How to Resolve the Most Common Soldering Problems

Part of your IPC soldering certification training is doing the actual work, and don’t get disappointed if you make mistakes at first. It’s better to realize your mistake earlier during your IPC online classes. It will certainly make you a better tradesman. By getting an IPC soldering certification, you’ll learn how to resolve these common soldering problems and prevent them from happening in the future.

Disturbed Joint

It I caused by any movement through mechanical, human, or both as the solder was solidifying. The joint surface appears to be frosted, crystalline, or rough. It might also display a ripple pattern on the surface of the joint. 

- Repair: You can fix a disturbed joint by reheating and allowing it to cool without any movement.

- Prevention: It can be avoided by doing proper preparation, including stabilizing the work in a vise and immobilizing the joint. 

Cold Joint

Cold and disturbed joints can look similar, but the cause isn’t the same. It occurs when the solder doesn’t melt completely. It is described by being rough, rigid, and uneven in appearance due to insufficient heat. Cold joints are unreliable and susceptible to cracks and failure over time.

- Repair: It can easily be corrected by reheating the joint using a hot iron until the solder flows.

- Prevention: Ensure that the soldering iron has been adequately pre-heated and with enough power when it’s operating.

Overheated Joint

It can happen if the solder hasn’t yet flowed well, or the temperature of soldering iron was set too high.

- Repair: You can only repair the overheated joint after cleaning it. Carefully scrape the burnt flux with the tip of a knife or using a toothbrush with little isopropyl alcohol.

- Prevention: Always use a clean and hot soldering iron to keep the formation of overheated joints.

Solder Starved Joint

It is a joint that has not enough solder in it. Solder starved joints are not strong joints and may develop stress crack and fail in the long run. 

- Repair: Since there is insufficient solder, reheat the joint and add more solder to have a reliable joint.

- Prevention: Always make sure to check if the solder amount is already sufficient or not. 

Untrimmed Leads

Leads that are too long pose a risk of touching other leads that can cause unwanted short circuits. Keep in mind that even if only one untrimmed lead remains, it can bend and create contact with adjacent traces.

- Repair: Trim all unnecessary leads just at the top of the solder points.

- Prevention: This joint mistake is dangerous and should always be avoided. Make it a habit to trim unnecessary leads in the future.

Solder Bridge

It can occur if the two separate joints accidentally melt together due to excessive solder applications. The bridge will create an unintentional connection which can affect the functionality of the board.

- Repair: In IPC online classes, fixing solder bridge is taught with the use of a solder sucker or wick to get rid of the excess solder.

- Prevention: Make sure to use only enough solders to avoid this problem in the future.

7 Things To Consider Before Designing Your Wire Harness

Before designing your wire harness, you need to follow the standard guidelines and best practices which you can also learn in more detail when you take an IPC 620 certification online with training.

In addition to acquiring an IPC certification online, you’ll also be able to avoid costly mistakes in your design by considering the multiple factors below:

1. Environmental Conditions

The first thing you must consider in your wire harness design among several factors is to determine the physical environmental conditions where your harness is going to be exposed.

Example of these conditions are as follows

· Extreme temperatures (hot or cold) Like wires to be routed near an engine or exhaust

· Areas with moisture/water, dirt/debris, oil, or chemicals.

· Areas which exposes wires to scraping, or shock/vibration

With these conditions in mind, you need to select the right kind of cable harness that will ensure protection from failures and insulation breakdowns.

2. Dimensions And Tolerances

You also need to be clear on your required lengths, and tolerances for the wires.  They should be long enough for bend radius and must reach the connector.

Another thing you might want to consider measuring is the wire ends, including the strip lengths.

3. Covering

Different types of coverings have their distinct purposes, and their own advantages and disadvantages.  As a wire harness designer, it’s your job to identify which cover suits a specific application.  

And you should also take note that not all parts of the wiring will require covering because sometimes, it causes a disadvantage with flexibility and future troubleshooting.

Examples of different covering types are braided loom, woven, split sleeve, tape, or conduit.

4. Wire Coloring And Labeling

If you require labels to help you quickly identify circuit names, you need to note on your drawing your prefered wire colors, and the text you want to be printed, or labelled on the wires.

Note the following:  color, text, connector labels, wire labels, or assembly label.

5. Wire Type

The type of wire you choose should also be based off its application because different wire types each have their own uses.

Different wire types have different voltage ratings, insulation material, and plating (bare or copper).  GXL and TXL wiring are best used for automotive purposes, while UL1015, UL1032, and UL1230 are best suited to control panels.

6. Splicing And Splice Locations

The method of splicing a wire also have different variations categorized by their specific use.  Carefully review this factor before designing your harness.

Examples of splicing methods are as follows: mechanical crimps, ultrasonic welds, jumps/daisy chain.

7. Testing

The last most important step is to identify the testing method.  Various testing types are as follows

· Continuity test

· High voltage test

· Functionality testing

· Cycle testing

Determine the type of testing based on specific use/application.

8. Conclusion

The wire harness effectivity, and functionality, will heavily depend on the design quality - an aspect of electronics assembly which is heavily emphasized when you take an IPC certification online.  A good design ensures that malfunction doesn’t occur, improves the service life of the wires, and organizes wires for easy access, maintenance, and troubleshooting.

All wire harness designs must adhere to  IPC/WHMA-A-620, so that’s the best place to start.  Consider acquiring an IPC 620 certification online to help you develop the right wire harness solution for your specific needs.

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