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e to sidebar hide from wikipedia the free encyclopedia hand tool for soldering electric soldering iron a gas fired soldering iron a soldering iron is a hand tool used in soldering it supplies heat to melt solder so that it can flow into the joint between two workpieces a soldering iron is composed of a heated metal tip the bit and an insulated handle heating is often achieved electrically by passing an electric current supplied through an electrical cord or battery cables through a resistive heating element cordless irons can be heated by combustion of gas stored in a small tank often using a catalytic heater rather than a flame simple irons less commonly used today than in the past were simply a large copper bit on a handle heated in a flame solder melts at approximately 185 c 365 f soldering irons are designed to reach a temperature range of 200 to 480 c 392 to 896 f 1 soldering irons are most often used for installation repairs and limited production work in electronics assembly high volume production lines use other soldering methods 2 large irons may be used for soldering joints in sheet metal objects less common uses include pyrography burning designs into wood and plastic welding as an alternative to ultrasonic welding history edit historical soldering irons front and torches back before the development of electric soldering irons the typical soldering iron consisted of a copper block with an appropriately shaped point supported on an iron rod and held in a wood handle immediately before use the iron was heated over a fire or in a charcoal brazier and it had to be reheated whenever it became too cool for use soldering irons were primarily used by tinsmiths and coppersmiths to work with thin sheet metal 3 a large copper block was required in order to have sufficient thermal capacity to provide useful heat after removal from the fire and copper is expensive this led to the development of soldering irons that had a small copper tip attached to an inexpensive cast iron block 4 some irons even had removable and replaceable copper tips 5 the first electric soldering iron had a very lightweight platinum tip heated by electric current flowing through the tip itself 6 by 1889 electric soldering irons were being developed with a resistance wire wrapped around the back end of the copper head and enclosed in a protective shell 7 alternatively the heating element could be enclosed in a relatively light weight hollow copper head 8 in 1894 the american electrical heater company began manufacturing electrical soldering irons on a large scale in detroit they started producing them and shortly after american electrical heater company released their line of soldering irons in 1905 scientific american magazine published a tutorial on making a soldering iron that clearly explains how early irons were made 9 in 1921 a german company founded by ernst sachs developed an electrical soldering iron similar to american electrical heater company iron in 1926 william alferink applied for a patent for the first soldering station 10 11 actual form factor of soldering irons edit electric soldering iron for electronic work in 1946 carl e weller applied for a patent for his soldering gun that could heat instantaneously and began production of the speedy iron in pennsylvania 12 it was manufactured through the weller manufacturing company and this product was the first instantaneous thermal soldering gun few years later they released to the market a soldering iron on with self adjusting temperature in 1951 the company wen products began manufacturing its own instantaneous soldering iron after a three years trial weller won for patent infringement 11 in 1960 weller got the patent for the soldering iron magnastat renewed in 1964 and 1971 13 this iron could control the temperature by using a temperature sensitive magnetic tip the magnastat became a best seller and it was included it in the w tcp soldering station in 1967 in fact within the patent as a complementary description it defines what today has become the de facto the redundancy is worth it form factor of the vast majority of current japanese and chinese irons hakko baku etc the now expired patent which even weller has stopped using on some models described an outer tube holding the coated copper tip clamped with a nut to the handle 14 located at the remote rear end of draw tube 26 and held thereto by peripheral flange 27 is a freely rotatable threaded nut 28 adapted to be threaded about nut receiving stud 29 of cover flange 21 to draw the tip 11 into proper engagement types edit soldering iron in use simple iron edit for electrical and electronics work a low power iron a power rating between 15 and 35 watts is used higher ratings are available but do not run at higher temperature instead there is more heat available for making soldered connections to things with large thermal capacity for example a metal chassis 15 some irons are temperature controlled running at a fixed temperature in the same way as a soldering station with higher power available for joints with large heat capacity simple irons run at an uncontrolled temperature determined by thermal equilibrium when heating something large their temperature drops a variation is the scope soldering iron common in australia which operates from a low voltage source such as transformer or battery and heats in seconds when the user pushes the thumb guard which then acts as a heat controller cordless iron edit small irons heated by a battery or by combustion of a gas such as butane in a small self contained tank can be used when electricity is unavailable or cordless operation is required the operating temperature of these irons is not regulated directly gas irons may change power by adjusting gas flow gas powered irons may have interchangeable tips including different size soldering tips hot knife for cutting plastics miniature blow torch with a hot flame and small hot air blower for such applications as shrinking heat shrink tubing temperature controlled soldering iron edit section of a soldering iron tip with an internal heating element simple soldering irons reach a temperature determined by thermal equilibrium dependent upon power input and cooling by the environment and the materials it comes into contact with the iron temperature will drop when in contact with a large mass of metal such as a chassis a small iron will lose too much temperature to solder a large connection more advanced irons for use in electronics have a mechanism with a temperature sensor and method of temperature control to keep the tip temperature steady more power is available if a connection is large temperature controlled irons may be free standing or may comprise a head with heating element and tip controlled by a base called a soldering station with control circuitry and temperature adjustment and sometimes display a variety of means are used to control temperature the simplest of these is a variable power control much like a light dimmer which changes the equilibrium temperature of the iron without automatically measuring or regulating the temperature another type of system uses a thermostat often inside the iron s tip which automatically switches power on and off to the element a thermal sensor such as a thermocouple may be used in conjunction with circuitry to monitor the temperature of the tip and adjust power delivered to the heating element to maintain a desired temperature 