1. Wire repairs

2. Connecting Wires  Very quick but...  Will it last?  Is this a professional job?  Would you pay a technician $75 per hour for this?

3. Crimp connectors  Advantages  Disadvantages

4. Solder connections A connection that will last.

5. For important circuits soldering is the preferred method of joining wires and terminals

6. Selecting the solder to use  Metal content 40/60 or...  Core flux type Rosin or Acid

7. Solder Composition  40/60 360 – 460 = 100 degree pasty range  60/40 360 – 375 = 15 degree pasty range  Impurities Are a possible problem in lower priced solders

8. Why is flux needed?

9. Oxidation  Definition: A common form of chemical reaction which is the combining of oxygen with various elements and compounds. The corrosion of metals is a form of oxidation, rust on iron for example is iron oxide

10. The problem  Oxidation will occur to a wire while it’s being heated to solder.

11. Flux Requirements  Remove oxidation  Prevent oxidation at soldering temperatures  Be easily displaced by molten solder  Be easily removed if needed

12. Flux Types  Acid Strong but always active  Rosin Weak but works well with new wires and terminals.  Active only at high temperatures  Leaves a protective coating at lower temperatures

13. Active temperatures of flux  Rosin Flux starts working at 225 degrees  Acid Flux Active even at room temperature

14. Selecting the right gun for the job

15. Gun Preparation Tighten the tips connection to the gun Clean and sand the tip Tin the tip

16. Joining wires

17. Careful how you shape the twisted wires  Taping this wire into a harness with others will be difficult Correct method

18. What is a Cold Joint?

19. Cold Joint

20. You want the solder to flow

21. Let the wire or terminal melt the Solder Note… The solder wire is not touching the iron

22. Protecting the wiring connection

23. Heat Shrink Installation

25. Demonstration and Assignments