Electronics > Repair

Splicing very short AL wires

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Ian.M:

--- Quote from: Postal2 on October 04, 2024, 12:06:25 pm ---I didn't come up with the idea of ​​soldering aluminum with tin. It's written in the book, and the chemical justification is given. There's also an explanation of why there shouldn't be lead in the soldering.

--- End quote ---
Cite please, and also quote why there shouldn't be lead.

I've just soldered a 4mm2 copper wire to the bottom of an aluminum Strongbow cider can using the under oil method.  The oil used was actually Petroleum Jelly (Vaseline), which left the bit clean.  Solder was ordinary Sn60/Pb40 rosin flux core off an approx 30 year old reel I have knocking around the bench. The label's long gone so I don't know the brand or exact flux core.   It did take several minutes scratching through a large blob of solder to get initial wetting.  Strength:  Pulling on the wire has partially inverted the dome  of the can bottom with no signs of separation.

Postal2:
This is a book for children in Russian, called "Advice for a Beginning Master". I don't even remember where it is.
I tried soldering with regular solder, I soldered a thick copper wire to an aluminum ruler and tried to tear it off. I already wrote the result.

Of course, I have been soldering electrical wires this way for many years, even those hanging from the ceiling.

Ian.M:
You wont have any joy soldering to thick aluminum unless you can get the whole part up to ~ 200 °C (or more like 230 °C for Pb-free) quickly enough not to form a thick oxide layer and hold it at temperature while scraping the solder pool into the surface to break through the oxide layer and start it wetting.  The can is ~ 100um aluminum sheet, not much thicker than heavy foil, and even so I can barely get enough heat into it with a Weller 8100D 100W soldering gun.  For thicker sheet, I'd need to assist with a hot air tool or a pencil blowtorch or put it on a PCB preheater.

Postal2:

--- Quote from: Ian.M on October 04, 2024, 12:53:24 pm ---... Weller 8100D 100W soldering gun. ...

--- End quote ---
But it's weak, no good. I solder with something like the one in the photo, only the handle is plastic.

Buy Weller as in the second photo - it will fit.

RoGeorge:
I did solder on Al sheet with normal 60/40 solder for electronics.  The trick is to solder underneath a thick drop of motor oil, so the air don't get to the Al and oxidize it.  Cooking oil might work, too.  Scratch the Al while it is covered with oil, then solder with a powerful enough soldering gun.  It needs a lot of heat.  Never tried that with Al wire, maybe it works, but practice first on another wire.

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