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1. Provide a brief description of the soldering process.
Soldering is a process that uses heated tin and lead (solder) to join wires or a connector to a terminal. As the solder is in hot liquid form during the soldering process it removes oxygen and moisture.
When the liquid solder cools it becomes solid and forms a very strong connection. This creates a joint that has excellent electrical conductive properties.
2. Name two types of flux that are commonly used in the automotive industry.
Rosin flux
Resin flux
No clean flux
3. Match up the type of soldering iron with it most appropriate description:
Simple Trigger gun Cordless
Use butane gas and are ideal for use in hard to reach places Iron: Cordless
Is mains powered and is ideal for quick jobs. Heats to set temperature providing an even heat.
Iron: Simple
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4. Why is it important to use a heat sink method when soldering near semiconductor materials?
To protect the semiconductor materials from exposure to high temperatures which may damage them
5. Why is it important to wash your hands after using solder?
Solder may contain iron which when injested can cause serious health problems
6. Provide two safety precautions to take to avoid fume inhalation when soldering
Ensure adequate ventilation is available Use a filter mask when soldering
7. What is a SDS?
A SDS is a safety data sheet that provides information on the properties of hazardous chemicals and how they need to be managed in the workplace.
8. Why is it important to remove residue from the work following soldering?
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9. What is the main function of a soldering iron stand?
To house a hot soldering iron during and after use.
10. What is a cold solder?
A cold solder describes a poor quality solder joint that has been moved before it has cooled.
11. Describe the procedure involved when soldering two electric wires.
Ensure adequate ventilation.
Select the right size and type of wire for the task.
Heat up the soldering iron in its holder. The tip should be clean without corrosion (oxidation).
Touch the solder to the flat part of the hot soldering iron. The solder should melt and continue until the tip is covered in solder. Using a wet sponge wipe off excess solder to leave a shiny coat of solder. Return the solder tool to its holder.
Using a wire strippers strip the wire insulation to expose the desired amount of wire for the connection.
Ensure the ends of both wires are clean.
Place some shrink tubing over one of the wires.
Twist the two wires together. Wires should be held firmly with hands or clamps to ensure a good join.
If the wire to be soldered is connected to a semi-conductor attach a metal clip (heat sink) between the solder joint and the material. This will protect the semi-conductor from heat damage.
Melt some solder onto the tip of the soldering iron and place the soldering iron under the twisted wires. Avoid hot components.
Feed some solder onto the soldering iron. The solder should melt and cover the joined wires. Continue until the join is completely covered and has turned a silvery colour.
Remove the soldering iron and allow the joint to cool (1 minute) while ensuring that the wires remain steady to prevent damage to the join. If the joint is moved before it has cooled a poor quality joint will result (this is known as a cold solder). A good solder joint will appear smooth and shiny, with the outline of the soldered wire clearly visible.
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12. For each of the following statements please indicate whether the statement is true or false. Please circle T or F as appropriate.
F Solder is usually made up of aluminium, iron and copper
T Rosin flux is made of pine sap and leaves and an ugly sticky residue
T Straight, bent, conical and flat are all types of soldering iron tips
F Heat shrink tubing expands when heated to cover electrical wires
T Solder comes in different diameters to suit different wire gauges
T Electrical insulation tape can be used as an alternative to shrink tubing
13. What is main benefit of using a thermostatically controlled iron?
The heat output can be precisely controlled.
14. List two electrical test tools that may be used to check an electrical circuit after soldering.
Multimeter LED Test lamp
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