Ex.

No:
Date:
SOLDERING, DE-SOLDERING AND CRIMPING PRACTICES

AIM:

To study and practice soldering, de-soldering and crimping techniques.

APPARATUS REQUIRED:

[Link] Apparatus Quantity

1 Soldering Iron
2 Soldering wire
3 De-soldering pump
4 Flux
5 PCB
6 Electronic components
7 Copper Wire
8 Crimping Lug
9 Cable cutter
10 Hand Crimper

SOLDERING:
Soldering is a joining process used to connect metal parts by melting a low-melting-
point filler metal called solder. The solder flows into the joint and, on cooling, forms a strong
electrical and mechanical bond. It is widely used in electronics to join components to printed
circuit boards (PCBs).

Soldering iron:

It is the main heating tool used in soldering. The iron tip transfers heat to the joint
so that the solder melts and flows properly. Temperature-controlled irons help avoid damage
to electronic components.

Solder wire:

Solder wire is the filler metal used to join two conductors. It is commonly made of tin–
lead or lead-free alloys. Good-quality solder ensures strong electrical conductivity and
reliable joints.
[Link] Theoretical value Measured value (Multimeter reading)
Flux:

Flux cleans the metal surfaces by removing oxide layers and prevents further oxidation
during heating. It improves the wetting action of solder, resulting in smooth and shiny joints.

Clean metal surfaces:

The surfaces to be soldered must be free from dust, grease, and oxidation. Clean surfaces
allow the molten solder to spread evenly and form a strong bond.

Soldering stand and tip cleaner:

A stand safely holds the hot soldering iron when not in use. A wet sponge or brass wool
is used to clean the iron tip, ensuring efficient heat transfer and consistent soldering quality.

Soldering Techniques:

Iron soldering:

Iron soldering is a manual soldering technique in which a heated soldering iron is

used to melt solder at the joint. It is commonly used for assembling, repairing, and testing
electronic circuits. This method offers good control, making it suitable for small-scale
production and laboratory work.

Mass soldering:

Mass soldering is an automatic or semi-automatic process used to solder many

joints simultaneously. Techniques such as wave soldering and reflow soldering are used in
mass production of electronic assemblies. It ensures uniform solder joints, higher
productivity, and reduced manual effort.

SOLDERING PROCEDURE:

1. Take one PCB, solder iron, solder wire and electronic components and give supply to
solder iron.
2. Place the iron at the angle of 45 degrees, with the tip touching as many elements of the
joints as possible.
3. Place the solder wire near the iron and let it flow. Pass it around the joints.
4. Remove the iron and let the solder flow in the area from where the iron has been removed.
5. When the solder has successfully flowed in the lead and track, take the solder away and
then remove the iron.

DE-SOLDERING

De-soldering is the process of removing solder from a joint to detach electronic components
from a circuit. It is commonly used during repair, replacement, and rework of electronic
assemblies without damaging the components or PCB.

I. With a de-soldering pump (solder sucker):

1. Set the pump by pushing the spring-loaded plunger down until it locks.

2. Apply both the pump nozzle and the tip of your soldering iron to the joint.

3. Wait a second or two for the solder to melt.

4. Then press the button on the pump to release the plunger and suck the molten solder into

the tool.

5. Repeat if necessary to remove as much solder as possible.

6. The pump will need emptying occasionally by unscrewing the nozzle.

II. With solder remover wick (copper braid):

1. Apply both the end of the wick and the tip of your soldering iron to the joint.

2. As the solder melts most of it will flow onto the wick, away from the joint.

3. Remove the wick first, then the soldering iron.

4. Cut off and discard the end of the wick coated with solder.

After removing most of the solder from the joint(s) we can remove the wire or component
lead straight away (allow a few seconds for it to cool).

CRIMPING:

Crimping is a joining process used to connect a wire to a terminal or connector by mechanically

deforming the terminal around the wire. It provides a strong mechanical hold and reliable electrical
connection without the use of heat or solder.

Basics of crimping terminologies:

1. Crimp Terminals and Wire Strands

The crimp terminal, also known as a connector or lug, is a crucial component in the wire
crimping process. These terminals are designed to be attached to the ends of wires, providing
a secure and stable connection. When working with stranded wire (consisting of multiple
wire strands), it's essential to consider all the strands and choose the appropriate terminal
based on the wire size.
2. Understanding Wire Gauge

American Wire Gauge (AWG) is the standard measurement for wire sizes. Knowing the wire
gauge is crucial for selecting the right crimp terminal and tool. 0 AWG is having the largest
diameter and 44AWG has the smallest diameter. For wire diameters larger than OAWG, the
AWG standard has specified three more gauges called 00 (2/0), 000 (3/0) and 0000 (4/0). For
0000 (4/0), 000 (3/0), 00 (2/0) and 0 (1/0), the AWG numbers are -3, -2, -1 and 0
respectively. The formula to calculate the diameter of an AWG wire in mm.

DAWG = 8.251*e-(0.1159) (AWG) mm

3. Selecting the Right Crimping Tool

The crimping tool is your key to success in the process of wire crimping. For optimal results,
pick a tool that matches the wire size and the crimp terminal that you are using. A ratchet
design in the tool for crimping ensures a uniform and stable crimp, contributing to the entire
quality of the connection.

The Wire Crimping Process:

1. Select the Correct Wire

Choose wires and expose the wire strands. If dealing with stranded wire, gently separate and
arrange the strands evenly. For solid wire, strip the insulation carefully, leaving the wire
intact. 2. Choose the Right Crimp Terminals

Based on the wire size and type, select the appropriate crimp terminal.

3. Select a Crimp Tool

The proper crimping tool is required to guarantee that the crimp is made to specifications.
There is no such thing as a universal crimping tool; they differ according to crimping design.

4. Crimp the Wire

The wire crimping procedure includes the following steps:

 Strip the end of the wire after measuring its length. When you enter the wire into the
crimp, it should be at least 1 or 2 mm long.
 Trim the insulation from the end of the wire strands to expose them.
 Insert the wire into the crimp. Take special care to ensure that all strands are properly
placed.
  Insert the wire and crimp into the crimping tool, making sure both are properly
positioned within.
 The tool should be cycled until it is released.
 Take out the crimp. Ensure that the wire is in the proper location and that the wire
insulation is secure.
 Give the wire and crimp a little twist to ensure they are secure.

POST LAB QUESTIONS:

1. What is De-soldering?
2. What is the purpose of flux in soldering? 3. What is the purpose of wire soldering?
4. Why is it important to clean the soldering iron tip?
5. What is the role of flux in de-soldering?
6. What are the advantages of crimping over soldering?

VIVA-QUESTIONS:
1. What are the different types of crimping tools?
2. What are the different types of soldering techniques?
3. What are the common types of wire connectors used with crimpers?
4. How does wire gauge affect the crimping process?
5. What are the common types of solder used in electronics?
6. What are the different methods of de-soldering?
RESULT:
Thus the significance of soldering, des-soldering and crimping techniques was
studies and successfully applied.