Do-it-yourself hammer soldering iron - Metalworker's Guide
It is impossible to imagine any process of assembling electronic components without the main tool - a soldering iron. However, not every electronics lover has the opportunity to buy this device, and the parameters of factory devices do not always correspond to the task.
In this article we will try to explain to you how to make a soldering iron with your own hands, without resorting to high costs.
Hammer soldering iron
First, let's look at the manufacturing process for the simplest soldering iron - a hammer soldering iron. This type of soldering iron is used for soldering large parts; it heats up over a fire, and, despite the outdated design, is still used in soldering work.
A block of copper of the required size must be flattened to give the required shape and processed with a file. We forge a holder from a steel tube and attach it to the tip. Then we select a comfortable handle - and the device is ready.
Of course, you won’t be able to solder radio parts with such a device, but it’s quite suitable for repairing a radiator and soldering large elements.
Lowest cost method
Factory-produced tips are not always suitable for soldering modern electronics, but it is not at all necessary to make a soldering iron at home with your own hands; it is enough to improve an existing industrial device - just wind a thin copper wire around the tip.
Device using a resistor
If, nevertheless, the factory device does not meet the requirements, then you can build a soldering iron yourself. To make a soldering iron in the shortest possible time, you need to use ready-made metal wire with the required resistance, which can be found in PEV-type resistors.
In addition to a strong source of energy, for example, a battery from a car or even a laptop, you will need pieces of a single-core cable and a plate of fire-resistant polymer for the holder (you can use PCB or wood).
To heat a homemade device, you need to pass current through a resistor, one of the ends of which will act as a tip.
We clean the rim of the resistor with a file and crimp it with copper wire with the insulation previously removed, this will give the structure strength and improve contact.
To improve the efficiency of the soldering iron, one resistor lead should be as short as possible and the other as long as possible.
For the manufacture of such a simple device, the Russian MLT resistor is best suited, the quality of which is much higher in comparison with Chinese models.
Complex manufacturing method
If you have the skills of a lathe and milling machine, as well as the appropriate tools, you can use resistors with higher power to make a homemade soldering iron.
The tip for the device will need to be processed in such a way that it fits tightly into the hole in the resistor body and that there is enough space for the thread with which we will fix the rod.
It should be noted that in this case the tip of the device will not be subject to tension. You will also need to provide a comfortable handle.
Temperature regulator
An important element for a soldering iron will be the presence of a temperature regulator, which you can also make yourself. Since the soldering process always involves melting the solder, the soldering iron simply needs a regulator. Below is one of the simplest assembly diagrams.
All you need is a resistor SP5-30 placed in a dielectric housing. However, the power of the soldering iron in this case will be limited and will range from 10 to 25 watts.
Stand
Another important accessory is the stand. A stand for a soldering iron can be easily found on sale throughout the Internet, but it is much more profitable to make it yourself.
The most common type is the wire stand, which is made from a thick, cone-shaped spring attached to a wooden platform. In addition, the stand can be made from fuses mounted on a wooden or textolite base.
If you need a portable stand, then any metal plate, for example, from an unnecessary desktop PC power supply, is suitable for making it.
The methods we have considered will allow you to significantly save on many parts and accessories, as well as make the manufacturing process as simple and safe as possible.
Photos of DIY soldering irons
Source: https://ssk2121.com/molotkovyy-payalnik-svoimi-rukami/
Construction and repair of an electric soldering iron
An electric soldering iron is a hand-held tool designed for fastening parts together using soft solders, by heating the solder to a liquid state and filling the gap between the parts being soldered with it.
Electrical circuit of a soldering iron
As you can see in the drawing, the electrical circuit of the soldering iron is very simple, and consists of only three elements: a plug, a flexible electrical wire and a nichrome spiral.
As can be seen from the diagram, the soldering iron does not have the ability to adjust the heating temperature of the tip.
And even if the power of the soldering iron is chosen correctly, it is still not a fact that the temperature of the tip will be required for soldering, since the length of the tip decreases over time due to its constant refilling; solders also have different melting temperatures.
Therefore, in order to maintain the optimal temperature of the soldering iron tip, it is necessary to connect it through thyristor power regulators with manual adjustment and automatic maintenance of the set temperature of the soldering iron tip.
Soldering iron device
The soldering iron is a red copper rod, which is heated by a nichrome spiral to the melting temperature of the solder. The soldering iron rod is made of copper due to its high thermal conductivity.
After all, when soldering, you need to quickly transfer heat from the soldering iron tip from the heating element. The end of the rod is wedge-shaped, is the working part of the soldering iron and is called the tip. The rod is inserted into a steel tube wrapped in mica or fiberglass.
A nichrome wire is wound around the mica, which serves as a heating element.
A layer of mica or asbestos is wound over the nichrome, which serves to reduce heat loss and electrically insulate the nichrome spiral from the metal body of the soldering iron.
The ends of the nichrome spiral are connected to the copper conductors of an electrical cord with a plug at the end. To ensure the reliability of this connection, the ends of the nichrome spiral are bent and folded in half, which reduces heating at the junction with the copper wire.
In addition, the connection is crimped with a metal plate; it is best to make the crimp from an aluminum plate, which has high thermal conductivity and will more effectively remove heat from the joint.
For electrical insulation, tubes made of heat-resistant insulating material, fiberglass or mica are placed at the junction.
The copper rod and nichrome spiral are closed with a metal case consisting of two halves or a solid tube, as in the photo. The body of the soldering iron is fixed on the tube with cap rings. To protect a person’s hand from burns, a handle made of a material that does not transmit heat well, wood or heat-resistant plastic, is attached to the tube.
When you insert the soldering iron plug into a socket, electric current flows to the nichrome heating element, which heats up and transfers heat to the copper rod. The soldering iron is ready for soldering.
Low-power transistors, diodes, resistors, capacitors, microcircuits and thin wires are soldered with a 12 W soldering iron. Soldering irons 40 and 60 W are used for soldering powerful and large-sized radio components, thick wires and small parts. To solder large parts, for example, heat exchangers of a geyser, you will need a soldering iron with a power of one hundred or more watts.
Soldering iron supply voltage
Electric soldering irons are produced designed for mains voltages of 12, 24, 36, 42 and 220 V, and there are reasons for this. The main thing is human safety, the second is the network voltage at the place where the soldering work is performed.
