually produced in rods with a diameter of about 8 mm or in the form of solder wire with a diameter of 2 mm. General purpose solder is often used for soldering copper wires, which looks like a hollow tube of tin-lead alloy. Inside such a tube there is flux powder.

Application of flux

In order for the solder and the wire material to interact with each other, and the connection to be high-quality, the wires must be cleaned of the oxide film and only then soldered. For cleaning, you can use sandpaper, and for subsequent processing, use a special substance - flux.

Flux will not only clean copper wires, but will also create a thin protective film that prevents oxidation of the material.

It is allowed to use both solid flux - pine rosin, and liquid - various types of soldering acids or a homemade composition.

Sometimes, in order to correctly and firmly solder copper wires to each other or to any metal object, they use only liquid flux. You can prepare it by dissolving ordinary pine rosin in ethyl alcohol.

Soldering acid is prepared independently by dissolving zinc granules in hydrochloric acid in the proportion of 412 grams of zinc per 1 liter of acid.

But it’s better to buy ready-made flux that meets all quality standards, since bringing acidic compounds to copper wires is undesirable.

How to solder correctly

To reliably solder copper wires, you need to prepare a soldering iron. If you do not tin the tip before work, the solder will not stick, but will roll off the rod in balls. This happens because the tip is covered with a layer of copper oxide and carbon deposits formed during previous soldering.

Preparing the soldering iron

For ease of work, some specialists sharpen the tip with a flat file to give it the shape of a spatula or flat screwdriver. The sharpening angle should be 45-60 degrees.

A non-burning tip (eternal) cannot be sharpened under any circumstances; special sponges are used for it.

The mechanically cleaned tip must be heated and then tinned. To do this, it is coated with flux.

If the flux is solid (rosin), simply immerse the tip in it. The rosin will melt and cover the heated surface. After this, you need to touch the solder bar with a soldering iron and heat it up. The molten solder will coat the tip, protecting it from further oxidation.

The procedure for tinning a soldering iron must be repeated as carbon deposits form on it. This happens because the temperature of the tip is much higher than the melting point of the solder, and over time it begins to burn. To reduce the likelihood of this happening, it is recommended to use a soldering iron with temperature control.

Preparing the wires

The copper wires to be connected also need to be prepared for soldering. First, remove the insulation from the ends at a distance of about 4 cm, strip them, twist them together and tinning them. Copper wires can be tinned as follows:

• heat the twist with a soldering iron;
• coat with flux;
• Apply a small amount of solder, spreading it over the surface of the wire.

The actions are similar to those performed when tinning a soldering iron tip. If you are going to solder stranded copper wires, then you must stock up on liquid flux, since it will be very difficult to cover the entire surface of the copper “hairs” with molten solid rosin. To get a quality connection, you need to heat the stranded wire and then dip it in liquid flux, which will wet the entire surface intended for soldering.

Further, soldering of stranded and single-core copper wires is carried out in the same way. The two or more conductors being joined are heated together and solder is applied to them. After applying it, it is necessary to ensure that the joint remains motionless while it cools. It is not allowed to accelerate cooling by wetting it or blowing air on it.

Copper and aluminum connection

When connecting copper and aluminum wires by soldering, you can encounter many difficulties, which can only be overcome by using alternative connection methods.

The fact is that both aluminum and copper are covered with an oxide film in air.

And if these films themselves do not affect the state of the conductor in any way and even provide fairly good conductivity, then when combined they contribute to the occurrence of a powerful chemical reaction.

Under the influence of moisture contained in the air, at the point of contact between aluminum and copper oxides, the process of electrolysis begins, that is, an electric current is formed due to the fact that the ions of both materials have different electrical potentials.

Electric current is the movement of charged particles - ions, and during their movement, metals at the point of contact are destroyed. At the same time, aluminum is more destroyed. Destruction causes the contact to deteriorate, and subsequently the electrical resistance of the connection increases and it heats up. With severe corrosion, when direct contact between the two materials has already been lost, an electric arc occurs, which completes the destruction.

It is recommended to connect copper with aluminum only through a third, neutral material. Most often, steel terminal blocks or clamps are used for this.

Source: https://svaring.com/soldering/praktika/pajka-mednyh-provodov

How to solder copper 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.

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

> Electrician's tips > How to properly solder with a soldering iron with acid

Most often, for soldering printed circuit boards in radio engineering products and household appliances, they prefer to use ordinary pine resin rosin, but it can be replaced with other components. When molten, it promotes the spreading of tin solder along the copper traces of the board.

