Electronics > Repair

Splicing very short AL wires

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soldar:
At this point it does not seem to me there is any practical way of soldering or brazing worthwhile for this unimportant project.

I am thinking I might try to find the tiniest screw terminal I can find, epoxy in place with the screw loose, and once it is held firmly in place tighten the screw. I think trying to tighten the screw with the terminal loose would most probably result in a broken AL wire.

I also think epoxy is safer then hot glue which is really not so rigid.

I could even solder a thin copper wire to the screw terminal.

mikerj:

--- Quote from: Postal2 on October 04, 2024, 11:47:45 am ---
--- Quote from: Ian.M on October 04, 2024, 11:42:41 am ---... and keep rubbing and scratching it into the surface till it takes.  ...

--- End quote ---
It pretends to be absorbed, but easily bounces off. Tin, however, is thoroughly wetted.

You can solder by dipping in molten zinc, but I have not done this, although I know that this is the standard method for soldering aluminum twists of several wires.

--- End quote ---

All I can say is you are doing it incorrectly.  Like Ian I have made strong, well wetted connections to Al with regular rosin cored flux, it's all in the technique.  If you have ever used the Al brazing rods it's a very similar method, abrading the oxide layer through the molten pool to allow the solder to wet the raw Al.

Greybeard:

--- Quote from: hanakp on October 04, 2024, 05:02:28 pm ---Like I wrote earlier, forget brushing, oil etc. Just get aluminium flux with hydrofluoric acid, then it will solder almost like copper wire.

--- End quote ---
I would never use anything containing hydrofluoric acid.
It's highly dangerous!
https://en.wikipedia.org/wiki/Hydrogen_fluoride

--- Quote ---Hydrogen fluoride is an extremely dangerous gas, forming corrosive and penetrating hydrofluoric acid upon contact with moisture. The gas can also cause blindness by rapid destruction of the corneas.
...
Health effects
...
Hydrogen fluoride is highly corrosive and a powerful contact poison. Exposure requires immediate medical attention.
It can cause blindness by rapid destruction of the corneas. Breathing in hydrogen fluoride at high levels or in combination with skin contact can cause death from an irregular heartbeat or from pulmonary edema (fluid buildup in the lungs).

--- End quote ---

jpanhalt:

--- Quote from: Greybeard on October 07, 2024, 07:01:50 pm ---I would never use anything containing hydrofluoric acid.
It's highly dangerous!
--- End quote ---

Then don't.  Presumably, you understood that your reference was to the pure gas.  Most people probably know that (EDIT: the flux) reference is to HF in dilute solution.  In such instances, it has many uses.  In the US, for example, Whink Products sells a rust stain remover for sinks and toilets in grocery stores (https://web.faa.illinois.edu/app/uploads/sites/6/2021/05/WHINK-Rust-Stain-Remover.pdf ).  It also works on blood stains on clothes, if all else fails.

(It looks like Whink was acquired by Rustoleum.  I don't know whether current products are the same.)

tooki:

--- Quote from: jpanhalt on October 07, 2024, 07:30:44 pm ---(It looks like Whink was acquired by Rustoleum.  I don't know whether current products are the same.)

--- End quote ---
On the product page, in the Technical Information tab, there is the download for the technical data sheet: https://www.rustoleum.com/-/media/6111FC40699C4F82811A045EFD907995.pdf

It still lists HF as the active ingredient.

It also lists Bitrex as an ingredient, which makes total sense from a safety standpoint, but man do I hate Bitrex in cleaning products, because of how Bitrex residues then spread everywhere and ultimately end up on your fingers, and then face. (In the case of this product, the relevant situation would be carpets, since all the other applications involve thorough rinsing.)

I once made the mistake of using alcohol that was denatured with Bitrex to clean my bathroom. It took weeks to get that damned bitterness gone. It’s actually a fascinating way to demonstrate how bacterial/viral cross-contamination works…

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