Manufacturing and Processes Report

Soldering

DS-219
PDPM IIITDM Jabalpur

June 2, 2020

Group D
Partha S. Hukai (2018518)
Saurav Basumotari (2018526)

Mentor
Prof. Puneet Tandon
Professor of Mech. Engg; Professor of Design at PDPM IIITDM Jabalpur, India

SUMMARY

This report details a project undertaken by Design undergraduate students at the PDPM Indian
Institute of Information Technology, Design, and Manufacturing, Jabalpur as a part of the course
DS-219. The goal of the project and the course was to gain experience and knowledge on the
manufacturing processes that go behind producing a tangible product.

In this particular assignment, we were asked to use our knowledge of manufacturing to ​solder a
cone and cylinder

Throughout the design process, both the assignment requirements and their corresponding
specifications have been kept in mind. The design process in its entirety is detailed throughout
this report, including methodology, procedures, analyses, and end results. A detailed description,
including plans and finalized design sketches of the components, is provided as well.
This report serves to document the entire process from the initial background research to final
recommendations for improvement to the final design. This report documents the entire design
process including the final manufacturing plan, the measures are taken to ensure that all
requirements of the assignment have been fulfilled and specifications have been validated, a
detailed description and analysis of every major manufacturing processes that are to be used to
produce the desired product, this also includes a description of the product and its features, and
finally, our recommendations concerning improving the final design and suggested future work.

Introduction

Soldering is a process used for joining metal parts to form a mechanical or electrical bond. It
typically uses a low melting point metal alloy (solder) which is melted and applied to the metal
parts to be joined and this bonds to the metal parts and forms a connection when the solder
solidifies. It is different to welding in that the parts being joined are not melted and are usually
not the same material as the solder

Principle of soldering

Soldering is very much similar to brazing and its principle is same as that of brazing. The major
difference lies with the filler metal, the filler metal used in case of soldering should have the
melting temperature lower than 450℃. The surfaces to be soldered must be pre-cleaned so that
these are faces of oxides, oils, etc. An appropriate flux must be applied to the faying surfaces and
then surfaces are heated. Filler metal called solder is added to the joint, which distributes
between the closely fitted surfaces. The strength of soldered joint is much lesser than welded
joint and less than a brazed joint.

Different types of soldering

Most of the solder metals are the alloy of tin and lead. These alloys exhibit a wide range of
melting point so different type of soldering metal can be used for variety of applications.
Percentage of lead is kept least due to its toxic properties. Tin becomes chemically active at
soldering temperature and promotes the wetting action required for making the joint. Copper,
silver and antimony are also used in soldering metal as per the strength requirements of the joint.
Different solder their melting point and applications are given in the Table
A solder is selected on the basis of its melting point. If metals to be joined have higher melting
point solder of higher melting point is generally selected. Solder of high melting point provides
better strength of the joint.

Types of soldering fluxes

Soldering fluxes can be classified as :

(a) Organic, and

(b) Inorganic fluxes.

Organic Fluxes Organic fluxes are either rosin or water-soluble materials. Rosin used for fluxes
are wood gum, and other rosins that are not water-soluble. Organic fluxes are mostly used for
electrical and electronic circuit making. These are chemically unstable at elevated temperatures
but non-corrosive at room temperature. Inorganic Fluxes Inorganic fluxes are consists of
inorganic acids; mixture of metal chlorides (zinc and ammonium chlorides). These are used to
achieve rapid and active fluxing where the formation of oxide films is problems.

Fluxes should be removed after soldering either by washing with water or by chemical Soldering
and Brazing solvents. The main functions performed by fluxes are :

(a) remove oxide films and tarnish from base part surfaces,

(b) prevent oxidation during heating, and

The fluxes should

(a) be molten at soldering temperature,

(b) be readily displaced by the molten solder during the process, and

(c) leave a residue that is non-corrosive and non-conductive.

