How to Tin a 100 Watt Soldering Iron

Encyclopedia

Today, as in the last century, the simplest and most common soldering iron is a hollow metal tube with a handle (wooden or heat-resistant plastic). At the end of the tube there is a rod called a “tip”, sharpened to a dihedral angle or cone. Inside there is a heating element with high resistivity. It runs on mains power, a step-down transformer, or a battery. This soldering iron is a popular, but not the only option.

Soldering - Permanent connection

Actually, the essence of soldering is heating the surfaces to be joined and the intermediary material – solder. The “intermediary” melts, fills the gap between the connected parts of the products and literally “grows” into them (diffusion occurs). The result is a strong, permanent connection.

For example, for soldering electrical wires, an alloy of tin and lead is used as solder. Before starting work, a so-called flux is applied to the joint, which is usually rosin. It is needed to dissolve and remove oxides and protect solder joints from oxidation.

In fact, soldering is used to “join” parts in products not only made of steel or aluminum, but also of cast iron, glass, graphite, ceramics, synthetics, etc. Solders are also different - hard and soft. In everyday life, soldering metals with soft solders is most common.

Soldering iron power

With the help of soldering, both tiny microcircuits and fairly massive structures are assembled.
Accordingly, soldering irons vary in their power. The most “weak” ones are up to 40 W , they are used for micro-installation.
“Medium weight” models to
Finally, the most powerful - over 100 W , they are used for volumetric installation.
There are dual-mode soldering irons with two working powers. For example, 30 and 60 W.

Which soldering iron is better to buy? It all depends on your specific goals.

Excess power will lead to rapid overheating and, as a result, tool failure. Due to the lack of watts, the device simply cannot cope with the task.

Not with electricity alone - gas and pulse soldering irons

Not in all situations can you use a traditional electric soldering iron due to the banal lack of electricity. In this case, gas will do. Its built-in burner is supplied with liquefied gas from a replaceable cartridge. Another option is to supply gas through a hose from an external source. It looks like liquid fuel soldering irons work.

In thermal air devices, heating occurs by blowing a stream of hot air. In infrared - thanks to the source of infrared radiation.

A pulse soldering iron differs in appearance - it is shaped like a pistol , at the end of which there are two electrical contacts. Switching on is done with a special key. More modern models have a power level control, making the tool more versatile.

The Dremel Versaflame blowtorch runs on liquefied butane. The universal attachment allows you to use the tool for various operations: soldering, heat shrinking, welding, etc.

Soldering iron option for “advanced users”

An important characteristic of any soldering iron is its operating temperature. Simple models do not have a clear temperature regime, and sometimes because of this it is not possible to do the job efficiently. For example, if the heating is insufficient, the solder will not melt to the required state and will not be able to fill all the necessary gaps. In this case, the so-called “cold soldering” will result, and the connection will be fragile.

In addition, if you have to deal with different options for work, it makes sense to purchase several soldering irons at once, with different powers.

But you can do it easier - buy a soldering station.

Microprocessor controlled digital soldering station Weller WDD 161V works with compressed air or inert gas

Soldering Station

A soldering station becomes indispensable if you often have to deal with the soldering process

This device has several advantages over a soldering iron. First of all, the current temperature of the “tip” is monitored; thanks to voltage regulation, it always corresponds to the set one. In addition, the station provides protection against overloads and static electricity.

The soldering station consists of several parts. Usually this is the soldering iron itself with a replaceable tip, an electronic adjustment unit, a stand for the soldering iron, as well as such convenient things as a desoldering pump for removing excess solder, a hot air gun, and tip cleaners.

Models differ in the number of connected soldering irons, and are single-channel and dual-channel. A two-channel station can include an assembly and desoldering iron. Also, stations can have different heating speeds, temperature adjustment ranges, voltage, power, dimensions and weight.

Sting without wasp

The “tip” of poling irons is usually copper, with a tinned end. During use, it changes color and burns. Nowadays, non-burning options are also available, which are also sometimes called “eternal”. Similar “stings” are also made of copper, but are covered with a thin layer of nickel on top.

It is recommended not to apply mechanical force when working with such a tool, as this can damage the integrity of the coating.

Diversity of tasks to be solved

The DREMEL VersaTip soldering iron operates on liquid butane gas and performs 6 operations: soldering, melting, heat shrinking, burning (pyrography), hot cutting, paint removal

Some soldering irons can not only solder, but also perform a number of other tasks. For example, the gas model DREMEL VersaTip is capable of performing six operations at once. The tool is suitable for soldering, melting, heat shrinking, burning (pyrography), hot cutting and paint removal. Such a variety of work can be carried out thanks to six interchangeable attachments.

The tool runs on liquid butane gas. You can use the device in any environment. The advantages of the model also include short heating time, fast recharging, and the ability to select temperature conditions.

A few words about the blowtorch

A conversation about soldering equipment would be incomplete without mentioning the blowtorch. These are open heating devices, also used for welding, melting, heating surfaces, burning out old paint on metal parts and other purposes.

