Soldering Tips & Lifetime Issues

“Coping with Lead-Free”

Weller University | © 2007 Cooper Industries, Ltd. Proprietary CONFIDENTIAL | 1

 Content

Why are we here?

To make sales and marketing personnel more valuable to their customer
by providing some basic knowledge to them about Lead-free solder and
it’s effect on tip life and hand soldering applications.

Weller University | © 2007 Cooper Industries, Ltd. Proprietary CONFIDENTIAL | 2

 Tip Construction

• Architecture of a Soldering Tip

– Copper Core
Responsible for the high heat
conductivity of the soldering tip.
– Iron Layer
Responsible for high wear resistance.
Copper
– Chromium (Chrome) Layer
Responsible for confining the wettable
area.
Chromium
plating – Tinned Working Area
Responsible for the wettability of the
soldering tip.
– Lead-Free Tinning
Responsible for protecting the working
Wettable area of the tip when it is new.
area

Fe

Cross Section LTC tip

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 Tip Construction

• Wettable Area of the Soldering

Tip
Wettable area – The wettable area is the working
area and is responsible for the heat
transfer.
– Tinning produces an intermetallic
bond between the Iron (Fe) layer
and the solder alloy (Sn, Pb, Ag,
etc.).
– When the intermetallic bond is
created, the tip is properly Tinned
Intermetallic phase
Intermetallic phase and remains wettable.
– The thickness of the intermetallic
layer grows with time and heat.
Fe Sn Temperature accelerates the growth
Fe Sn
rate. This will Lead to more
dissolution of the Iron, more erosion
50µm
50µm
and a higher risk of oxidation.

Weller University | © 2007 Cooper Industries, Ltd. Proprietary CONFIDENTIAL | 4

 Tip Appearance

Soldering tip defects

What does a “degraded” soldering tip look like?
What does an “oxidized” tip look like?

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 Tip Appearance

• Soldering Tip Defects

– The change from a Lead bearing solder alloy to Lead Free has a
significant influence on the durability of soldering tips in hand
soldering applications. The higher percentage of Tin and the higher
melting temperature of the Lead Free solders act more
aggressively on the soldering tip and accelerate the reduction of tip
life. In addition, Lead-free solders typically use a more aggressive
flux formulation to compensate for the higher melting point alloys.
– The most significant reasons for soldering tip defects:
• Non-wettability of the Iron layer due to oxidation or surface
contamination.
• Erosion of the Iron layer due to Flux activity level,
mechanical degradation, cracks / voids, etc.
– With proper care of the soldering tip, life expectancy can be
increased to a reasonable level, even when using Lead Free
solders.

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 Tip Appearance

What does a “degraded” soldering tip look like?

Soldering
process

LTC Soldering Tip “New” LTC Soldering Tip

“Eroded”

Customer feedback
Weller University | © 2007 Cooper Industries, Ltd. Proprietary CONFIDENTIAL | 7
 Tip Appearance

– Eventually, the soldering tip is degraded by the

soldering application. This means that the Iron
layer that protects the Copper core is
compromised. The exposed Copper erodes
quickly because of the extremely high
temperature and corrosion rate of Copper.
– The durability of the soldering tip is directly
relative to the Iron layer thickness.
– As soon as the Iron layer is compromised, tip life
Well used LTC tip is over and the condition will be indicated by a
noticeable hole in the Copper core.
– The tip wearing process can be segregated into
Hole caused by three levels:
corrosion
• Corrosion caused by flux activity
• Erosion of the Iron plating into the solder
alloy (increased by high Sn content).
• Mechanical stress caused by abrasive
cleaning or “aggressive” soldering.
– A soldering tip is a consumable component
Cross section of a degraded LTC soldering tip (much like the tires on a car) and a degraded tip
is not an actual tip defect.

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 Tip Appearance

• Surface Contamination of a
Soldering Tip
– A soldering tip becomes contaminated
and produces a non-wettable surface
– The typical appearance of a
contaminated soldering tip is shown in
the these photos
– The tips exhibit a “blackened or charred”
surface finish that is very difficult to
remove
– A contaminated tip can normally be
rejuvenated by a low solids, mildly active
wire core solder, Tip Activator (Tinner)or
Weller Polishing Bar (WPB1)
– The heat transfer of a contaminated
soldering tip is significantly reduced
– The risk of surface contamination grows
considerably when using higher tip
temperatures (840°F < 30 Sec.’s)

Weller University | © 2007 Cooper Industries, Ltd. Proprietary CONFIDENTIAL | 9

 Tip Appearance

• Surface Contamination of a Soldering

Tip
– A properly tinned tip will protect the wettable
surface of the tip and will displace any surface
contamination that may otherwise occur
– Proper maintenance of the soldering tip will
reduce the risk of surface contamination and
non-wettability.
– In many cases, surface contamination may
show up as a form of “rust”, which is indicative
of a customer using “tap” water supplies that
contain high mineral contents (iron, magnesium,
etc.)
– When “rust” is evident on the Iron plated
Chrome
working area, the Chromium layer above the
area
Iron plating and the Tip Retainer, it is time to
recommend using a “Distilled or Deionized”
Iron water supply
Plating – Tips exhibiting “rust” should be discarded due to
the fact that the rust will also contaminate the
soldering connection
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 Tip Appearance

