Soldering is a process of joining two metal pieces with a special material called solder, which flows over preheated pieces to bond them together. It requires a soldering iron, solder wire, and flux to clean the surfaces. Different metals require different solders and heating methods.
Welding joins two pieces of metal, such as electrical wires, fusing them together with another metal to form a strong bond. Many people use this technique in their field, from electrical and plumbing engineering to jewelry and crafts. In a delicate process, a special material, called solder, flows over two preheated pieces and bonds them together in a process similar to welding or brazing.
The soldering process is complicated and intimidating in practice, but easy to understand in theory. Basic supplies include a soldering iron, which is a metal pole that heats up to a specific temperature through electricity, like a regular iron. The solder, or wire, is often an alloy of aluminum and lead and needs a lower melting point than the metal being joined. Finally, a person doing this technique needs a cleaning resin called a flux to ensure that the joint pieces are incredibly clean. The flux removes any oxides on the metal surface that would interfere with the molecular bond, allowing the solder to flow smoothly into the joint.
The first step in soldering is cleaning the surfaces, initially with sandpaper or steel wool, then melting the flux onto the parts. Sometimes, the flux is part of the thread alloy, in an easy-to-use blend. Then, the pieces are both heated above the solder’s melting point (but below its own melting point) with the iron. When touched at the joint, this precise heating causes the wire to “flow” at its hottest point and creates a chemical bond. The material should not drip or drip, but spread evenly, coating the entire joint. When it cools, it produces a firm and even connection.
Various metals can be welded together, such as gold and sterling silver in jewelry, brass in clocks and watches, copper in water pipes, or iron in leaded glass windows. All of these metals have different melting points and therefore use different welds. Some “soft” wires, with a low melting point, are perfect for wiring a circuit. Other “hard” solders, such as making a bracelet, need a torch rather than a soldering iron to get hot enough. Electrical engineers and hobbyists alike can benefit from learning the art and science of this process.
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