In production where all equipment is grounded and there is high humidity, it is allowed to use soldering irons with a voltage of no more than 36 V, and the body of the soldering iron must be grounded.
The on-board network of a motorcycle has a DC voltage of 6 V, a passenger car - 12 V, a truck - 24 V. In aviation, a network with a frequency of 400 Hz and a voltage of 27 V is used.
There are also design limitations, for example, it is difficult to make a 12 W soldering iron with a supply voltage of 220 V, since the spiral will need to be wound from a very thin wire and therefore many layers will be wound; the soldering iron will turn out to be large and not convenient for small work. Since the soldering iron winding is wound from nichrome wire, it can be powered with either alternating or direct voltage. The main thing is that the supply voltage matches the voltage for which the soldering iron is designed.
Soldering iron heating power
Electric soldering irons come in power ratings of 12, 20, 40, 60, 100 W and more. And this is also no coincidence. In order for the solder to spread well over the surfaces of the parts being soldered during soldering, they need to be heated to a temperature slightly higher than the melting point of the solder.
Upon contact with a part, heat is transferred from the tip to the part and the temperature of the tip drops. If the diameter of the soldering iron tip is not sufficient or the power of the heating element is small, then, having given off heat, the tip will not be able to heat up to the set temperature, and soldering will be impossible.
At best, the result will be loose and not strong soldering.
A more powerful soldering iron can solder small parts, but there is a problem of inaccessibility to the soldering point.
How, for example, can you solder a microcircuit with a leg pitch of 1.25 mm into a printed circuit board with a soldering iron tip measuring 5 mm? True, there is a way out: several turns of copper wire with a diameter of 1 mm are wound around such a sting and the end of this wire is soldered. But the bulkiness of the soldering iron makes the work practically impossible.
There is one more limitation. At high power, the soldering iron will quickly heat up the element, and many radio components do not allow heating above 70˚C and therefore the permissible soldering time is no more than 3 seconds. These are diodes, transistors, microcircuits.
The soldering iron stops heating for one of two reasons. This is a result of chafing of the power cord or burnout of the heating coil. Most often the cord frays.
Checking the serviceability of the power cord and soldering iron coil
When soldering, the power cord of the soldering iron is constantly bent, especially strongly at the point where it exits and the plug. Usually in these places, especially if the power cord is hard, it frays. This malfunction first manifests itself as insufficient heating of the soldering iron or periodic cooling of it. Eventually, the soldering iron stops heating.
Therefore, before repairing the soldering iron, you need to check the presence of supply voltage in the outlet. If there is voltage in the outlet, check the power cord. Sometimes a faulty cord can be determined by gently bending it where it exits the plug and soldering iron. If the soldering iron becomes a little warmer, then the cord is definitely faulty.
You can check the serviceability of the cord by connecting the probes of a multimeter turned on in resistance measurement mode to the pins of the plug. If the readings change when bending the cord, the cord is frayed.
If it is discovered that the cord is broken at the point where it exits the plug, then to repair the soldering iron it will be enough to cut off part of the cord along with the plug and install a collapsible one on the cord.
If the cord is frayed at the point where it exits the soldering iron handle or the multimeter connected to the pins of the plug does not show resistance when bending the cord, then you will have to disassemble the soldering iron. To gain access to the place where the spiral is connected to the cord wires, it will be enough to remove only the handle. Next, touch the multimeter probes successively to the contacts and pins of the plug. If the resistance is zero, then the spiral is broken or its contact with the cord wires is poor.
Calculation and repair of the heating winding of a soldering iron
When repairing or making your own electric soldering iron or any other heating device, you have to wind a heating winding made of nichrome wire. The initial data for calculating and selecting wire is the winding resistance of a soldering iron or heating device, which is determined based on its power and supply voltage. You can calculate what the winding resistance of a soldering iron or heating device should be using the table.
Knowing the supply voltage and measuring the resistance of any heating electrical appliance, such as a soldering iron, electric kettle, electric heater or electric iron, you can find out the power consumed by this household electrical appliance. For example, the resistance of a 1.5 kW electric kettle will be 32.2 Ohms.
Let's look at an example of how to use the table. Let's say you need to rewind a 60 W soldering iron designed for a supply voltage of 220 V. In the leftmost column of the table, select 60 W. From the top horizontal line, select 220 V. As a result of the calculation, it turns out that the resistance of the soldering iron winding, regardless of the winding material, should be equal to 806 Ohms.
If you needed to make a soldering iron from a 60 W soldering iron, designed for a voltage of 220 V, for power supply from a 36 V network, then the resistance of the new winding should already be equal to 22 Ohms. You can independently calculate the winding resistance of any electric heating device using an online calculator.
After determining the required resistance value of the soldering iron winding, the appropriate diameter of the nichrome wire is selected from the table below, based on the geometric dimensions of the winding. Nichrome wire is a chromium-nickel alloy that can withstand heating temperatures up to 1000˚C and is marked X20N80. This means that the alloy contains 20% chromium and 80% nickel.
To wind a soldering iron spiral with a resistance of 806 Ohms from the example above, you will need 5.75 meters of nichrome wire with a diameter of 0.1 mm (you need to divide 806 by 140), or 25.4 m of wire with a diameter of 0.2 mm, and so on.
I note that when heated by every 100°, the resistance of nichrome increases by 2%. Therefore, the resistance of the 806 Ohm spiral from the above example, when heated to 320˚C, will increase to 854 Ohms, which will have virtually no effect on the operation of the soldering iron.
When winding a soldering iron spiral, the turns are laid close to each other. When heated red-hot, the surface of the nichrome wire oxidizes and forms an insulating surface. If the entire length of the wire does not fit on the sleeve in one layer, then the wound layer is covered with mica and a second one is wound.
For electrical and thermal insulation of the heating element winding, the best materials are mica, fiberglass cloth and asbestos.
Asbestos has an interesting property: it can be soaked with water and it becomes soft, allows you to give it any shape, and after drying it has sufficient mechanical strength.
When insulating the winding of a soldering iron with wet asbestos, it is necessary to take into account that wet asbestos conducts electric current well and it will be possible to turn on the soldering iron into the electrical network only after the asbestos has completely dried.
