When you are deciding which solder wire is the best to use for your job, whether it is for stained glass soldering, electronic assembly, or even industrial soldering, there are a few things to consider. You need to choose the right alloy, the flux, and the best diameter size of the solder wire for your application.
Below are some tips to help you choose the best solder wire:
Best Solder Wire for Electronic Assembly Soldering
Alloy
First, are your parts all lead-free? Then you’ll need to use a lead-free Solder to join them. Choose from SAC305, Sn96 or a reduced / no silver alloy. If your product is exempt from RoHS, then you can proceed with a leaded solder alloy. 63Sn/37Pb is still the primary lead-bearing alloy used when lead-free is not required.
Best Solder Wire Diameter
For electronic work, it is generally best to choose a solder wire with a thinner diameter. A good rule of thumb is a range of 0.015 inches to 0.032 inches in diameter. It might be as simple as matching the solder wire diameter to the component or connectors that you’re soldering. Your soldering iron tip size should also be compatible with the solder wire that you choose.
For work on surface mounted devices, a solder wire with a diameter at the lower end of the above range should work well. The best choice is a solder wire diameter that is small enough that you don’t end up with extra solder on the joint that you’re connecting.
Flux
Since solder wire for electronic assembly has a core flux, you need to consider whether you want to use a water-soluble flux, a rosin flux or even a no-clean flux which is determined by your application.
Best Solder Wire for Stained Glass Soldering
Alloy
For stained glass soldering, when considering the alloy of the wire, you can choose lead or lead-free for the job. If you are soldering giftware or jewelry, you should use lead-free wire. Since these items will be worn or touched, lead-free is the better choice for health reasons.
For flat glass soldering any alloy from 50/50 to 60/40 or 63/37 is typically used.
Best Solder Wire Diameter
When choosing the best solder wire diameter for stained glass, it is generally recommended to use either 0.125 inches in diameter or 0.062 inches. If you are soldering flat stained glass, 0.125 inches is usually the best diameter.
For sun catchers, jewelry, or giftware, 0.062 to .125 inches.
Flux
When soldering stained glass, you want to make sure to choose a flux that is made for either came lead or copper. A variety of inorganic and organic acid fluxes are available to solder both lead and copper base metals.
Best Solder Wire for Industrial Soldering
Alloy
Many leaded and lead-free solder alloys can be used to solder industrial components together. First decide if lead-free compliance is necessary and if not then traditional lead-bearing alloys such as 50/50 and 60/40 can be used. Most lead-free alloys are stronger than leaded ones but require more heat to flow and wear soldering tips out at 2-3 times the rate of soldering with leaded solders.
Best Solder Wire Diameter
While there isn’t a specific solder wire diameter requirement for industrial soldering, we recommend a solder diameter range of .062 to .125 inches. Choose the optimal diameter by the size of the parts – the larger the part the larger the solder joint and thus soldering iron tip.
Flux
The flux you choose depends on the parts you are soldering. For stainless steel, the best flux is a high-activity flux that has a phosphoric acid-base. If you are soldering galvanized steel, brass or copper, on the other hand, organic acid or inorganic acid fluxes can be used. Use only organic acid fluxes near electrical parts, as inorganic flux residues are highly corrosive.
The best solder wire for your job depends on your preferences, application as well as the melting point of the solder wire. You might need to experiment with different types of solder wire to see which works best for you.
