It’s most basic form it is a mechanical connection between two or more

similar or dissimilar materials made by heating and melting a third

“filler” material. The two materials you’re joining do not melt during the
process of soldering—only the solder melts. It’s a fairly simple process
that has been around for at least five thousand years.
The two most common methods of generating heat for soldering are
using a flame or using an electrical source. The electrical source can
generate its heat by radiation, induction, conduction, or through several
other methods.
EXPERIENCE
Your first experience with soldering might have been plumbing. Most
homes used have copper water pipes, they are joined with solder. The
metal-based solder and chemical flux (which prevents oxidation) used
on the copper pipes is different from the type used in electronics, but the
process is generally the same. The pipes are cleaned, and a flux is
applied to keep the metal from oxidizing. Heat is applied, typically with
a flame from a blow torch, and solder is then introduced into the joint.
This type of soldering uses lower temperatures than other methods, and
is sometimes referred to as soft soldering. The solder used for copper
pipes must be lead-free, since lead is toxic if consumed, and the flux
must be safe for use on water pipes. Once the soldered connection has
cooled, the pipes are ready to be used, often for years without fail.
 Copper water pipe soldering
Silver soldering is another common soldering technique. It’s also called
hard soldering because of the higher temperatures (above 840°F or
450°C) used to melt the filler materials. This is opposed to soft soldering
(below 840°F or 450°C) used for electronics and copper pipes.

Hard soldering is the most common type of soldering used for jewelry-
making and repair, but it has other uses, too. Hard soldering has one
main advantage over soft soldering: it forms a much stronger bond
between the materials. The downside is that the much higher
temperatures make it impractical for temperature sensitive electronic
components.
Brazing is another type of hard soldering that utilizes a high temperature
to join materials. With brazing, the filler material is typically a brass
alloy that is heated to just above its melting point and, through capillary
action, is drawn into the joint between the materials to be connected. It
makes an incredibly strong joint, but not typically as strong as a well-
executed welded joint.
The most basic definition of soldering is an electrical and mechanical
connection.

PRINCIPLE OF SOLDERING
The filler metal used in case of soldering should have the melting
temperature lower than 450oC. The surfaces to be soldered must be pre-
cleaned so that these are faces of oxides, oils, etc. An appropriate flux
must be applied to the faying surfaces and then surfaces are heated.
Filler metal called solder is added to the joint, which distributes between
the closely fitted surfaces.

Defination and Explanation

Soldering is the process of joining two or more metals together at a
temperature lower than the melting points of the metals. In its molten
state, solder chemically dissolves part of the metal surfaces to be joined.
However, most metals exposed to the atmosphere acquire a thin film of
tarnish or oxide; the longer the exposure the thicker the film will
become. This film is present even though it is not visible, and solder
alone cannot dissolve it. A soldering flux with a melting point lower
than the solder must be used to “wet” the metal and allow the solder to
penetrate it and remove the film. The flux melts first, removing the
tarnish or metallic oxide, and also preventing further oxide from forming
while the metal is being heated to soldering temperature. The solder then
melts, floating the lighter flux and the impurities suspended in it to the
outer surface and edges of the molten fillet. The solder cools and forms
an alloy with the metal. Most of the flux is burned away during the
soldering process; any residue is removed by appropriate cleaning
methods.
DIFFERENT TYPES OF SOLDERS
Most of the solder metals are the alloy of tin and lead. These alloys
exhibit a wide range of melting point so different type of soldering metal
can be used for variety of applications. Percentage of lead is kept least
due to its toxic properties. Tin becomes chemically active at soldering
temperature and promotes the wetting (cover or touch with liquid ) action
required for making the joint. Copper, silver and antimony are also used
in soldering metal as per the strength requirements of the joint. Different
solder, their melting point and applications are given in the Table.

Common Soldering Alloys and their Applications

A solder is selected on the basis of its melting point. If metals to be
joined have higher melting point solder of higher melting point is
generally selected. Solder of high melting point provides better strength
of the joint.

TYPES OF SOLDERING FLUXES

Soldering fluxes can be classified as :

(a) Organic, and
(b) Inorganic fluxes.

Organic Fluxes
Organic fluxes are either rosin or water soluble materials. Rosin used for
fluxes are wood gum, and other rosin which are not water soluble.
Organic fluxes are mostly used for electrical and electronic circuit
making. These are chemically unstable at elevated temperature but non-
corrosive at room temperature.
Inorganic Fluxes
Inorganic fluxes are consists of inorganic acids; mixture of metal
chlorides (zinc and ammonium chlorides). These are used to achieve
rapid and active fluxing where formation of oxide films are problems.
Fluxes should be removed after soldering either by washing with water
or by chemical solvents.
The main functions performed by fluxes are :
(a) Remove oxide films and tarnish from base part surfaces,
(b) Prevent oxidation during heating, and
(c) Promote wetting of the faying surfaces.
The fluxes should
(a) Be molten at soldering temperature,
(b) Be readily displaced by the molten solder during the process, and
(c) Leave a residue that is non-corrosive and non-conductive..

PRECAUTIONS
Some precautions are to be followed to keep the soldering tools as
described below.
(a) Selection of correct tool according to the process. A defective tool
should not be used.
(b) Electrically heated solder iron should have proper earthing .
(c) Hot solder iron, when idle, should be placed on its proper stand.
(d) Tip of the solder iron should be cleaned before, its use.
(e) Solder iron should be gripped at its handle while in use.
SOLDERING TOOLS
The main tool used for soldering is the soldering iron. In addition to
soldering some consumable are also used in the process of soldering like
fluxes, solder wire or stick and spelter.
These are described below.
Soldering Iron
It consists of a copper bit attached to iron rod at its one end, and a
wooden handle at the other end. It is used to melt the filler metal and
paste it to make the joint. A soldering iron can be a forge soldering iron
which is heated in a furnace to have sufficient temperature to melt the
filler metal or it can be electric solder iron.
Electric solder iron is heated by passing electric current through it. Use
of electric solder iron is popular and cost effective. It is used in making
very precise joints in electronic and electrical equipment.
Spelter
Spelter is an alloy of zinc and copper in equal proportion. This is one of
the filler metal with low melting point with other desirable properties to
make good quality solder joint.

SAFETY PRECAUTIONS IN SOLDERING

(a) Keep solder iron always on its stand.
(b) All electrically operated instruments/equipment should have proper
earthing.
 (c) Sometimes emission of (smoke) soldering operation may be
poisonous due to a particular type of flux. Operator should have
protection from the same.
(d) Flux should be applied gradually while soldering.
(e) While diluting HCl, water should not be added to HCl but HCl
should be mixed into the water drop by drop, to avoid accident.
(f) Work place should have enough ventilation and smoking should be
strictly prohibited during the operation. Work place should have the
facility of first aid.
(g) It should be noted down good quality surface preparation always
contributes to good quality joint.