Source: https://YDoma.info/tehnologii-remonta/kak-payat/kak-payat-ustroystvo-payalnika.html
Homemade soldering iron with your own hands at home
The need to solder may arise not only for radio amateurs. Soldering may also be required when repairing an electrical outlet or a 12-volt car battery. In some cases, you need a mini-soldering iron for microcircuits, which may not always be at hand. Therefore, many craftsmen are wondering how to make a soldering iron with their own hands.
What is a homemade soldering iron?
There are several options for making a homemade soldering iron. The simplest model to use is a 200 V soldering iron with a resistor. The advantages of such a soldering iron are that there is no need to find a special power supply. In addition, the power of the device can be independently varied, which expands the scope of its application and allows this tool to be used for repairing both small household appliances and metal pans.
In this case, the sting is a red copper element, which allows you to regulate the power of the device.
Structure and principle of operation
Soldering irons, regardless of configuration, are simple in design. They are a copper rod (tip), which interacts with the heating element during operation. This structure is placed in a tube, which acts as a housing. The heater is powered from the electrical network, for which a wire is connected to it. The design also includes a handle made of a material with low thermal conductivity.
Required material
To make a homemade soldering iron you will need the following materials:
- red copper rod (this material is characterized by high thermal conductivity, the thickness of the rod depends on the required power of the product), most often a wire with a diameter of 1.5 mm and a length of 40 mm is chosen;
- copper foil;
- resistor (must correspond to the required power of the soldering iron);
- nichrome wire 0.2 mm (length approximately 35 cm);
- silicate glue (liquid glass);
- talc (mixed with silicate glue to obtain an insulating layer);
- asbestos thread;
- wires (they must correspond to the power of the product, and some of them must be heat-resistant);
- a metal tube that will serve as a housing;
- a handle or any similar product made of a material with low thermal conductivity.
Calculations of the amount of material and its parameters must be performed based on the selected power.
In addition to the materials indicated, you will need a standard set of tools:
- heat source (this could be a stove, it doesn’t matter if it’s electric or gas);
- wire cutters;
- tweezers;
- pliers;
- file;
- spatula (or similar wooden or plastic object);
- a rag (you will need a lot of it) to remove the insulating mixture.
The first stage is performing calculations. They are based on the laws of physics, in particular Ohm's law. For example, a 100 ohm resistor will be used for manufacturing.
The current strength in this case will be 2.2 A, which means that the power of the soldering iron will become 484 W, which is too much for such a device. This means that you will need to reduce the voltage using a capacitor (it is better to take a 10 µF part up to 300 V).
In this way, you can reduce the voltage by almost 4 times, that is, to 0.5 A, obtaining a soldering iron power of 55 W, which is less than the original one.
After the calculations have been carried out and the necessary materials and tools have been prepared, you can proceed to mechanical assembly. It is performed in the following sequence:
- First you need to make a sting from a copper rod. To do this, you need to sharpen one end of the wire to a bilateral angle of 40-45°. It is not necessary to maintain this angle; it is enough to sharpen at the angle at which it will be convenient to work in the future. Tin the processing area.
- Wrap the tip in copper foil, leaving the working part free (no more than 10 mm), then place the tip in the resistor, fix it with an insulating mixture (you must first combine silicate glue and talc to obtain a dough-like mass). This also protects the main part from cracks during operation. The insulating layer must be baked by holding the device over a heat source.
- If nichrome wire is used, it is wound on silicate glue and then covered again with an insulating layer.
- Strengthen the insulation at the junction of the wires and the heating element, for which asbestos thread is suitable (you can additionally use a ceramic sleeve).
- The resulting structure must be placed in a prepared iron tube, onto which a handle made of heat-resistant material (preferably wood or PCB) is then attached. First, you need to cut a hole in the hole of the handle through which to pass the wire (by analogy with industrial soldering irons), with the help of which the device is connected to the network.
Tips and nuances of work
There are several nuances that can simplify the work of assembling and operating a homemade soldering iron.
PE or PEV type parts can be used as a resistor. These resistors are capable of extinguishing resistance modes, and it will not be possible to do without them during the further operation of the soldering iron. It is allowed to use a resistor of the MLT-05 series. It is characterized by a resistance of about 5-10 Ohms, which may be suitable for a DIY micro-soldering iron.
You need to pay attention to other nuances:
- The paint from the resistor must be removed. To do this, you can use a medical scalpel or fine sandpaper.
- The legs of the resistor also need to be cleaned (in most cases, only one leg will need to be cleaned, since the second will be used as a live part of the soldering iron).
- The hole into which the tip will be inserted must be larger in diameter than the tip. This is necessary so that the tip does not come into contact with the cup and the device does not overheat.
Safety
When working with a homemade soldering iron, you must follow safety precautions:
- during operation, you must constantly ensure that the tip does not come into contact with electrical wires, which can cause damage to the cable insulation and its melting, which will lead to a short circuit;
- it is necessary to periodically inspect the wiring and the device itself for damage, this will prevent electric shocks;
- In addition to the electric soldering iron, you need to make a stable stand for it so that it does not roll off the work surface and hit other objects or people;
- You need to work in a well-ventilated area, since rosin and solder can emit toxic fumes.
The soldering iron should always be held by the handle (not by the cable).
Source: https://electrod.biz/payka/samodelnyj-payalnik.html
How to make a pulse soldering iron with your own hands
A pulse soldering iron heats up much faster than a regular one and allows you to quickly install or dismantle a wide variety of components of electrical and electronic devices. It is equipped with a voltage regulator, so you can conveniently control the heating temperature. This device uses copper wire as a tip.
What type of device does a gasoline blowtorch have?
How to use the device? After connecting to the network, you must select the voltage level suitable for specific work.
After that, all you have to do is press the button and start soldering.
While the button is held down by the user, the device warms up the tip.
How does a pulse soldering iron work? The design of this device provides for the use of a mains voltage converter to high frequency voltage, as well as an HF transformer.
All this is controlled by a microprocessor, which maintains the tip heating temperature at the desired level and turns off the device when used for more than 20 seconds to protect against overload.
A pulse soldering iron works on the following principle: when you press a button, the secondary winding of the transformer is closed and the tip is heated. By releasing the switch, you open the contacts, so no current is supplied to the winding.