This allows you to reliably solder the legs of radio components and the ends of connecting wires. Rosin allows you to effectively solder copper, tin and silver products.

In order to solder galvanized and stainless iron, radiators, buckets, pans, various alloys, brass and other metals, you can use acid solutions.

Bottle with acid solution for soldering metals

Acidic solutions

It is important to choose the right acid solution. It depends on the type of metal from which the parts are made. This could be an aluminum or copper radiator, a kettle that needs to be soldered, copper, brass or roofing iron:

1. Galvanized iron. Places where it is necessary to solder are treated with an acid solution, correctly called (zinc chlorate). This composition can be bought in specialized stores; the easiest way is to prepare it yourself.

To do this, it is enough to throw pieces of zinc into 100 ml of hydrochloric acid, which can be removed from the body of AA batteries. After the chemical reaction is completed, the zinc will dissolve, releasing a large amount of hydrogen.

It is correct to carry out the process in a well-ventilated area, in the absence of open flame.

After the solution has cooled and settled, the upper transparent yellow part is poured into a clean glass container. The sediment is poured into the ground; it is not recommended to drain into sewers with metal pipes. Acid can damage pipes and seals. The remaining part of the solution is ready for processing galvanized iron roofing.

How to solder sheets of roofing iron

1. Stainless steel. Before soldering, the surface is cleaned and treated with phosphoric acid, which contains the following elements:
   

• up to 50% zinc chloride;
• ammonia up to 0.5%;
• dissolves in water with a pH concentration of 2.9%.

Phosphoric acid is used for soldering as a flux and for cleaning metal from rust.

The solution can be transparent, light yellow or colorless; when heated to 213ºC, it is converted into H4P2O7 (pyrophosphoric acid), which degreases the surface of metals. The composition dissolves the oxide film on various metals and alloys:

• stainless steel;
• brass;
• Nickel alloys;
• copper alloys;
• alloys of carbon metals and low-alloy steel.

Application of acids

To solder metal products (pipes, radiators, buckets, pans), the surface of the elements is thoroughly cleaned, using a file or sandpaper. An acid solution is applied to the cleaned areas with a brush, after which solder is melted to a liquid state on the surface with a soldering iron.

How to solder correctly with a soldering iron

Liquid solder tins the cleaned areas; when boiling, the acid flux comes to the surface. When the solder hardens, the soldered elements are securely and hermetically fixed.

You can solder with a powerful soldering iron or an open flame from a gas burner. Various heat sources can be used depending on the surface area to be heated and the melting point of the solder.

Remains of acid flux are washed off with water, preferably a soapy, alkaline solution, this will prevent further corrosion of the metal.

Machined and brazed stainless steel elements

Acid can damage skin and muscle tissue, and inhaling vapors can damage the respiratory organs. When contacting air, hydrochloric acid enters into a chemical reaction, and smoke is visible above the open container. To work correctly in these conditions, wear safety glasses, rubber gloves, a gas mask, or a respirator.

If the solution gets on the skin, wash this area of ​​the body with a 6% alkaline solution or plain soap. It is not recommended to solder radio circuit boards with fluxes containing acid. The acidic components are difficult to wash off and contribute to the breakdown of copper tracks. It is better to replace them; there is a special paste for this.

Soldering acid solutions should be stored correctly in containers made of the following materials:

• glass;
• ceramics;
• porcelain;
• fluoroplastic

Such dishes do not react with acid; the prepared composition can be stored in it for a long time.

Soldering without a soldering iron

At home, if you don’t have a soldering iron, you can solder copper wires with a diameter of up to 2 mm. For soldering radiators and utensils, special solder, blowtorches, and gas torches are used, since the copper rod of the soldering iron is not able to heat a large surface area. There are several ways:

1. Tinning and soldering wires in molten solder . The wire is first heated, applied to a piece of rosin, it melts and spreads evenly over the surface of the connection. The wire is twisted and lowered into molten solder in a tin can over a fire; it can be heated with a blowtorch. In order to solder the twist, it is advisable to hold it in boiling tin for up to 1 minute. The copper wires will heat up and the alloy will fill all the gaps between the twisted wires. In this way you can solder small parts made of copper, brass and other alloys.

Tinned and soldered copper wire

1. Soldering wires in the trench . The stripped and twisted wires are laid in a 2-3 cm piece of aluminum tube, 0.5-1 cm in diameter, sawn lengthwise. The top is filled with a mixture of fine shavings of solder and rosin dust, and from the bottom this structure is heated with a lighter, candle or small blowtorch.

Heating the solder with a blowtorch (torch)

The mixture melts and thoroughly envelops all wire connections. After hardening, the aluminum gutter is removed and the joint is insulated.