15 16 in some models the firmware for the control circuitry is free software that can be modified by the end user 17 18 19 another approach is to use magnetized soldering tips which lose their magnetic properties at a specific temperature the curie point as long as the tip is magnetic it closes a switch to supply power to the heating element when it exceeds the design temperature it opens the contacts cooling until the temperature drops enough to restore magnetisation more complex curie point irons circulate a high frequency ac current through the tip using magnetic physics to direct heating only where the surface of the tip drops below the curie point 20 soldering station edit temperature controlled soldering station a soldering station has a temperature control and consists of an electrical power supply control circuitry with provision for user adjustment of temperature and display and a soldering iron or soldering head with a tip temperature sensor the station will normally have a stand for the hot iron when not in use and a wet sponge for cleaning it is most commonly used for soldering electronic components other functions may be combined for example a rework station mainly for surface mount components may have a hot air gun vacuum pickup tool and a soldering head a desoldering station will have a desoldering head with vacuum pump for desoldering through hole components and a soldering iron head soldering tweezers edit soldering tweezers in use soldering iron stand for soldering and desoldering small surface mount components with two terminals such as some links resistors capacitors and diodes soldering tweezers can be used they can be either free standing or controlled from a soldering station the tweezers have two heated tips mounted on arms whose separation can be manually varied by squeezing gently against spring force like simple tweezers the tips are applied to the two ends of the component the main purpose of the soldering tweezers is to melt solder in the correct place components are usually moved by simple tweezers or vacuum pickup hot knife edit a hot knife is a form of soldering iron equipped with a double edged blade that is situated on a heating element these tools can reach temperatures of up to 1 000 degrees fahrenheit 538 degrees celsius allowing for cuts of fabric and foam materials without worry of fraying or beading hot knives can be utilized in automotive marine and carpeting applications as well as other industrial and personal uses 21 stands edit a soldering iron stand keeps the iron away from flammable materials and often also comes with a cellulose sponge and flux pot for cleaning the tip some soldering irons for continuous and professional use come as part of a soldering station which allows the exact temperature of the tip to be adjusted kept constant and sometimes displayed tips edit the wikibook practical electronics has a page on the topic of soldering choosing a soldering tip some common soldering iron tips also known as soldering bits note that there are different tip style naming conventions from manufacturer to manufacturer some very typical names are listed here used plated tip with remains of solder flux most soldering irons for electronics have interchangeable tips also known as bits that vary in size and shape for different types of work 22 23 15 common tip shapes include bevel chisel 24 25 and conical 24 25 an example of a more specialist tip is spoon or gull wing which features concavity see the above image for renderings of a few different tip shapes and some of the names given to them pyramid tips with a triangular flat face and chisel tips with a wide flat face are useful for soldering sheet metal fine conical or tapered chisel tips are typically used for electronics work tips may be straight or have a bend concave or wicking tips with a chisel face with a concave well in the flat face to hold a small amount of solder are available 26 27 tip selection depends upon the type of work and access to the joint soldering of 0 5mm pitch surface mount ics for example is quite different from soldering a through hole connection to a large area a concave tip well is said to help prevent bridging of closely spaced leads different shapes are recommended to correct bridging that has occurred 28 due to patent restrictions not all manufacturers offer concave tips everywhere in particular there are restrictions in the usa 28 older and very cheap irons typically use a bare copper tip which is shaped with a file or sandpaper citation needed this dissolves gradually into the solder suffering pitting and erosion of the shape citation needed copper tips are sometimes filed when worn down iron plated copper tips have become increasingly popular since the 1980s citation needed because iron is not readily dissolved by molten solder the plated tip is more durable than a bare copper one though it will eventually wear out and need replacing citation needed this is especially important when working at the higher temperatures needed for modern lead free solders citation needed solid iron and steel tips are seldom used because they store less heat conduct it poorly and rusting can break the heating element citation needed iron plated tips may feature a layer of nickel between the copper core and the iron surface 22 a nickel chrome outer plating may be used further back from the very tip as solder does not stick well to this material this avoids solder wetting parts of the tip where it would be unwanted 22 some tips have a heater and a thermocouple based temperature sensor embedded to facilitate a more precise temperature control ts100 and t12 for instance cleaning edit spool of solder 1 6mm when the iron tip oxidises and burnt flux accumulates on it solder no longer wets the tip impeding heat transfer and making soldering difficult or impossible tips must be periodically cleaned in use such problems happen with all kinds of solder but are much more severe with the lead free solders which have become widespread in electronics work which require higher temperatures than solders containing lead exposed iron plating oxidises if the tip is kept tinned with molten solder oxidation is inhibited a clean unoxidised tip is tinned by applying a little solder and flux a wet small sponge often supplied with soldering equipment can be used to wipe the tip for lead free solder a slightly more aggressive cleaning with brass shavings can be used soldering flux will help to remove oxide the more active the flux the better the cleaning although acidic flux used on circuit boards that is not carefully cleaned off will cause corrosion a tip which is cleaned but not retinned is susceptible to oxidation soldering iron tips are made of a copper core plated various metals including iron the copper is used for heat transfer and the other platings are for durability copper is very easily corroded eating away the tip particularly in lead free work iron is not cleaning tips requires the removal of oxide without damaging the iron plating and exposing the copper to rapid corrosion the use of solder already containing a small amount of copper can slow corrosion of copper tips in cases of severe oxidation not removable by gentler methods abrasion with something hard enough to remove oxide but not so hard as to scratch the iron plating can be used a brass wire scourer brush or wheel on a bench grinder can be used with care sandpaper and other tools may be used but are likely to damage the plating safe...