Is it possible to make a pulse soldering iron with your own hands?
A pulse device is much more expensive than a regular one, but we know a great way to save money. For this purpose, you can make a device with your own hands. But first you need to select a suitable current source.
The device can be made:
- From a power supply with a step-down transformer. The advantage of this method is a very simple circuit in which the leads of the secondary winding are connected directly to the conductive busbars (the soldering iron tip is, in turn, attached to them). Disadvantages - rapid failure of the primary winding of the transformer, large dimensions and weight of the finished device, the occurrence of vibration during the soldering process, which is unacceptable when working with small parts.
- From an electronic transformer. It significantly outperforms the previous PSU in size and weight, and is also completely devoid of the above-mentioned disadvantages.
In this article we will look at the process of manufacturing a device from a transformer that supplies power to 12-volt halogen lamps. This device comes in a very convenient case, which can be easily converted to a pulse soldering iron.
Stages of making a pulse soldering iron with your own hands
To turn an electronic transformer into a modern, cost-effective soldering device, you will need to perform several steps:
- We dismantle the transformer. The main purpose of this stage is to separate the parts of the core from each other and remove the secondary winding of the power supply.
- We select a suitable tire for re-winding. A two-core copper wire with a cross-section of approximately 6-7 millimeters is suitable for this.
- We make only one winding, after which we separate it from the core with cardboard or other material that does not allow current to pass through.
- We tinning the ends of the winding.
- We connect the converted power supply to the network and close the ends of the new secondary winding with stranded copper wire. It should heat up or melt in just a couple of seconds. It is this sign that indicates that we are moving in the right direction.
- We make the tip of our future soldering iron. Copper wire with a diameter of 1-2 millimeters is suitable for this purpose.
- We attach the tip to the ends of the secondary winding. It is best to use bolts in order to conveniently replace worn or heavily contaminated wire in the future.
- We place the power supply in the case. At this stage it is important to ensure that there is no contact between it and the tire. It is best to install insulating materials that can withstand prolonged temperature loads - fluoroplastic or fiberglass, ceramic parts.
- If necessary, we make a handle, close the case and begin working with the device.
Additionally, you can install the following parts on the device:
- LEDs that will provide voltage indication. It can be determined by the brightness level of the LED elements.
- Button to turn the device on and off. This component must be used in the design, since only when it is pressed will voltage be applied to the tip. The button is mounted directly at the power input.
- Variable resistor for voltage regulation. This detail will allow you to conveniently operate the device.
In addition, the pulse soldering iron can be equipped with a microcontroller to improve control efficiency. Select the correct firmware to ensure reliable protection against overheating and overload of your homemade device.
Source: https://steelfactoryrus.com/kak-sdelat-impulsnyy-payalnik-svoimi-rukami/
Why can't you use chrome wire in a soldering iron? — Website about
If you, a fellow hobbyist, have already “outgrown” a soldering iron with a voltage regulator, but have not yet “grown up” in your ambitions to a professional soldering station, then this might be interesting.
The ability to change the supply voltage of a soldering iron designed for 220 V, among other things, allows you to return to operation an already burnt-out one.
And use it in the future, for example, with a switching power supply from an imported TV, which at the output gives exactly half of the network one.
Bringing these two products together results in an intermediate option between a soldering iron with a regulator and a full-fledged soldering station. Any radio amateur can do this. I’ll show you how to do this using the example of changing the supply voltage of a Chinese-made soldering iron, which was not trustworthy for use without modification.
Disassembling the soldering iron
To disassemble the soldering iron, it was necessary to completely unscrew two screws connecting the protective casing to the heating element and holding the tip, and three self-tapping screws securing the working part to the handle. Remove the insulation from the wires and unscrew the connecting twists.
Mica with soldering iron spiral
There is a heating element inside the protective casing. That's what they have to do. It is necessary to change the amount of wound nichrome wire - change the resistance of the heating element.
Now it is 1800 Ohms, 400 Ohms are needed.
Why exactly so much? Currently working with a UPS, the soldering iron has a resistance of 347 Ohms, its power is from 19 to 28 W, there is a desire to make the second one less powerful, so I added Ohms.
Soldering iron rewind
Winding a soldering iron tip
The tip is reinserted into the heater, clamped with screws and into the drill chuck. If you disassemble and unwind excess nichrome while holding the heating element in your hands, then everything will be much more complicated. The tie wire is removed.
The released fiberglass and mica wrappers are removed. In the mica on the side of the tip, there is a slot into which a conductor is inserted, going from the nichrome to the network wire - therefore, the weakened mica wrapper is removed from it rather than unwinding. Mica is a very fragile material. The end of the nichrome wire wound to the conductor is disconnected. Its thickness is just over 4 microns.
Nichrome must be wound onto something round; the ideal option is a spool of thread. He unscrewed it, rewinded it, and so on until the end. There is no need to disconnect the second end of the nichrome wire.
Soldering iron wire resistance
Now you need to wind a length of 400 Ohms, and in centimeters it will be approximately 70 (the total length of nichrome wire 300 cm is 1800 Ohms, hence 400 Ohms will be 66.66 cm).
At a length of 70 cm, a latch (clothespin) is placed and in the hanging position of the coil, slightly guiding with your fingers, winding is carried out at intervals ensuring its termination at the first conductor.
The number of attempts is not limited, the main thing is not to tear the nichrome. At the end of winding, a control resistance measurement is required.
As soon as we manage to wind the required amount of nichrome, we cut the wire with an allowance of 1 - 2 cm and wind it to the conductor. We put on the mica winding, passing the conductor into the slot in it and press it against it (naturally on top of it).
We install a fiberglass winding on top and, compacting it by pressing, wind the binding wire. A heating element designed for power supply voltage of 85 – 106 V is assembled.
Soldering iron assembly
Since the working part was previously attached to the handle with incomprehensibly clumsy and short screws, they had to be replaced. To do this, holes for new screws were deepened in the attachment points on the handle.
Before connecting the power cable with the conductors going to the nichrome heater, a plastic clamp was installed and adjusted on it.
The casing of the heating element ends with a kind of cooling radiator, through holes in it and is attached to the handle. To increase the cooling effect, the gap between it and the handle was increased using metal washers.