Solder shavings can be sharpened with a coarse file.

1. A thin copper wire up to 0.75 mm can be laid on aluminum foil, sprinkled with a mixture of rosin and tin shavings, wrapped tightly and heated for 3-4 minutes. The solder will evenly fill all the elements at the soldering site; after cooling, the foil can be removed and discarded.

How to prepare solder paste

Soldering paste is sold in radio parts stores, but you can prepare it yourself. To 32 ml of hydrochloric acid add 12 ml of ordinary water, then pieces of zinc - 8.1 g. For this, enamel dishes are used.

How to tin a soldering iron: preparation and care of the soldering iron

After the dissolution reaction is completed, tin – 8.7 g is added to the composition. When the second dissolution reaction is completed, the water is evaporated to a paste-like consistency of the solution. The paste is transferred to a porcelain container, where powder is poured, which contains:

• lead – 7.4 g;
• tin – 14.8 g;
• dry ammonia – 7.5 g;
• zinc – 29.6 g;
• rosin – 9.4 g.

This paste is mixed with 10 ml of glycerin, heated and stirred.

How to solder correctly, sequence of actions:

• The parts at the soldering site are cleaned, the wires are twisted;
• the paste is applied with a brush in a thin layer;
• the surface for soldering is heated with a plasma lighter, torch, candle or alcohol tablet, or even with matches or over a fire until the paste melts;
• After melting, the soldering elements are removed from the heat source, and the solder hardens.

The paste is very effective when it is necessary to solder copper wire, small parts made of alloys based on copper, brass, such as radiators, samovars and other products.

Soldering utensils

How to install a socket with your own hands correctly

Buckets and pans with holes no more than 5-7 mm in diameter are recommended to be soldered without using a soldering iron with POS-60 solder. Leaky places on the dishes can be reliably soldered. To do this, the holes are carefully cleaned with sandpaper from the inside of the container. The hole along the edges is given a conical shape, the cleaned areas are treated with a solution of soldering acid with a brush.

In order to prevent solder leakage from the outside, all bottoms or individual places where holes need to be soldered are covered with thin tin plates. Powdered solder and rosin are poured into the cleaned holes from the inside. The soldering areas are heated over an open fire until the solder melts and fills all the cracks.

For radiators, stripping and soldering are carried out from the outside. To prevent solder from leaking inside, the hole is covered with a plate of tin, galvanized iron, or can be replaced with copper or brass. The choice depends on the material from which the radiator is made. Homogeneous metals and alloys that are similar in composition are easier to solder.

After completing the soldering process of radiators, the internal and external surfaces are thoroughly washed with an alkaline, soapy solution in order to prevent the effect of acidic components on the metal.

Bottle with flux for soldering aluminum

When it is necessary to solder aluminum parts, special solders are used:

• 4:1 mixture of tin and zinc;
• 30:1 mixture of tin and bismuth;
• 99:1 tin and aluminum powder.

The sequence of surface treatment is the same as for preparing iron utensils. In order to properly solder aluminum, rosin is added to the powder, but the melting point must be above 500ºC. It is recommended to stir the solder in the hole, using a thin copper soldering iron tip.

PCB soldering paste

The composition is not much different from the paste that is used to solder without a soldering iron; the powder includes the following components:

• tin – 14.8 g;
• rosin – 4 g;
• zinc dust – 738 g;
• lead powder – 7.4 g.

For a paste-like consistency, add diethyl ether - 10 ml, it can be replaced, use glycerin - 14 ml.

Soldering sequence:

• the legs and tracks of the printed circuit board are cleaned;
• in order to solder, the legs of the parts are inserted into the holes of the board;
• places where it is necessary to solder on the board are lubricated with paste;
• the paste is heated with a soldering iron until it melts;
• The solder spreads and hardens, providing reliable electrical contact between the parts and the traces of the printed circuit boards.

  GOST 859 2001 copper grade

Soldering lessons.

You can learn how to solder correctly by watching this video.

From the above information it follows that, if desired, and if certain materials are available at home, you can solder in various ways, achieving high-quality fastening of parts and tightness of containers.

Soldering copper pipes using a torch

You can solder with or without a soldering iron almost all metals, alloys, aluminum, brass, copper, electrical circuit wires for various purposes, metal utensils, radiator housings and other pieces of equipment.

Source: https://ssk2121.com/kak-payat-med-payalnikom/

How to properly solder wires with a soldering iron?

A soldering iron is most often used to connect wires, as this is the easiest and most reliable way to get a high-quality result.