Gas, alcohol, kerosene, and gasoline can be used as fuel. The most common option is a gasoline blowtorch, which is characterized by economical fuel consumption and ease of use.

Gas models are sometimes also called a “gas burner” or “gas cutter”; they are used for soldering metals and in various construction and repair work where an open, powerful flame is needed.

There are also more universal options.

Special task

In addition to soldering irons for metal, tools for soldering polypropylene pipes, a popular material in the modern construction market, are widely used. Both externally and essentially these are completely different devices.

There are three types of soldering of polypropylene pipes: socket, butt and electrofusion . In everyday life, the most common is socket soldering (or socket soldering). It is used when you need to connect elements with a diameter of up to 49 mm. Connections are made using special couplings - they, like pipes, are heated to the required temperature and connected.

The socket soldering machine is an electric heating device. Its main part is a heating element of a special sword-shaped shape, with holes, adapted for installing welding nozzles for different pipe diameters (for example, 20, 25, 32, 40 mm). The nozzles are covered with non-stick material; they must be periodically wiped to remove any adhering plastic. A thermostat is installed to maintain the set temperature.

The DENZEL DWP-1500 plastic pipe welding machine comes complete with a case, 6 nozzles, a wrench for replacing them and scissors for cutting plastic pipes

Machine for welding plastic pipes Prorab 6405K, in a case, tape measure, stand, screwdriver, pipe cutting knife, wrench, gloves, set of welding attachments

Safety is everything

Soldering is not welding. As you know, sparks do not fly from it, but the danger of starting a fire is quite real. Therefore, work on a clean table from which foreign objects have been removed. Make sure that there are no flammable or fusible materials nearby, and that the soldering iron cord is not twisted or stretched.

Be careful and careful not to get burned. After work, be sure to wash your hands and ventilate the room. The soldering iron can only be stored when it is cold.

Anna Kotova; photo: New Technologies LLC, Promelektronika Group of Companies; Dremel

Source: https://ml-dom.ru/info/encyclopedia/1500/44630/

4 simple ways to make a soldering iron from scrap materials

Are you here:

Sometimes there are situations when the owner simply cannot do without a simple soldering iron. For example, you need to tin a multi-core cable for an outlet, or remove a part from a burnt-out device. At such moments, you have to either borrow a tool or postpone the matter indefinitely. After all, not everyone wants to buy an expensive soldering iron or soldering station if he is not a repairman.

However, there is a simple way out of this situation - to assemble a small soldering iron yourself; it is just right for small work. The manufacturing process will not take much time and effort, but you will be able to save some money and gain invaluable experience. Next, we will tell you how to make a soldering iron with your own hands at home.

You will be offered several designs, and you can choose the one that suits you best.

Idea No. 1 – Use a resistor

The first and simplest technology for making an electric soldering iron with your own hands is using a powerful resistor. The device will be designed to operate at voltages from 6 to 24 Volts, which will allow it to be powered from various current sources, and even make a portable version powered by a car battery. In order to make your own instrument, you will need the following materials:

• Soviet wirewound resistor (WWW), covered with ceramic insulation with a resistance of 20 Ohms and a power of 7 Watts. You can choose components with other characteristics, depending on what power you want to make the soldering iron and what voltage you plan to power it from. Here is the simplest formula for calculation: R = U²/P. Where R is resistance measured in Ohms; U is the voltage that is planned to power the soldering iron, in Volts; P is the desired heater power in Watts. This part can be bought at the market or in a radio parts store, or it can also be pulled out of an old Soviet device.
• Textolite or plywood plate for making a comfortable handle. You can also use other non-conductive materials that can withstand high temperatures, such as some types of plastic.
• Two copper rods of different sections. The thicker one is selected strictly according to the internal diameter of the resistor. The quality of heat transfer from the heating element to the tip, and therefore the heating time and ease of operation, will depend on this. The second one should be thinner; it will act as a sting. Using a file, you will need to sharpen it to a shape that is convenient for you. The main types of stings are shown in the picture. I would immediately like to note that the most convenient option is the type of flat screwdriver, since it is convenient to transfer solder to the place of work, and it is possible to both solder massive contacts and perform delicate work.
• 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:

1. You need to drill a hole in the end of a thick copper rod and drive the thread under the screw using a tap. It is also necessary to cut a groove for the retainer, which in our case is the spring ring. This can be done using a triangular file or a hacksaw for metal.
2. From the second end, drill a hole with a diameter similar to that of a thin rod, which will act as the tip of a mini soldering iron.
3. All elements of the rod must be assembled into one whole, as shown in the photo.
4. The resistor is prepared for attaching the soldering iron tip, which must be inserted and secured at the back with a screw and washer.
5. From a textolite or plywood plate you need to make a comfortable handle with your own hands with a seat for a resistor and wire. To do this, use a jigsaw to cut out two identical halves of the handle and make holes and recesses for screws and nuts.
6. A power cord must be connected to the heater terminals. It must be screwed to ensure reliable contact.
7. The finished homemade soldering iron is twisted and tested.