Tests
Soldering iron current consumption 190 mA
The UPS with which the soldering iron will work at the output under load gives from 85 to 106 V. Current consumption is 190 mA, this is at the minimum voltage. Power 16 W.
Soldering iron current consumption 240 mA
At maximum voltage, current consumption is 260 mA. Power 26 W. The desired has been received.
Heating rate
Finally, a test for heating duration. Up to 257 degrees in 2 minutes 20 seconds. An excellent result, if you take into account that from a 225 V network it heated up to 250 degrees in 5 and a half minutes.
Table. Dependence of the resistance of the heating element on the power and voltage of the soldering iron
And here is a table that will help you navigate the required resistance of the heating element, depending on the desired power and the available supply voltage. Author: Babay iz Barnaula.
Electronics repair
Source: https://kak-vse-ustroeno.ru/nauka-i-tehnika/pochemu-v-payalnike-nelzya-stavit-hromovuyu-provoloku.html
What can be made from nichrome wire
Nichrome wire is not such a hard-to-find material as it might seem at first glance. Some stores charge quite an impressive price for it. However, there is no need to spend money when you can get the material completely free or for pennies.
Nichrome wire is a component of all heating elements of household appliances. A regular electric kettle contains about one and a half meters of such wire; it can also be found in old models of irons, which contain about 2 meters of nichrome.
If you have a non-working fan heater, you can also remove nichrome wire from it. It is quite easy to get it out of faulty toasters and hair dryers. Nichrome can be removed from the heating element in the washbasin.
You need to carefully open the tenu with a grinder and clean the wire from the white insulation.
A minimum investment will be required if you purchase the cheapest soldering iron for 50 rubles. There is a wire with a cross-section of 0.1 mm and a length of about 2 meters. In this case, the wire with the plug and other parts are also a bonus, so we can assume that the nichrome wire was received practically for nothing. Among budget purchases, it is worth noting spirals for open-type tiles, which can be selected with different sections.
The qualities of nichrome wire can be determined by its types. It can be designed for heating elements, resistance elements and tubular electric heaters.
There is a fairly simple way to determine that nichrome is used in the device. You need to check the wire with a magnet. Kanthal, similar to nichrome, is magnetic, unlike nichrome.
Usually, at home, such wire is very convenient for cutting foam and polystyrene. To do this as quickly and efficiently as possible, you can build a simple cutter, the main part of which will be a hot nichrome string.
To do this, you need to prepare a step-down transformer, a lining made of some pipe with a thickness of at least 2 cm, and the thickness of the foam plastic should also be at least 2 cm. You also need springs for tensioning the string and the nichrome wire itself. As a base, you can take a tabletop, board or sheet of corrugated board.
For shaped cutting of foam plastic, you will need a cutter made of fairly thick wire, which will be attached to an insulated handle.
Soldering irons are not the least important tool for a home craftsman. Depending on what they are intended for, their appearance and design can be very different from each other. For example, it is impossible to use the same tool for soldering a car radiator and working with microcircuits and transistors.
A soldering iron is necessary for soldering various microcircuits and parts.
It is not always possible to buy a soldering iron with the required characteristics. But it is quite possible to make such an electric soldering iron with your own hands, especially since this work is not particularly difficult - if only you had the time and desire.
How to make a homemade vice - read here.
Soldering irons with a resistor as a heating element
The easiest tools to make are those in which a fairly powerful resistor acts as a heating element. Let's look at a few examples of how to make a soldering iron of this design.
Soldering iron made from wire resistor
The design of a soldering iron "gun".
It is clear that in order to make such a soldering iron with your own hands, you need a suitable wirewound resistor. For a 12 V soldering iron that can be powered not only from an appropriate current source, but also from a car battery, a 20 Ohm resistor rated at 7 W is suitable.
Source: https://MyTooling.ru/instrumenty/chto-mozhno-sdelat-iz-nihromovoj-provoloki
Making a soldering iron with your own hands at home
Many people use homemade soldering irons. There are quite a lot of implementation options, since these tools are sculpted from what is at hand or can be easily found. The most labor-intensive process is to make a soldering iron, similar to a factory one, but of low power. Here is an example of what and how to make a miniature soldering iron for microcircuits at home. It is assumed that the soldering iron will receive power not directly from the network, but through a 220/12 V transformer.
List of components for a homemade 12 volt soldering iron
You will need the following materials:
- copper wire with a diameter of 1.5 mm - about 40 mm long
- copper foil - a small rectangle 30x10 mm or a little larger
- nichrome wire 0.2 mm – 350 mm
- a tin tube or piece of tin to make a casing for the heating element
- silicate glue (liquid glass)
- talc for the production of an insulating layer with the addition of silicate glue
- handle made of heat-resistant plastic
- electrical cord with plug
Some auxiliary things will also be required:
- heat source (electric or gas oven)
- standard tools (nippers, tweezers, pliers, file)
- non-standard devices (something in the form of a narrow small spatula - wooden or plastic)
- a lot of rags (remove very sticky insulating mixture from hands and tools)
Sequence of actions for assembling the tool
The description of the process is given schematically, since implementation usually does not cause difficulties.
Important!
The finished soldering iron can be connected, as already mentioned, to the network via a transformer or to a 12-volt power supply rated for a current of 1 A. This soldering iron can work with microcircuits, but care should be taken to protect against static electricity.
An alternative option to such a soldering iron is of interest to those who are unpretentious about the appearance of the device they will have to work with. The trick of this solution is that a PEV-10 or PEV-7.5 resistor is used as a heating element. All that remains is to insert the tip, which is fixed in a copper tube tightly seated inside the resistor, and take care of good fixation of the resistor contacts, which cannot withstand certain mechanical loads.
how to make a mini soldering iron with your own hands
The following video will help you figure out how to make a homemade mini soldering iron:
Source: https://elektrik24.net/instrumentyi/payalniki/kak-sdelat-svoimi-rukami.html
3 simple ways to make a soldering iron from scrap materials
/ Articles / 3 simple ways to make a soldering iron from scrap materials
On the Internet you can find many instructions for making powerful soldering irons from improvised materials.
To create some products, you need good knowledge of radio engineering, but in most cases, a homemade soldering tool can be easily assembled even by a novice electrician.