Various types of twisting, winding with electrical tape and other handicraft methods are not reliable or increase the resistance of the wires, which leads to overheating of certain areas and deterioration in the performance of the circuit.

Soldering wires with a soldering iron is not as difficult as it seems from the very beginning, but here you need to adhere to certain rules.

To carry out this procedure, you do not need any special soldering iron for wires, since all this is done with an ordinary tool that can be purchased at any store. The main thing here is the soldering technology itself, the correct selection of the necessary materials and other features that affect the final result.

Features of soldering wires

Soldering wires with a soldering iron with acid and other types of flux is almost always carried out according to the same scheme. Regardless of what kind of flux is used and what kind of solder was selected, the same operations are carried out for the connection.

In some cases, if there is no great responsibility, then even consumables can become interchangeable.

If we are talking about contacts that may be subject to stress, or are located in another unfavorable environment, then it is necessary to strictly follow the technology.

Many craftsmen claim that soldering wires with a soldering iron to the board and to each other is one of the simplest. In fact, this is really not the most difficult procedure. The main problem here is choosing the right solder and fixing the wires so that they remain motionless until the connection is made. Selecting a comfortable position is not always possible, since much depends on the specific situation, but when working with small household appliances and electronics, no problems arise.

This procedure is one of the most common, since it is very often encountered in everyday life when repairing various things. Thus, it is worth knowing how to properly solder wires with a soldering iron, even if the need for this has not yet arisen.

Soldering tools

The main tool for soldering, without which this process would be completely impossible, is a soldering iron. Its main parameter is the appropriate power, which will allow the flux and solder to melt, but will not significantly exceed their boiling point.

Basic tools for soldering wires

In addition, the following additional tools and consumables may be needed:

• Flux - serves to improve the properties of solder during soldering;
• Solder is the main material with which parts are soldered to each other;
• Solvent – ​​helps get rid of splashed consumables;
• Magnifying glass – needed mainly when working with small wires;
• Tweezers – for working with small parts and holding solder;
• Soldering iron stand;
• Pliers;
• A small file for cleaning contacts.

Source: https://svarkaipayka.ru/oborudovanie/payalniki/kak-pravilno-payat-provoda-payalnikom.html

Is it possible to solder copper with tin?

Most often, at home, there is a need to solder copper pipes when installing water pipes or heating systems. Copper is a good material for water pipes. It does not corrode, has a smooth surface that ensures good water flow, does not become overgrown with deposits, and not only does not contain harmful substances, but even has bactericidal properties. Copper plumbing can last a very long time, 50 years or more.

A little theory

When soldering in general and copper tubes in particular, lap joints are usually used. They make it possible to ensure sufficient structural strength even if soft solders with relatively low strength are used. It is believed that to ensure satisfactory solder joint strength, the overlap should be at least 5 mm. In practice, much higher values ​​are usually used, which provides a good margin of safety.

Mutual overlap of elements in the pipeline is ensured through the use of fittings or pipe expansion and flanging operations. Parts of pipes and fittings are inserted into each other.

In this case, between the elements being connected, just such a gap is provided (0.1-0.2 mm) that is necessary for the action of capillary forces, which are a prerequisite for most types of soldering.

Under their action, the molten solder is spontaneously drawn into the gap, distributed evenly over the entire contact surface and tightly seals the connection. Capillary forces allow solder to be fed from below.

Copper pipes

Copper pipes come in annealed (soft) and unannealed (hard) varieties. The first are obtained as a result of annealing - heating to 600-700°C with gradual cooling. This operation returns copper to its natural ductility, lost during machining (stamping or rolling) during manufacturing.

Annealed pipe has some technological advantages over unannealed pipe. While inferior to it in strength, it is much superior to it in ductility. The value of its elongation at break can reach 40-60%. This means that the annealed pipe can be bent if necessary without fear of rupture.

Observing, of course, certain relationships between the diameter of the pipe and the bending radius (R = 3d-8d, depending on the bending method). Annealed copper pipes can prevent a water pipe from bursting when it accidentally freezes - thanks to the plastic deformation of the metal, which prevents the pipe from rupturing.

Anyone who has at least once encountered the replacement of steel “frozen” pipes is able to fully appreciate this advantage.

Annealed pipes are supplied in coils of 50 and 25 m, unannealed pipes are supplied in the form of measured pieces (rods) 3 and 5 m long.

Pipe connection methods

If you wish, you can do without fittings at all, or, in any case, with a minimal amount of them. True, for this you need to have a special, expensive tool that allows you to perform certain operations with pipes, namely bending, expanding and flanging. Using bending, you can do without corner fittings.

