Soldering 101

When a piece of equipment fails or a vehicle quits moving, it is often due to an electrical failure. Most electrical failures tend to happen at the point of a connection, where two or more wires are joined together or where wires are connected to electrical components. When attempting to repair that failed connection, such as rejoining two pieces of wire, or trying to re-establish an electrical connection to a component, soldering may be the way to go. 

Soldering is a process where a metal alloy, called solder, is melted to join two or more wires together, or to make an electrical connection to a component, such as a circuit board. When completed, the soldered connection creates a strong and permanent bond between the wires. 

Soldering is a fundamental skill to have if you frequently work with electrical devices. Whether you are working, repairing or modifying something for your shop or a customer, learning the nuances of soldering can be a game changer.

To create a soldered connection, you need some special tools and materials.

Soldering iron – The main types of soldering irons are corded electrical, cordless/battery powered or gas powered.

Solder – It usually comes on a spool, and it looks like a shiny, flexible wire that melts and liquifies when heated. It then hardens when cooled to complete the connection. 

Flux – This is a chemical that is applied during the soldering process to help the solder flow and bond to the wires or connection. Flux can also be blended into the solder formulation itself when the solder is manufactured. 

Power source – A power source is necessary to get the soldering iron hot.

Once you have the necessary tools and equipment, you are ready to begin soldering.

1. Set Up: Gather all the necessary tools and materials and choose a well-ventilated area to work.
2. Prepare Soldering Iron: Plug in the soldering iron and let it heat to the appropriate temperature. Clean the tip of your soldering iron by wiping it on a damp sponge or brass wire sponge. This removes any old solder or debris.
3. Tinning the Iron: Before starting, it's essential to tin the soldering iron tip by melting a small amount of solder onto it. Spread it evenly across the tip’s surface. This helps transfer heat efficiently to the joint and prevents oxidation of the tip.
4. Flux Application: Apply a small amount of flux to the areas you'll be soldering if your solder doesn't already contain flux.
5. Heat the Workpiece: Hold the tip of the soldering iron against the joint where you want to apply solder. Heat it for a few seconds to ensure it reaches the necessary temperature for soldering.
6. Apply Solder: Once the joint is heated, touch the solder to it. Allow the solder to melt and flow evenly onto the joint. Apply just enough solder to form a good connection. Be careful not to add too much solder as it can create messy joints and potentially damage the components.
7. Cooling: After soldering, allow the joint to cool naturally without moving the components. 

Soldering gives you the benefit of a secure and reliable connection that can handle vibration and environmental factors like moisture or temperature. It also allows superior conductivity of electricity through the connected wires, which improves the performance and efficiency of the electrically powered equipment.

Soldering can also be performed on a wide range of wire types, including both stranded and solid wires. While soldering can produce excellent results, it takes a bit of practice to become proficient.

To learn more about soldering and all the electrical products that you’ll need to keep the current flowing, contact your Kimball Midwest Sales Representative today. If you don’t already have a rep, we can help you