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DESIGN AND CONSTRUCTION OF A DC SOLDERING IRON

 

ABSTRACT

This work is on a dc soldering iron. A dc soldering iron joins two metal work pieces by means of a third metal (solder) at a relatively low temperature, which is above the melting point of the solder but below the melting point of either of the materials being joined. This device composes of a heating element, and a copper tip. Soldering iron tips are made of copper core plated with iron. The copper is used for heat transfer and the iron plating is used for durability.

 

 

CHAPTER ONE
1.1                                                        INTRODUCTION
Soldering is described as process in which two or more items (usually metal) are joined together by melting and putting a filler metal (solder) into the joint, the filler metal having a lower melting point than the adjoining metal. Soldering differs from welding in that soldering does not involve melting the work pieces. In brazing, the filler metal melts at a higher temperature, but the work piece metal does not melt. In the past, nearly all solders contained lead, but environmental and health concerns have increasingly dictated use of lead-free alloys for electronics and plumbing purposes. Soldering work is performed by soldering iron.
A soldering iron is a hand tool used in soldering. It supplies heat to melt solder so that it can flow into the joint between two workpieces.
A soldering iron is composed of a heated metal tip and an insulated handle. Heating is often achieved electrically, by passing an electric current (supplied through an electrical cord or battery cables) through a resistive heating element. Cordless irons can be heated by combustion of gas stored in a small tank, often using a catalytic heater rather than a flame. Simple irons less commonly used than in the past were simply a large copper bit on a handle, heated in a flame.
Soldering irons are most often used for installation, repairs, and limited production work in electronics assembly. High-volume production lines use other soldering methods.[1] Large irons may be used for soldering joints in sheet metal objects.
For electrical and electronics work, a low-power iron, a power rating between 15 and 35 watts, is used. Higher ratings are available, but in this work we are focusing on dc specifically 12v powered electric soldering iron.

1.2                                             OBJECTIVE OF THE PROJECT
Soldering makes quick and neat connections to electronic equipment, plumbing and jewelry. Heating the metals with a soldering iron melts the solder onto the joint, forming the bond as the solder cools. The main objective of this work is to design a 12vdc powered soldering iron that can be used to perform the mentioned tasks.

1.3                                              PURPOSE OF THE PROJECT
The purpose of this work is build a hand tool used in soldering, that supplies heat to melt solder so that it can flow into the joint between two work-pieces, which composed of a heated metal tip and an insulated handle.

1.4                                          ADVANTAGES OF THE PROJECT
Dc soldering iron is lightweight, compact, and portable.  Soldering irons supply heat to melt solder.  This provides an electrically conductive connection.

1.5                                         SIGNIFICANCE OF THE PROJECT
D.C Soldering irons are most often used for installation, repairs, and limited production work in electronics assembly. High-volume production lines use other soldering methods. Large irons may be used for soldering joints in sheet metal objects.

1.6                                          APPLICATION OF THE PROJECT
Soldering iron is used in plumbing, electronics, and metalwork from flashing to jewelry.
Soldering iron provides reasonably permanent but reversible connections between copper pipes in plumbing systems as well as joints in sheet metal objects such as food cans, roof flashing, rain gutters and automobile radiators.
Jewelry components, machine tools and some refrigeration and plumbing components are often assembled and repaired by the higher temperature silver soldering process. Small mechanical parts are often soldered or brazed as well. Soldering is also used to join lead came and copper foil in stained glass work.
Electronic soldering iron connects electrical wiring and electronic components to printed circuit boards (PCBs)
1.7                                              PROBLEM OF THE PROJECT
Below are the problems of the work:

  • When using  this device, Careful removal of the flux residuals is required in order to prevent corrosion;
  • Large sections cannot be joined;
  • Fluxes may contain toxic components;
  • Soldering joints cannot be used in high temperature applications;
  • This device has a Low strength of joints.

1.8                                       PROJECT REPORT ORGANIZATION
The project report has been organized into five chapters for orderliness and easy understanding of the information on the report design.
Chapter one contains introduction design objectives, purpose, application, advantages, limitation, significance of the report and report organization
Chapter two dealt on system component analysis literature review and theories/modules of design.
Chapter three contains the system design description of the system building blocks system specification block diagram and the description of the overall operation of the system.
Chapter four describes the implementation testing and results of the project.
Chapter five finally dealt on the cost analysis calculation and recommendation for further improvement and ended with a page for references.

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