Next, we will talk about how to make a soldering iron with your own hands at home, without having professional skills in working with radio equipment. 3 simple instructions will be provided to your attention, from the simplest to the most complex!
Idea No. 1 – Use a resistor
The first and simplest technology for making an electric soldering iron with your own hands is using a resistor. The device will be designed to operate at voltages from 6 to 24 Volts. In order to make the instrument yourself, you will need the following materials:
- Resistor with characteristics: resistance 20 Ohms, power 7 Watts.
- Textolite plate for making a comfortable handle.
- Two copper rods of different sections. The thicker one is selected strictly according to the internal diameter of the resistor. The second one should be thinner, for the convenience of soldering microcircuits with a small tip.
- One bitten off spring ring (will serve as a retainer), a screw and a washer. You can see all the components in the photo below.
To make your own soldering iron from a resistor at home, you must complete the following steps:
Please note that with such a portable gun you can easily solder microcircuits and even make a charger for a car battery with your own hands. It can work not only from the power supply, but also from batteries. We came across many reviews on the forums where this homemade version was connected from a 12-volt cigarette lighter, which is also very convenient!
instructions for making a simple electrical appliance
Idea No. 2 – Second life for a ballpoint pen
Another unusual, but at the same time simple idea for making a soldering iron with your own hands from scrap materials. In this case, we again need a resistor, but in this case it is no longer a PEV (as in the previous version), but an MLT.
So, first you must prepare the following materials:
- Ballpoint pen of the simplest design.
- Resistor with characteristics: resistance 10 Ohm, power 0.5 W.
- Double-sided textolite.
- Copper wire with a diameter of 1 mm.
- Steel wire with a diameter of no more than 0.8 mm. It should be noted right away that the steel must take shape and at the same time not be soft; later you will understand why.
- Wires for connecting to the network.
Making a soldering iron from a pen at home is quite simple, you just need to follow these steps:
That's the whole technology for creating a homemade mini soldering iron at home. As you can see, there is nothing complicated and all the materials can be found at home by disassembling old equipment. This tool can be used to solder SMD components on microcircuits with your own hands.
https://www.youtube.com/watch?v=x9g3HvrdVVA
How to make a more complex model of a mini soldering iron at home?
review of a device with nichrome wire operating on 12 Volts
Idea #3 – Powerful impulse model
Well, the last option is suitable for those who are already more or less familiar with radio engineering and know how to read the corresponding diagrams. A master class on making a homemade pulse soldering iron will be provided following the example of this diagram:
The advantage of a more powerful tool is that the tip will heat up within 5 seconds after turning on the power, and the heated rod can easily melt tin. At the same time, you can make it from a switching power supply from a fluorescent lamp, slightly improving the board at home.
As in previous examples, we will first consider the materials from which you can make a soldering iron with your own hands at home. Before assembly, you must prepare the following available tools:
- Ferrite ring from a pulse converter. The primary winding of the transformer should consist of 100, maximum 120 turns of copper wire with a diameter of 0.5 mm. The secondary winding is represented by one turn of a copper busbar, with a diameter of no more than 3.5 mm.
- Copper wire, with a diameter of 1.5 to 2 mm, as a tip.
All you need is to connect the tip to the secondary winding, which, in fact, is already part of it. After this, one of the ballast terminals must be connected to the mains winding of the transformer and that’s it, consider that you have managed to make a good, fast-heating pulse soldering iron at home!
In addition, we recommend watching a video that shows how to easily make a soldering iron stand at home, as well as a temperature controller:
Simple instructions for making an adjustable device
Don't want to waste time creating an electrical device? Roman Ursu will tell you how to make a simple but effective soldering iron from a lighter without a spiral or mica:
Compact lighter heater
We still recommend using either the first or second option, which is more understandable and easier to manufacture. As for the transformer version, although it is more powerful, it is still not so convenient to use. We hope that these photo instructions were useful for you and finally, we recommend that you watch all the video examples in which the assembly process is discussed in more detail!
instructions for making a simple electrical appliance
How to make a more complex model of a mini soldering iron at home?
Simple instructions for making an adjustable device
review of a device with nichrome wire operating on 12 Volts
Compact lighter heater
Photo gallery (21 photos)
15.12.2016
Source: http://gopb.ru/stati/3-prostyx-sposoba-sdelat-payalnik-iz-podruchnyx-materialov/
How to make a pulse and miniature soldering iron with your own hands?
A DIY soldering iron is a good alternative to expensive store-bought counterparts. A properly designed product will cope with all the tasks that you may encounter in everyday life (restoring flying contacts, soldering wires when they are extended, etc.).
Figure 1. Diagram of a simple soldering iron.
In the modern market of power tools, soldering irons are presented in a wide range. These can be both domestic and foreign models, which differ not only in cost, but also in design and principle of operation.
Therefore, before you start assembling a homemade soldering iron, you need to consider the classification of this tool and understand the operating principle of each type.
With this knowledge, you will be able to make a functional product that will not only be convenient to work with, but also safe.
Types of household soldering irons
A soldering iron is an electrical tool that is designed to connect metal elements together using solder. Metal alloys based on copper, tin, lead, etc. are used as solder.
The simplest soldering iron consists of the following elements (Fig. 1):
Figure 2. Diagram of a mini-soldering iron with a nichrome heating element.
- sting;
- kernel;
- heater;
- frame;
- pen;
- power cord with plug.
The rod and tip are made of red copper. This is due to the fact that this material has high thermal conductivity, due to which the heat from the heating element (nichrome spiral thread) is freely transferred to the solder, resulting in metal soldering.
In addition to a tool with a spiral heating element (EPSN), there are also other types of soldering irons, among which the most popular are:
- Induction. The principle of its operation is based on an inductor element. A magnetic field is generated around the ferromagnetic core using an inductor, which leads to heating of the tip.
- Ceramic. In this tool, the working element is a ceramic rod, which heats up when an electric current is applied to it. Ceramic products are characterized by high efficiency, rapid heating of the tip, the ability to adjust the output temperature and durability.
- Pulse. Such a soldering iron looks like a gun, which is put into operation by holding down the start button. The main advantage of a pulse tool is the almost instantaneous heating of the tip (within 4-6 s).
- Rechargeable. A battery is used as a power source. The power of such a product is about 16 W, so it can only solder simple electronic elements.
