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Tips
Tips

To solder or not to solder, and where...

Everything in the universe is either an insulator, or a conductor. This is determined by the the number of electrons in the vallance ring of the atom that the item is made of. Gold is an excellent condutor (but too rich for all of us), copper is a conductor, & lead and tin (solder) are insulators but affordable. Nobody really cares about these detials.

The most important factors in wire or terminal connections are conductivity, security, & cleanliness. Secondary factors include ease of use, time, and cost. Lead/Tin solder is used commonly because it is a compromise. It melts at low temperature (easy to use), it is cheap, and it holds most electrical conductors fairly well. BUT it is NOT a good conductor. Silver solder is more expensive, melts at a higher temp (more diffulicult to use), but is a BETTER conductor. Compromise.

Solder connections have a better reputation because crimp conductors are OFTEN not kept clean or secure. What kind of connections are used in your high amperage house circuit breaker box? Screw studs, which are effectively crimp, and certainly not solder. However, most houses don't vibrate like cars, and and are generally cleaner.

If you solder, mechanically CLEAN it 1st. Next, make the connection mechanically tight if possible. This includes twisting wires, wraping wires through terminal holes if possible, proper size wire and pins. Use CLEAN solder. Acid core cleans better but is corrosive in the long run (many years), rosin core is less corrosive but doesn't clean as well, - compromise. Cover joint or terminal w/ heat shrink or tygon tubing secured at both ends w/ tywrap or lacing cord. Absolutely important give joint some mechanical support, or strain relief. Think of solder as good glue, but is is not welding.

If you crimp, mechanically CLEAN it 1st. Use proper size wire and crimp connectors. There is a major difference in the connector. Cheap one are made of materials with more tin and less copper. Use the PROPER crimp tool for the connector. Most crimp connectors are designed to crimp the wire and the wire inslulation separately. Crimp the wire 1st. Then give it a moderate tug. If the wire slips out, you didn't have a good connection. Next crimp the insluation. Give it a slightly bigger tug. Better to fail now than down the road. Cover joint or terminal w/ heat shrink, or tygon tubing secured at both ends w/ tywrap or lacing cord. Absolutely important give joint some mechanical support, or strain relief.

Compromise; some people drink Falstaf and Hamms, some heavy dark micro brew, and yes some people even like Coors Light.

Blueghost
 
well yeah, but silver oxidises and silver oxidise is not conductive. Cooper has a higher conductivity than gold and in spite of golds cost it's sole claim to fame in the electronics world is it does not tarnish or corrode. ONTOH you really cannot label solder [Lead] and tin as insulators. Tin is used extensively over copper connectors to minimise dissimilar metal and electrolytic effects between copper and ferritic/non ferritic faying surfaces. Lead must have a reasonably high conductivity as a conductor or it would isolate many barrel type connector joints - should it possess the characteristics of an insulator. However, as was mentioned you can clean a joint prior to soldering with out the use of an acid and it is strongly suggested that this method be used.---Fwiw---Keoke
 
Geee, more than I knew about soddering stuff. Thanks.
 
All this is basically correct, but the differences in conductivity really don't matter for what we're doing, since the joint resistance, in all cases, is very low. Silver solder (which is really brazing) isn't realistic for electrical use; the melting temperatures are too high. Also, rosin flux is fine--and the best thing to use--for copper wires; once a good soldered connection is made, the flux used to do it has no further effect. Except, if it corrodes the connection, which acid fluxes will do. Acid fluxes are absolutely illegal for any electrical or electronic equipment, for this reason. Acid fluxes are OK, even necessary, for things like soldering steel, but only when they can be washed off with lots of water. And, yes, if you don't start out with clean, uncorroded copper wire, you won't get a good connection, no matter what you do. This is the single most important rule of soldering.
 
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