Safety Precautions
1. Heat
Although solder has a relatively low melting point this temperature is more than high
enough to cause serious burns to people or objects. It is important to hold the soldering
iron only by the insulated handle, never touch the heating element or tip when the
soldering iron is on. The soldering iron will remain hot for some time after it is turned off
so we always check that it has cooled down before touching it, e.g. if changing the tip.
When not soldering always keeping the soldering iron in a proper holder so that you
don’t touch it accidently and it doesn’t heat or burn other objects such as the benchtop.
Don’t hold parts being soldered with your hands as these will also be heated when being
soldered. Don’t flick molten solder from the soldering iron or wipe the tip on brass wool
type tip cleaners. If using a hot plate for surface mount soldering do not touch the hot
plate.

2. Toxic materials
Leaded solder contains lead which is a harmful material. Use of this type of solder will
probably involve handling it and your skin may become contaminated by it. Although it
is unlikely that the lead can be absorbed directly through your skin it may be ingested
indirectly if it is transferred by handling food whilst your skin is contaminated. Always
wash your hands thoroughly before eating or handling food. Solder flux creates fumes
when heated during soldering which may be harmful if inhaled. Use a fume extractor to
avoid inhaling fumes.

3. Spattering
Solder and flux can spit or spatter when heated. Always wear eye protection (safety
glasses) when soldering.

4. Electrical Safety
 Electric soldering irons are plugin appliances and must have a current safety test tag. The
test will confirm that the soldering iron conforms to electrical safety standards and has
not been damaged at the time of the test. Before use you should visually check that the
soldering iron does not have damage such as melted insulation on the lead, broken or
cracked handle or exposed conductors. Don’t use damaged equipment and report the
damage. For electrical safety the exposed metal parts such as the tip and heating element
are earthed. Don’t solder on any live equipment as contact with the earthed tip may cause
damage to the equipment or soldering iron.

Soldering tools

1. Soldering Iron

2. Soldering Wire
 3. Soldering paste/flux

PROCEDURE

First, we made a sheet metal cone and cylinder from the given measurements which was
presented on our previous report of sheet metal, After making the cone and cylinder we were told
to solder it with the help of soldering rod, soldering iron and flux, in order to join the 2 parts
together and ultimately make it in the shape of a funnel.

For making cylinder we were given a galvanised iron sheet which has to be cut in the given
measurements with extra length on both sides to connect it later via bending and hammering

First, the soldering iron was connected to the socket and it was left on for few minutes to heat
with its tip away from any other surface for safety reasons (mention above), after around 2-3
minute we first applied flux at the tip of soldering iron then hold the cylinder and cone in the
position and touch it to the flex or soldering paste and then to the soldering wire at the top
circumference of the cylinder and lower bottom of the cone together with minute pressure of
soldering iron to the surface of the funnel

The hot iron melts the wire and then we immediately apply that melted paste on the joint. We
repeat these two steps until we completely secure the joint of the cylinder and cone
Atlast it was finally let cooled down and polished a little bit for final product eg. funnel
POSSIBLE DEFECTS

Most defects in soldering are inaccuracies in its surface roughness or the angle of joint .There are
several possible causes for these defects, including the following:
1. Wrong holding position of the parts
If the parts are hold in wrong position or at an worng angle( other than 180 degrees) this
could produce a bad fill or slanted funnel overall

2. Faluty tool
 Soldering iron or soldering wire could be faulty resulting in a bad fill and thus ultimately
creating a bad joint

3. Improper method for applying melted wire

Recommendation
As we have no previous experience with the soldering iron and welding we were having some
trouble on the applying the molten metal over the edge, hence our surface were uneven , we
would like to recommend the clear techniques and instruction beforehand so we could use the
soldering iron with little ease

Conclusion
The goal of this assignment was for us students to learn more process of soldering and making a
cylinder with the metal sheet

To that extent, it has to be concluded that the objective of the assignment has been successfully
achieved as the team was able to not only learn more about the workings of the tools but also
perform an operation to machine apart.