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 a power supply, but also from a battery. We came across many reviews on the forums where this homemade version was connected from a 12-volt cigarette lighter, it’s also very convenient!

Please note that when first turned on, all soldering irons may smoke and stink for a while. This is normal for any model, as some elements of the paintwork fade. This will stop later.

instructions for making a simple electrical appliance

Idea No. 2 – Second life for a ballpoint pen

There is another unusual, but at the same time simple idea on how to make a soldering iron with your own hands from scrap materials for soldering small parts or SMD components. In this case, we will again need a resistor, but now not a PEV (as in the previous version), but an MLT, with a power of 0.5 to 2 Watts.

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, you can wind it from an old inductor or buy a single-core copper wire insulated at an electrical store and carefully remove it with a stationery knife
• Steel or copper wire with a diameter of no more than 0.8 mm.
• 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:

1. Remove the paint layer from the surface of the resistor. This operation can be carried out using sandpaper, a needle file or a file, or, in extreme cases, a knife. The main thing is not to overdo it, so as not to damage the resistor. If the paint is difficult to remove, connect the product to a regulated power source and heat it up a little.
2. There are 2 wires coming out of the barrel, cut one of them and drill a hole in this place for the copper wire (diameter 1 mm). To prevent the wire from coming into contact with the cup (this must be avoided), make a countersink with a thicker drill, as shown in the photo below. In addition, you need to make a small cut for the wire directly on the resistor cup. A triangular file will help you with this again.
3. Bend the steel wire into the shape of a handle with a fastening in the form of a ring, with a diameter similar to that of a drink on a cup. If you have copper wire, then you need to clamp the cup in it and twist it using pliers so that the contact is reliable, but do not overdo it, otherwise you will wrinkle the body. Remember that the wire must be without varnish insulation.
4. Carefully cut out a board from a double-sided PCB with your own hands, exactly the same as shown in the example in the photo. It is not necessary to buy a new sheet of PCB. You can use a jigsaw to cut out a suitable piece from any unnecessary double-sided board. Or do without it altogether: twist the wire with wires and attach them to the handle using superglue. The main thing you need to pay attention to is that the distance between the heating element and the handle is more than 5 cm, otherwise the plastic may melt.
5. Next, you need to assemble a homemade soldering iron from a handle, which should not cause any difficulties.
6. All that remains is to install the thin tip into the seat. To prevent the copper wire from burning through the resistor, you need to make a protective layer of a piece of mica or ceramic between the back wall and the tip.
7. The last thing you need to do is connect the homemade product to a 1 A power supply and a voltage of no more than 15 Volts using wires.

That's the whole technology for creating a homemade mini soldering iron at home. As you can see, there is nothing complicated in making this tool, and you can easily handle it, and all the materials can be found at home by disassembling old equipment or looking for them in bins.

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

This 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 this tool is that the tip heats 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 primary winding of the transformer and all elements of the circuit must be secured in a reliable housing, which will protect you from accidental electric shock, since the circuit contains a life-threatening voltage of 220 volts!

The principle of operation of this design is that the ballast from the lamp creates an alternating voltage, which is applied to the primary winding of the transformer and is reduced to low values, while the current increases many times.

One turn, which is essentially the tip of the soldering iron, acts as a resistor through which heat is dissipated.

When you press the button, current is supplied to the circuit, and rapid heating occurs; after the button is released, the tip quickly cools, which is very convenient, since you do not need to wait long for the instrument to heat up and cool down.

Idea No. 4 – Simple wire version

There is another option for making a miniature soldering iron - using nichrome wire. To do this you will need:

1. A piece of nichrome wire. You can remove it from old heating elements, wire resistors, irons, hair dryers, etc. The main characteristic of such wire is its diameter, because it determines the resistance of the coil and, accordingly, the power of the tool being manufactured. You can calculate the required length for your diameter using the formula specified in the instructions for option No. 1. The resistivity of nichrome depending on the diameter is given in the table below.
2. A piece of wood with a round cross-section.
3. A piece of copper wire with a diameter of 1.5-5 mm, a length of 15 cm.
4. A small piece of fiberglass insulation for wires.
5. A little plaster. Sold in construction stores, another name is alabaster. Many people have little left over after renovation.
6. Wires.

Manufacturing process:

1. Drill a hole in the block for copper wire 3 times larger than its diameter.
2. Place a piece of copper wire in it so that it protrudes about 5 cm and secure it there with thick plaster putty, let it dry.
3. Place insulation on the copper rod, which is the tip, and wind the required amount of nichrome wire, leaving a distance between the turns. Also put insulation on the ends and bring them closer to the handle. Then connect the twists with the wires. Tape them to the handle with electrical tape.

That's all, you have another simple and reliable soldering iron design, made by yourself.

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!

Also read:

instructions for making a simple electrical appliance 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

Source: https://samelectrik.ru/3-prostyx-sposoba-sdelat-payalnik-iz-podruchnyx-materialov.html