DIY mini soldering iron
Figure 3. The pulse soldering iron is designed to perform simple work on assembling electronic microcircuits.
To make your own miniature soldering iron for working with microcircuits, you need to prepare the following tools and materials:
- 12 V power supply or transformer;
- heat source (gas or electric oven);
- pliers, wire cutters, file;
- nichrome wire 0.2 mm thick and 30-35 cm long;
- copper wire with a cross-section of 1.5 mm and a length of 3.5-4.5 cm;
- metal tube;
- plastic handle;
- electrical cord with plug;
- copper foil;
- silicate glue;
- talc.
The diagram of a mini-soldering iron with a nichrome heating element is shown in Fig. 2. First of all, a sting is made from copper wire. To do this, one end of it is sharpened with a file to a convenient shape (double-sided angle or cone). Treated areas should be tinned.
Then an insulating solution is mixed from silicate glue and talc. Next, the tip of the future soldering iron must be wrapped in copper foil. In this case, the working part of the product (about 1.0-1.5 cm) should be open. A thin layer of the prepared electrical insulating mixture is placed on top of the foil and dried at a temperature of 120-140°C.
Figure 4. Electrical circuit of a homemade pulse soldering iron.
The next step is winding the nichrome wire. The coils should be tight, the length of the straight end should be about 3 cm, and the curled end should be 6 cm. Then the product is once again covered with the prepared solution and dried at the same temperature.
The long end of the wire is laid on a metal tube so that there is a maximum distance between it and the smaller end. After this, the final treatment with an insulating solution and baking is carried out. The heating element with the tip is ready.
At the last stage, a power cord is pulled through the handle, to which the protruding ends of the nichrome wire are connected. Bare areas should be insulated with the remaining mixture. To protect your hands from burns, you can put a special casing made of thermal insulating material on the heating element. You need to connect such a homemade soldering iron through a step-down transformer or a power source that produces 12 V.
Assembling a pulse soldering iron
The DIY pulse soldering iron is designed to perform simple work on assembling electronic microcircuits. The working element in it, as in the first example, is a copper wire, the heating of which is carried out using a pulsed electric current of low voltage (Fig. 3).
Before making a pulse-type soldering iron, you need to prepare the following tools and materials:
Soldering iron operation diagram.
- tester;
- pliers, wire cutters, file;
- electronic transformer;
- copper wire 1.5 mm thick;
- copper wire with a diameter of 1.0 mm;
- Light-emitting diode;
- on/off button;
- dielectric stand;
- insulating housing.
The electrical circuit of a homemade pulse soldering iron is shown in Fig. 4. The main element of this tool is an electronic transformer, which can be based on a 40 W switching power supply installed in fluorescent lamps. In this block, remove the secondary winding of the transformer, and then use 1.0 mm thick copper wire to make 1-2 turns around the core.
After this, the modified transformer is mounted in a pre-prepared housing in the form of a pistol. The tool's on/off button will act as a trigger. In place of the barrel, a dielectric stand is installed with a copper tip at the end in the form of a loop.
The working element is connected to the ends of the wire wound around the transformer. When you press the start button, the circuit closes, causing the copper tip to heat up. To visualize the operation of the soldering iron, it can additionally be equipped with an LED.
When soldering, it is not recommended to press the button for a long time, as this can lead to overheating of the transformer and damage to the tool.
There is nothing difficult in making a soldering iron with your own hands, so everyone can handle the upcoming work. Please remember that this product runs on electricity. Therefore, during the work process, follow all electrical safety rules, which will protect you from injury and the tool from premature failure.
Source: https://masterinstrumenta.ru/info/payalnik-svoimi-rukami.html
DIY soldering iron from a resistor
In many areas of activity, there is a need to ensure strong permanent connections between parts that have the same or different chemical composition. This type of connection includes soldering, which is based on fastening two or more parts using heated solder.
The difference in the chemical composition and physical properties of both the parts themselves and the solders used requires different heating temperatures at the joints. Usually soldering is divided into low-temperature and high-temperature.
In the first case, it is necessary to ensure that the added solder is heated to a temperature of 450 °C; in the second case, the temperature must be significantly higher than this mark. To implement this technological process, modern manufacturers offer a large number of types of soldering irons.
True, such an electrical device as a soldering iron can be made independently at home. The most important thing is to understand the scope of its application, what you plan to solder: microcircuits in electronic equipment or samovars.
Required physical characteristics for a homemade soldering iron
The wide selection of soldering irons on the market today makes it easy to choose a device to solve specific problems. However, many people try to have a homemade soldering iron. To do this, you should consider the required physical characteristics of a homemade soldering iron.
These characteristics are divided into the following quantities:
- voltage supplied to the heating element (for electric soldering irons);
- heating element power;
- the presence of a power regulator;
- the size and shape of the sting;
- solder heating method;
- handle configurations;
- cost.
According to the first parameter, either a standard alternating voltage of 220V, or a constant voltage of 12V, 24V is supplied to the electric soldering iron. The voltage value determines the power of such soldering irons. It has discrete values at 20 W intervals. That is, 40 W, 60 W, 80 W and so on. More advanced devices have a special power regulator for the soldering iron.
Homemade battery-powered soldering iron
The size and shape of the soldering iron tip has a fairly wide range of design solutions. Often, special attachments are used to work with complex radio-electronic devices (for example, for soldering microcircuits, depending on its design).
Modern soldering irons use the following methods for heating solder:
- Using an electric current applied to a heating element. In this case, the following are used: nichrome wire, ceramic rod, induction coil, pulse converter.
- Gas apparatus. The solder is heated due to the combustion of the gas jet. You can call it a mini welding machine. Such devices belong to professional equipment.
- Infrared stations. The solder is heated using infrared radiation. It creates a heating zone from 10 millimeters to 60 millimeters. The size and shape of the heating zone may vary depending on the design of the infrared window.
Gas soldering iron design
The most commonly used devices are those that heat the tip using electric current. The small number of elements and the simplicity of the design allow us to say that you can make a soldering iron with your own hands.
The procedure for self-assembly of a soldering iron
The need to have a homemade soldering iron can be dictated by two considerations: the characteristics of existing samples do not meet specific requirements, and the desire to reduce the cost of purchasing a soldering iron. To understand how to make a soldering iron with your own hands, you need to consider its structure.