Expansion (increasing the diameter of the pipe end) allows you to do without couplings when soldering pipes. By using flanging, you can avoid purchasing tees (or corners, if you cut the pipe and install a plug at its end).

You just need to keep in mind that when using flanging, the outlet pipe must be smaller in diameter than the main one.

To perform all these operations with pipes, you must have manual or electric tools: a pipe bender, a beading machine and an expander.

When using pipe benders , the bending radius must be no less than 3.5d (d is the diameter of the pipe) for a diameter of up to 15 mm, and 4d for a diameter of 18 mm. When using a bending spring - no less than 6d.

Branded pipe benders are not cheap, so information about homemade pipe benders may be useful.

An excessively small radius may cause the pipe to rupture or collapse. Annealed pipes can be bent to a smaller radius, but a tight bend (less than 3d) is unfavorable from a flow point of view. Annealed pipes can also be carefully bent by hand. In this case, to avoid flattening, the bending radius must be no less than 8d.

Poorly executed bends, in which the pipe has flattened and the cross-section has lost its round shape or the inner surface of the bend has gathered like an accordion, cause turbulent flows in the pipe bend, which leads to erosion-corrosion damage.

Unannealed (solid) pipe, up to a diameter of 18 mm, can be cold bent with a pipe bender. Larger diameter pipes should be softened at a temperature of 500-600°C before bending.

The operation of the expander is based on the radial expansion of the segments of the cam mechanism inserted inside the pipe. The expandable copper pipe must be annealed (soft).

Thanks to the lever system, pressing on the tool handles creates the necessary force required for plastic deformation of the metal. Everything is very simple - insert the cam tip into the pipe, squeeze the handles and get a socket into which you can insert a pipe of the same diameter.

You can make a coupling from a piece of pipe by expanding both ends of the workpiece. If necessary, the end of the unannealed (solid) pipe can be annealed yourself.

flanging operation is somewhat more complicated than the expansion operation. It consists of two stages: drilling a hole with a special calibration drill and the flanging itself.

After the hole is drilled, it is necessary to insert into it a mandrel with sliding antennae lubricated with grease, and attach the outer part of the device to it, which serves as a stop when drawing. After that, a power tool is connected to the outer part.

Rotation of the spindle pulls the mandrel out of the hole. In this case, by spreading the antennae, flanging is carried out - bending the edge of the drilled hole outwards.

Now you can insert a bend into the pipe, which is a piece of pipe with a smaller diameter. To prevent it from protruding too much from the inside and preventing the movement of water, two protrusions are formed on its walls using a special tool. The latter rest against the socket, ensuring that the outlet is immersed in the hole to a strictly defined depth.

The described beading method involves the use of power tools, but there are also manual models.

Solders and fluxes

The use of low-temperature solders allows soldering to be performed at a temperature that has little effect on the strength of copper, but they produce a seam with worse mechanical characteristics. Solders for high-temperature soldering provide greater strength to the seam and allow high operating temperatures of the system, but in this case the copper is annealed and more skill is required, since it is easy to burn out the metal.

Low-temperature soldering is most in demand in water supply and heating. There are many low temperature lead-free solders that provide fairly good quality copper soldering. These are alloys of tin with antimony, copper, silver, bismuth, and selenium. The main part (up to 95-97%) of them is tin, the rest is other elements.

Silver-containing solders, for example, S-Sn97Ag3, containing 97% tin and 3% silver, have the best technological properties. Copper-containing solders, in particular S-Sn97Cu3 (97% tin and 3% copper), have somewhat worse, but quite good qualities. There are three-part solders containing tin, silver and copper (for example, a composition with 95.5% tin, 3.8% silver and 0.7% copper).

The most versatile and widely used is tin-copper solder. The disadvantage of tin-silver alloys is their higher cost compared to tin-copper alloys.

These solder compositions provide good seam quality and meet all the requirements for strength, durability and reliability of water supply and heating systems. Solders of other compositions are practically not used.

In fact, lead-tin solders are also suitable for low-temperature soldering of copper, but if a pipeline for drinking water is being soldered, they must be abandoned due to the harmfulness of lead.

Compositions containing zinc chloride are mainly used as fluxes for low-temperature soldering. However, it is hardly worth paying special attention to its composition when purchasing flux. There are many effective fluxes for soldering copper; you just need to purchase any composition designed for this. For example, F-SW 21 or rosin-vaseline paste, consisting of rosin, zinc chloride and technical petroleum jelly. The paste form is the most convenient for applying to parts.

Source: https://crast.ru/instrumenty/mozhno-li-pajat-med-olovom