Electronics > Repair

Splicing very short AL wires

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Ian.M:
Incidentally the glassfibre pencil brush is https://cpc.farnell.com/unbranded/10191/fibreglass-pencil-4mm/dp/SABU10191 or similar.   If its working right you can see the oil or flux turn black with abraded aluminum particles.   Getting the brush clean afterwards is a PITA - I just burnt off the Vaseline with a lighter then used switch cleaner and its discoloured but at least not greasy - so it may be better to keep a brush insert just for this job.

The problem with soldering wire will be keeping the oil and solder there.  Try making a shallow depression near the edge of a piece of pine wood with a very small V notch up to the edge for the wire, and clamping it at the right height for the wire to be level.

However the last time I needed to get a solder joint to aluminum magnet wire I crimped a duPont pin terminal to it (use a tiny smear of Noalox) and simply soldered to the pin!  Its much easier and is pretty much foolproof.   :horse:

Postal2:

--- Quote from: Ian.M on October 04, 2024, 12:27:32 pm ---... Solder was ordinary Sn60/Pb40 .........  Strength:  Pulling on the wire has partially inverted the dome  of the can bottom with no signs of separation.

--- End quote ---
I don't know how you did it. I've always been able to tear a drop of regular solder off the ruler, but with tin the wire itself just comes off. But I've tried both. Why don't you try with tin.

Ian.M:
.... because I don't have any SN100C solder handy.  I do have a small pack of SAC405 I keep for Pb-free repair work, but at 4% silver that stuff is too pricy to mess about for no reason.  I suspect we are in violent agreement that high tin solder will work to tin aluminum.  You contend SnPb doesn't - others disagree.

Postal2:
Tin is a food metal, sold for repairing saucepans. I don't think it's a problem to find it. Try it, compare, and don't forget to tell us.

themadhippy:

--- Quote ---Cooking oil might work, too.
--- End quote ---
it does

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