Solder cables to single and multipin connectors / tag boards.

1. Reference to procedures in the relevant AMM and WDM - Soldered connections are used in aircraft electrical wiring to form a continuous and permanent metallic connection having a constant electrical value. - Not necessary to make solder joint within the aircraft - Carried out strictly/monitor iaw AMM,WDM and Mod Drawing - SWPM Chapter 20-40-00 - maintained in good condition to avoid generating sparks and should not be used when flammable vapours are present in the atmosphere. (CAAIP Part 5 Leaflet 5-1) - Tip must be grounded to prevent esd (CAAIP Part 9 Leaflet 9-4) - Ensure solder is type specified and correct for work in hand 2. Methods of soldering # Soft Soldering - needs special care i.e. Overheating+slow cooling=brittleness - excess solder = short circuit (socket insert,plug pins) - not impair the operation of spring contact - not obstruct plugs and sockets mating BL6-1 - joining metals without intentional fusion of basic metal - lower melting point than metal to be soldered - strength 1.continuity and adhesion of solder film 2.mech properties of solder <- verify by destruction (pulling apart) - solder film 1.thin= brittle 2.thick= low shear strength - Solders and fluxes -comply with British Standard or DTD spec Spec Material BS 219 Soft Solders BS 414 Rosin-corded solder wire DTD 599 Non-corrosive flux for soft soldering DEF 34/1 Tinning and soldering solution - Solder : Stick form (flux separated/BS 219), Wire flux (rosin flux core/BS 414) - BS 219: Added antimony (increase strength/not use on zinc or galvanised work) - BS 414: Circular cross sectional/activated or non-activated flux/more efficient/five grades Tin Lead Temp (C) Purpose 65 35 183 185 Elect/Radio/Instruments (common use) 60 40 183 188 -same50 50 183 212 Any assy/allow some power loss 40 60 183 234 At comp less liable to damage 20 80 183 - 276 Blobbing electrical lamps # Silver Soldering - Joining of material by molten filler alloy drawn by capillary attraction into space to be joined. - Low temp brazing - uses filler alloy (copper/silver) 505 to 805C EGT/JPT/TGT compensating lead termination - Strength = strength of materials joined - design of joint.cleanliness,method of applying,composition of materials, materials specified and competency of personnel. - necessitating of heat treatment restore material properties coz involved high temp - wash flux, if on dissimilar metal,allow cooling first (minimise stress cracking and residual stresses)

3. Practice of soldering for cables and multi-pin connectors/tag boards a) Tool and equipment - soldering iron pencil shape tip (precise soldering) using 3-prong grounded cable (prevent stray voltage) - solder preferable is rosin core wire size is matter (not too big since can create bridge is excessive) 60% Tin 40% Lead consist of flux (produce fumes-carried out in well ventilated area,wear PPE) b) Preparation - Tinning coating/applying small layer of solder to iron tip helps in heat transfer between tip and component/base from which it flow from - Cleaning effect on strength and resistance of joint scotch brite to remove tarnish on PCD (or simply using rubber (blue hard) using acetone or isopropyl few blast to make it dry good practice if wipe the component leads - Placing the components start with small/flatten components bend legs 45 (if cant,put some masking tape) do for all comp to be soldered so that no extra turning back just to put another comp. c) Soldering - Apply heat to comp. legs - Put solder and let it flow - If board bubbling, remove solder iron (overheated occur) d) Inspect and clean up - Inspect the final product (magnifying glass) - Trim legs and remove excessive flux #conformal coating protection against environment hazard (moisture/dirt/chemical) 4. General considerations and use of heat shields # Heat Shields to prevent others pre-soldered component disturbed. # Heat sinks Heatsinks are a must for the leads of sensitive components such as ICs and transistors. If you don't have a clip on heatsink, then a pair of pliers is a good substitute. 5. Soldering of Aluminium points to consider - Require high heat input to solder - Avoids uneven expansion and contraction - 280 370C hand iron/gas torch/furnance/induction coil - Pre-position of solder heat applied to adjacent place ( to bring up quick temp/solder melt indirect heating) - Jigging light shake (allow solder to fill the gap by capillary action)[0.05mm to 0.1mm] - Al solder may produce purgent smell - Using tin-zinc or tin-cadmium alloys

Extras: Cold Solder Joints

A "cold solder joint" can occur when not enough heat is applied to the component, board, or both. Another common cause is a component moving before the solder has completely cooled and solidified. A cold joint is brittle and prone to physical failure. It is also generally a very high resistance connection which can effect the operation of the circuit or cause it to fail completely. Cold joints can often be recognized by a characteristic grainy, dull gray colour, but this is not always the case. A cold joint can often appear as a ball of solder sitting on the pad and surrounding the component lead. Additionally you may notice cracks in the solder and the joint may even move. Below is the shocking image of every example of a bad solder joint you will ever see. It appears that this FM transmitter kit was assembled using the technique of "apply solder to iron then drip onto joint". If your joints are looking like this, then stop and practice after rereading this page. Note that not a single of of these joints is acceptable, but amazingly, the circuit worked.