On most occasions, Soldering stations are mostly used in manufacturing or servicing workshops. They usually consist of an electric mains power supply, a soldering iron and a bench stand. Prices for soldering stations can vary largely, with the cost of replacement tips at a similar proportion. One of the world’s leading brands at the moment are a firm called Weller Pace Metcal.
The technology used for the TCP IRON and PS, PU soldering stations is the same as the W61, W101 and the W201 irons, although the main voltage is reduced to 24v, so to create a safer working environment for the welder. A wide range of tips are manufactured by Weller Pace Metcal, which covers all shapes and sizes.
Modern technology has powered ahead with a new ruling that dictates Lead Free Soldering. The latest range of Weller Soldering stations are the WS81, which is analogue and the WSD81 being digital – these replace the old TCP iron and the PS51 Power.
These new stations give an even more precise temperature with a much quicker response time, is light in weight and a much easier handling mechanism for the soldering iron. Replacement parts are also less expensive and come with antistatic protection, helping make these Soldering Stations essential for all workshops, especially those with an emphasis on lead free soldering.
The new ruling/directive is now ensuring that manufacturing companies increasingly use unleaded solder. Unleaded solder is available in various forms that come with or without silver, with some lead free solders containing corrosive fluxes which make them quite tough on soldering iron bits. Lead free soldering also requires a much more precision sensitive working temperature of around 350c for it to flow properly. A good soldering station that provides this would be the WELLER WSD81.
There are a number of ways in which Soldering can be done. These include passing parts over a small fountain in a container of molten solder - this is known as Wave Soldering. Heating assemblies are another method, using an Infrared lamp or a point source like an electronic soldering gun or brazing torch. Reflow soldering ha recently been used too.
The difference between soldering and brazing is not consistent as the only difference tends to be the melting temperature. Different equipment and is needed for this as most soldering irons are unable to achieve high enough temperatures for brazing. Brazed connections are often as strong or nearly as strong as the parts they connect, even at elevated temperatures.
The equipment that is used to apply the required heat to metal parts that are to be fused together is a soldering iron, which normally comes with a soldering station. This piece of equipment enables the solder to move smoothly between the metallic surfaces, so that they are bound strongly and hermetically.
The humble soldering iron works with a heated metal tip and a handle that is essentially insulated. An electric current of some sort, whether cable or battery is what enables the heating supply that is required. Gas combustion via a tank is also another method of providing the heating supply.
A soldering station which is usually temperature-controlled is a unit that is used mainly for soldering electronic components. The soldering irons on a soldering station can be different, depending upon whether the iron is being used for lead-based or lead-free solders, both of which use varying temperatures, with lead-free soldering requiring a much higher temperature.
Although many different forms of temperature control are used, the most basic of all is a variable control, which is just like a dimmer switch on a light. The thermostat is also another method, which sits inside the tip of the soldering gun.
The Curie point is a name given to a method where magnetized soldering tips are used. These work in such a way that it loses its magnetic properties when a certain temperature is reached. For as long as the tip is magnetic, it sticks to the heating element, and then loses contact when cooling down.
Currently, the most advanced soldering tools are digital irons. The temperature on these is controlled by a complex microprocessor within the soldering station. This works by the microprocessor monitoring what is known as a thermocouple within the tip of the gun.
Where soldering is required in inconvenient places like cars and small, hard to reach delicate areas prevent the use of a soldering station due to its size. So to help with situations like these, a pistol shaped soldering tool has a trigger which is not to dissimilar to a firing gun or drill, in order to make it possible to use with one hand and to reach awkward places. The gun uses a tin-based solder for maximum conductive contact. Most modern guns also come with fast switches that let the gun cool down quickly, so that it can be put down in a matter of seconds and help prevent any potential fire damage.
