Rules for soldering aluminum and copper wires

The most common connection method in modern wiring is wire soldering. This method is characterized by a high degree of reliability of the electrical connection, which in turn provides high fire safety and overall operational safety. How to achieve the desired result, correctly and safely perform this work, we will consider below. Let's start with the preparation. The theoretical and practical aspects of soldering copper and aluminum conductors will be described below. We will not consider the choice between copper and aluminum in detail. We only note that although copper costs more, it is far superior in quality and durability to aluminum wiring. So, to your attention, the order of soldering wires in the junction box.

What tools and materials will be needed?

The choice of tools and materials that we need will be determined by our specific goals, as well as the soldering methods used. The main tool that is used is either an electric soldering iron or a gas burner. Well, then there will be, in general, a standard set for soldering. We will need:

  1. Knife for cutting wire insulation - do not forget to grind or use a stationery knife. Also can make an electrician knife with your own hands.
  2. Pliers, for twisting conductors.
  3. Solder and flux. Flux is a substance by which we remove oxidation from the surface we solder. Solder is what directly veins are soldered together.
  4. File - a small file is suitable.

Junction box

When soldering wires with a soldering iron or gas torch, different solders and fluxes can be used. So, copper wires need solder based on a mixture of tin and lead - these are solders of the POS-40, POS-50, POS-60 grades. For soldering aluminum wires, such grades are suitable - P-250A (zinc and tin), TsO-12 (zinc and tin), CA-15 (zinc and aluminum), A (zinc, tin, copper). Rosin is used as a flux - an organic material containing a mixture of resin acids of coniferous trees. Rosin is the most common and inexpensive option. There are also methods for soldering with acid as a flux, but it is not recommended to use them because of their harmfulness. In addition, acid gives twist corrosion over time.

Let's solder!

When all the necessary tools and materials are ready, we take up the job. Consider the technology of soldering copper wires in a junction box. At home, the most common connection method is to solder the twists of single-core conductors. We clean them from isolation - we will remove 4-5 cm from each end. For good quality twisting should be tightly twisted and crimped the ends with pliers. About, how to make a good twist, we told in a separate article. Just do not overdo it, otherwise you can break off the current-carrying vein.We pick up a soldering iron, which should be sufficiently warmed up, and begin to impregnate our twist with rosin so that it penetrates between the wires as best as possible. Then a solder consisting of tin and lead is applied to the soldering iron tip, and gradually warming up the junction, we achieve uniform application of solder. It should penetrate well between the wires. When they are “painted” in silver, they can be considered tinned. Learn more abouthow to tin wire, you can in our corresponding article.

In order to tin a stranded copper conductor, it is necessary to twist all the small veins into one core well and tighten with pliers. Then apply rosin with a soldering iron and then the necessary solder.

Tinned veins

A distinctive feature of the soldering of aluminum wires is the high degree of oxidation of aluminum in air. And if the conductors are oxidized, then soldering them during electrical installation will already be problematic. Therefore, it is necessary to constantly mechanically clean the surface from oxidation and simultaneously perform tinning. For heating, a gas burner is used, the flux is selected based on the method of soldering and wire cross-section.

Spike aluminum wiring photo

With a knife, carefully cut the insulation from the cores of about 5 cm. We clean the surface until a characteristic shine appears using the same knife, or we will use sandpaper. Next, you need to connect the veins in the form of a groove, which is formed as a result of joining the lap veins, by double twisting. We take the burner and begin to heat the twist to about the melting point of the solder. We continue to heat the joint and rub the soldering spot with a special stick of solder. The groove will fill with solder. The entire surface is treated in the same way until it is completely covered with tin.

By the way, the pros and cons of existing methods for connecting wires in a junction box we reviewed in the corresponding article, which we strongly recommend that you read!

Some features of the process

We also recommend that you pay attention to several rules that will help to make high-quality soldering of wires with your own hands.

Check the soldering iron tip before starting work. It must be clean. If on it there are bumps, sinks, black soot, then such a sting needs to be cleaned, otherwise it will not be able to take solder normally. Take a small file, put the sting to it at an angle and clean it so that the luster of copper is visible. Then re-tin its end. In the process, sometimes pay attention to his condition and try to keep it clean. You can also use fine sandpaper to clean the tip of the soldering iron.

Cleaning the sting with a sponge

We always begin to solder from the side of the core that is farthest from the insulation, since it can melt, its properties are violated, which is unacceptable. Gently twist the joints with pliers, without unnecessary effort, so as not to break the wires, especially this applies aluminum wiringwhich is especially brittle.

Before applying the solder, even on the connection of copper wires, try to clean the surface of the core with a knife to a shine, you will see that the solder is applied much easier. This applies to both copper, single-core and multi-core, as well as aluminum conductors.

Do not forget to carefully isolate the joints at the end of the work. Cotton or polyvinyl chloride insulation should be used for these purposes. Wrap them around the twisting places so that the insulation comes in a few centimeters from the bare place. Learn more about how to insulate the wires correctly, you can find out in our article.

Despite the fact that soldering is not a super fast way, it provides a good quality connection. And everything that is described in the complex will help you increase the safety of the work, as well as increase the service life and reliability of the electrical wiring.

Finally, we recommend that you watch the video, which details the technology for soldering electrical wiring in distribution boxes:

Using a gas burner

The use of a special soldering iron for pipes

So we looked at how the wires are soldered in the junction box. We hope that the provided instruction was useful and understandable for you!

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Using a gas burner

The use of a special soldering iron for pipes

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One comment

  • Magomed

    For tinning, I used a mixture of rosin with alcohol. So the conductor is better covered. Pre-twisted the tinned ends, and not tinned. Tinned harder to gently twist. And with not tinned there is a risk of not completely tinning, and, accordingly, not completely soldering the twist. Those. oloao may not be available everywhere. Given that you are standing on a stepladder, this is important.

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