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Soldering 550m of copper wire

Discussion in 'Electronic Basics' started by Goran, Jun 19, 2013.

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  1. Goran

    Goran Guest

    I have to solder 550 - 600m of 1mm copper wire.
    Wire must be completely covered with solder.

    It will take some time to do this on regular basis ( with soldering iron
    ) so i was thinking to make some kind of slot in some aluminium housing
    and melt the lead alloy in it.

    Then i can put the wire in it and draw it slowly throe this slot.
    Additionally i can set some stepper motor on the other side to
    automatize the whole process.

    1.) Could this be done on this way ?

    2.) Would this work with iron wire ?

    Regards !
  2. Jasen Betts

    Jasen Betts Guest

    step one: order 600m of tinned copper wire.


    buy two 1000' (305m) rolls unless you need it to be continuous
    "some time" is an understatement. This is wrong newsgroup for what is
    essentially a industrial process.
  3. The most obvious question is "why"?

    You've asked in .basics so it may be that your logic about this is faulty.
    You've not explained what this is about, simply want a solution, and from
    experience here since before sci.electronics was split up into the current
    subgroups, people often ask questions that are the wrong questions, since
    they haven't started with the actual question.

    I can't see why you need solder coated copper wire. I can see why you
    might want it protected against tarnish, I can see why you might want to
    make it easier to solder to, I can see why you might want it to keep hi Q
    if this wire is used for winding coils, but all of that comes other ways,
    not coating it in solder.

  4. Tom Biasi

    Tom Biasi Guest

    Maybe a troll? He can buy tinned wire and he is talking about doing two
    football fields of wire.
  5. Jamie

    Jamie Guest

    I think it would be cheaper to get tinned copper wire ready made..

    However, if you insist, a solder pot with a deep roller in it so you
    can wrap the wire around it and pull.

  6. Phil Allison

    Phil Allison Guest

    "Jasen Bleats"

    ** Err - tin plating and solder coating are different things.

    .... Phil
  7. Goran

    Goran Guest

    Yes, as you mention it this are different things.
    In this alloy i have to use 70 or more % of lead.

    Solder pot and solder bath suggested by Jamie and John is the only
    solution. The problem is that i dont know if this will work.
    I can melt lead and put some tin in it to get the alloy but will this
    alloy stick to wire ?

    In general it should be no problem if the wire is oxides free...
  8. Goran

    Goran Guest

  9. Jamie

    Jamie Guest

    And then you have electroplate.

  10. That reminds me of all the debate in the amateur radio magazines about
    soldering to aluminum. No it can't, yes it can. ANd then when it was
    esplained, one I scheme I remember was "liberally apply oil to the
    surface, scrape the surface under the oil, then start soldering" or
    something like that. The oil keeping it from oxidizing, the scraping to
    thet the existing oxidation off.

  11. Phil Allison

    Phil Allison Guest

    "John Fields"
    "Phil Allison"

    ** "Tinned copper wire" sold as solid wire on a reel is ** tin plated **.

    Do try to follow the context - fuckhead.

    .... Phil
  12. This sounds like a real PITA. What is the purpose? (Maybe there is some other solution?) Once you get away from the eutectic mix of tin and lead the solder has this temperature range where it's not really solid or liquid..but this weird mixture, I have no idea what happens when you try and coat a wire with it.

    You might try a post on the rec.crafts.metalworking. Lots of political 'junk', but just ignore that.

    George H.
  13. Goran

    Goran Guest

    I try to make some soldering pot with camping gas stove.
    I melted lead and soldering wire (40/60) and am guessing that final
    ratio is around 70 % lead 30 % tin.

    Then i took copper wire mesh ( that i cleaned before ) i put this into
    pot. I grease it before i put it in the pot.

    Well, it looks like am doing something wrong because the copper was just
    partly covered with lead.

    Rest of it looks like it was oxidized.

    What am doing wrong ?
  14. Jamie

    Jamie Guest

    Get some pipe acid, the stuff used to wet the pipes before soldering.
    it's clear and usually comes in a squirt bottle.. Dip the copper in
    that first..
    You obviously are working with old copper.

  15. Is that stuff corrosive? I remember warnings in the magazines where
    people had used plumbing flux, only to learn it was corrosive and the
    wrong thing for electronic soldering.

  16. If you've got a deep fryer you need the grease.

  17. Fred Abse

    Fred Abse Guest

    Very big deal.

    I've seen it done. Freshly drawn wire after vacuum annealing run through
    a hot acid flux bath, followed by a cotton wiper, followed by a pure tin
    bath, then a final water-wet cotton wiper, then spooled. All at 200 feet
    per minute.

    After a few minutes, the acid fumes get to your eyes.

    The guys working in the "tinner" were all in their twenties and thirties,
    and looked about sixty.

    An interesting place. Wherever you stood in the plant, you could see a
    thousand tons of copper in various forms. That was back in the day when
    telcos were using the stuff as fast as it was being dug out of the ground.
  18. amdx

    amdx Guest

    Oh, you must be *new here, this is what Phil does.
    Just treat it as entertainment.
    Mikek :)

    * I know, I know.
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