23 February 2005Manufacturing / Production Technology, Hardware & Services
Dries van Schalkwyk, DS Communications
Resistance soldering is a method of soldering that is performed with the use of a special type of controllable equipment that American Beauty has developed to produce an intense heat, which can be applied directly to the specific area being soldered.
When standard 220-240 AC line voltage is passed through one of its specially-designed, isolated step down transformers, the incoming voltage is converted into a safe, low-voltage, high-amperage, AC output current. When this converted current is passed through the proper type of resistive alloy, intense heat can be generated. Varying the output current, or the type and size of the resistive alloy being used, will allow one to control the amount of heat that is being generated.
Because of the intense level of heat that is available with 'resistance soldering' equipment, one is able to perform applications where very high levels of heat may be required. This includes lead-free soldering, silver soldering and even brazing applications. By matching the appropriate 'hand piece' and 'power unit', resistance soldering equipment may be used for soldering everything from components on a circuit board to sweat soldering up to 3" diameter copper tubing.
Resistance soldering equipment can also be used for thermal wire stripping applications, simply by changing the hand piece. This includes stripping of wires that have high temperature (PTFE type) insulations.
There are several benefits when using resistance soldering over other methods. These include, but are not limited to the following:
* Quality: Because a higher level of heat is available directly where it is needed, fewer cold solder joints are produced. The flux being used will be more thoroughly activated allowing for better wetting and there will be less chance of getting solder into unwanted areas.
* Efficiency: A more direct and higher level of heat means faster soldering takes place, allowing for less heat dissipation into the work piece. This means faster cooling and fewer rejects caused by damage to heat sensitive components. The amounts of solder and flux needed will decrease and solder times can be cut by more than half.
* Repeatability: More consistent solder joints will be no problem because of the direct heating approach. By properly setting the power unit's output and performing consistent time-cycling, solder joints will be much more uniform. Being able to rely more on the soldering equipment for consistency means easier training of operators.
* Safety: There is no chance of an operator being shocked by hazardous voltages from the power unit or hand piece, since only very low AC voltage is produced. Because heat is generated by resistance soldering equipment only during the actual soldering application, there are no hot tools left idling in the work area, and no open flames. Because soldering is more rapid, there is also less accumulated heat in the work and tools.
* Savings: Improved quality means a lower rejection rate and less rework. Greater efficiency lowers overall operating and utility costs, and less solder and flux will be required. Consistent repeatability and ease of use reduces the amount of time required and the costs associated with the training new operators. Increased safety helps to reduce the likelihood of incurred costs associated with accidents or injuries.
For more information contact Dries van Schalkwyk, DS Communications, +27 (0)11 314 4101, [email protected]
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