A typical electric soldering iron includes: a heating element for the soldering iron, a tip, a body, a protective apron, a handle, and a lead wire. All of the listed elements can be made with your own hands or selected from ready-made elements from others, for example, faulty appliances.
Currently, there are a large number of homemade designs of such devices. The most popular are the following:
- changing an existing design or adding necessary parts (for example, changing the diameter of the tip);
- adding a soldering iron heating power regulator;
- homemade micro-soldering iron;
- resistor device.
Changing the design of a soldering iron involves changing the shape of the tip, and thereby reducing the power and time of contact with the part.
There are times when even low-power soldering irons (for example, 25 W or 40 W) are not able to solve the required problem. In this case, a nichrome wire is wound in a spiral onto the finished tip, leaving one end free, as a new tip. Thus, it is possible to significantly reduce the diameter of the tip, which reduces the contact area with the part.
The use of a homemade power regulator in combination makes it possible to obtain improved heating characteristics. In amateur radio literature, you can choose a power regulator circuit based on your requirements, access to the required radio components, and experience in assembling radio devices.
Schematic diagram of a 36V soldering iron power regulator
Typically, a thyristor or triac is used as a regulating element. A microcontroller is used to stabilize the output parameter. The choice of body shape remains with the manufacturer. More often, ready-made housings are used: sockets, extension cord housing, housing from a mobile phone power supply, and so on. Therefore, making such a power regulator for a soldering iron yourself is quite simple.
Homemade hammer soldering iron
For soldering large parts, you can make a homemade hammer soldering iron. It received such a specific name due to the tip, which is shaped like a hammer. The power of such a soldering iron can reach 200 watts.
It's not difficult to make. The most important thing is to think over a system for reliable fastening of the tip. Usually it is quite massive. The main problem in manufacturing is the difficulty of finding a blank for the tip.
The simplest miniature soldering iron
For soldering small parts, you can use a micro-soldering iron yourself. To make it, parts from a burning device are used. You will get the simplest miniature soldering iron.
The simplest DIY soldering iron
In this case, it is necessary to replace the tip and give it the required configuration. Most often, ordinary copper wire with a diameter of 0.16 mm is used.
Soldering iron with a resistor as a heating element
An interesting design can be implemented using a powerful resistor. With its help, you can make a soldering iron with your own hands. To assemble such a device you will need the following parts:
- Resistor of the PEV series, designed for power up to 10 W, with a rating of 15 to 27 Ohms. It should be taken into account that it will be connected to a 12V or 24V network.
- Copper rod. It will act as a soldering iron tip. It should be taken into account that the outer diameter of the rod must correspond to the inner diameter of the resistor hole. The rod should fit tightly in this hole. You can provide a hole into which a bolt will be screwed to secure the rod.
- A ready-made spiral, which is present in the resistor, is used as a heating element. It is designed for a specific resistance and will provide the necessary dissipation power.
- Power cord with plug.
- Handle for attaching the resistor. It must be made of dielectric material and have high thermal insulating properties. In addition, for convenient operation, the handle must be given an ergonomically sound shape.
If such a device is planned to be used to solve a wide range of problems, it is advisable to connect it to a power regulator.
DIY electronics
A soldering iron designed for 12 Volts from your own autohorse can be made in an hour or two, which can be very useful for a home craftsman.
The basis of the heating element will be, believe it or not, a resistor PEV-10 or PEV-7.5! This design is just an example, and the flight of fancy of crazy hands is unlimited here. The main thing here is to have two copper rods of different diameters and the PEV resistor itself.
I found a description of such an original design on the Internet. Damn, live forever and learn! For how many years I have been interested in electronics and various crafts, but I have never heard of this and would not have thought about it myself.
In fact, if you are not in the garage, you will need to solder something into some device in your car, because you will not have 220 volts at hand. So such a homemade soldering iron, made with your own hands in an hour, can really help you out in such a situation. And if you have a powerful old transformer with a 12-volt output lying around, then this miracle soldering iron will also work at home!
PEV resistors
These resistors come in high power.
I remember at the factory when I worked as a radio assembler, we had soldering irons at 36 volts and they were regulated in a primitive way: through the sequential connection of such huge resistors into their power circuit, similar to these, but only with cylindrical regulation. For this, resistors of the PPG-25G type were used. As the temperature decreased, part of the energy was dissipated on this resistor, and given that we had 40-watt soldering irons, these resistors got really hot.
That's Russian ingenuity! In fact: resistors are made of ceramics, designed for enormous heating (I know, I’m telling you as a practitioner), they are made firmly, reliably - it can be used as a heating element of a soldering iron. The number in the name means the power of the resistor, if you haven’t guessed.
The design of a homemade soldering iron
Well, now all that remains is to fix the soldering iron tip inside the PEV-10 (PEV-7.5) resistor, and attach a handle to its terminals. And, as I mentioned, the conclusions, like everything else in these resistors, are made for centuries - you’ll tear them off!
This is roughly how a sting is made, together with a body that transmits heat, from two copper rods, inserted inside the resistor.
In the large rod, recesses are drilled on both sides: for the tip itself and for the mounting bolt. Then threads are cut into them. The thread is also cut on the tip of the future soldering iron.
On the large rod you need to make a groove for the steel retaining ring, then put it on.
After which the structure of the tip and the heating element of the soldering iron are assembled together.
Hehe, cheap and cheerful!
Source: http://anod7.ru/payalnik-dlya-avtomobilya-na-12-v/
Disassembling and rewinding the soldering iron
If you, a fellow hobbyist, have already “outgrown” a soldering iron with a voltage regulator, but have not yet “grown up” in your ambitions to a professional soldering station, then this might be interesting. The ability to change the supply voltage of a soldering iron designed for 220 V, among other things, allows you to return to operation an already burnt-out one.
And use it in the future, for example, with a switching power supply from an imported TV, which at the output gives exactly half of the network one. Bringing these two products together results in an intermediate option between a soldering iron with a regulator and a full-fledged soldering station. Any radio amateur can do this.
I’ll show you how to do this using the example of changing the supply voltage of a Chinese-made soldering iron, which was not trustworthy for use without modification.