• Oxidation of a Soldering Tip

– A non-tinned soldering tip will oxidize
when left exposed to air and will create
a non-wettable surface
– An oxidized tip cannot normally be
reactivated by standard flux and
remains non-wettable
– The heat transfer capability of a non-
wettable soldering tip is significantly
lowered
– The risk of oxidation grows as tip
temperatures increase (840°F < 1min)
– A properly tinned tip will protect the
wettable surface of the tip and prevent
oxidation from occurring
– Proper maintenance of the soldering tip
will reduce the risk of oxidation and
non-wettability.
Weller University | © 2007 Cooper Industries, Ltd. Proprietary CONFIDENTIAL | 11
 Tip Appearance

• Oxidation of a Soldering Tip

– An oxidized soldering tip typically shows no
“blackening or darkening” of the wettable area
or of the Chrome area
– The wettable area exhibits a dull grey, grainy
appearance
– The Chrome (Chromium) area may turn to a
“Bronze or Blue / Bronze” which indicates that
it has been heated
– There is nothing in the metallurgical make-up
of a soldering tip that will allow the metals to
turn “black” (see Contaminated Soldering
Tips)
– This also holds true for the Stainless Steel on
the Tip Retainer

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 Tip Lifetime

• Soldering Tip Life Cycle

– A new tip has a Copper core
covered by an Iron layer. The Iron
layer protects tips against corrosion
caused by the flux and intermetallic
migration caused by the solder
alloy
– The high Tin content of Lead-free
solder alloys begins to dissolve the
Iron layer much quicker than Lead
Soldering tip after 20,000 cycles with Sn / Pb bearing solders
– Mechanical stress / pressure also
contributes to the abrasion of the
Iron plated surface
– More aggressive solders and fluxes,
along with higher temperatures,
increases the corrosion rate
– After the Iron layer is penetrated, the
tip is rendered useless as the
Copper core will quickly dissolve

Soldering tip after 10,000 cycles with Lead Free SAC

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 Tip Lifetime

Tip Life Test Equipment

Solder Feed Test
equipment assists with
Fume Extraction long term customer Alloy
/ Flux testing
Test equipment delivers
reliable and consistent
Soldering Tip test results
Test equipment used to
determine optimum
Tip blend of Iron plating
Cleaning versus tip geometry.
Solder Feeder
However, the variables
associated with the
operator are non-
existent in this type of tip
life testing

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 Tip Lifetime

• Tip Life Using Lead Free Solder Alloys

– Comparison Sn95.8Ag3.5Cu0.7 (SAC) to Sn60Pb40
– SAC alloy erodes the Iron plating up to 4 to 5 times faster than Lead bearing solder.

Durability
DurabilityHT-2
HT-2 SAC
SAC/ / Sn60
Sn60
9000
9000 8000
8000
8000
8000
7000
7000
6000
6000
Cycles
Cycles

5000
5000
4000
4000
3000
3000 1714
1714
2000
2000
1000
1000
00
11
lead
leadfree
Test with reduced Iron layer thickness @ SAC
725°F
free SAC leaded
leadedSn60
Sn60

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 Tip Lifetime

• Reviewing the Iron Layer of a

Durability
DurabilityHT-2
HT-2 Soldering Tip
– Weller Soldering tips have an Iron
4000
4000 layer thickness of between 0.006”
3500 and 0.0157” (150µm and 400µm)
3500
per side, depending on the
3000
3000 geometry of the tip.
2500 – The Iron electroplating process is
CCy yc cleles s

2500
2000
a highly sophisticated plating
2000 operation.
1500
1500 – There is a linear relationship
1000 between the Iron thickness and
1000
the life of a tip.
500
500
1515 3030 5050 7575 100 120
– The Iron layer has 3 important
100 120 characteristics.
Iron
Ironlayer
layerthickness
thicknessµm
µm • +Plus—Long Life
• +Plus - Excellent wettability
Durability test of a HT 2 soldering tip with
• - Minus - Heat conductivity is
Sn/Ag/Cu (SAC) solder alloy. Tip temperature @
five times lower than Copper.
725°F
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 Tip Lifetime

• Results of Increasing the Iron Layer of a

Soldering Tip
– Weller has increased the Iron layer thickness to an optimal value
for performance and durability without increasing end user tip cost.

Comparison
Comparison::LTD
LTD400µm
400µm/ /LTD
LTD200µm
200µm
15568
15568
16000
16000
14000
14000
12000
12000
10000
10000
Cycles
Cycles 8000 6325
8000 6325
6000
6000
4000
4000
2000
2000
00
11 22
LT-400
LT-400 LT-200
LT-200

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 Tip Lifetime

• Impact of the Geometry of a Tip

to the Iron Layer Thickness
– The Iron layer thickness is dependent on the
geometry of the soldering tip.
– Fine Pointed Tips have more Iron on the
front of the tip versus more equal Iron on
Chisel and Screwdriver shaped tip styles
Solder Follows
the Heat Source, – A thick Iron layer reduces heat transfer. This
preventing solder from applies especially to fine pointed tips (conical
adhering to the point of
the tip and long shank tip styles).
– Fine pointed tips form an area with more Iron
on the end of the tip. Underneath the working
area of the tip there is no Copper to
Sn efficiently transfer heat.

Cu
– For that reason the Iron layer thickness is
limited by the geometry and is approximately
0.006” (150µm) for fine pointed tips.
Chrome layer
blocks flow – This represents the optimal balance between
of solder performance and durability.
Cross section of LT1S

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 Tip Lifetime

• The Ideal Iron Layer of a Fine Pointed Tip.

– An Iron layer of 0.006” (150µm) over the Copper core ensures the best possible heat
transfer / thermal performance.
– However, the thinner Iron reduces the life of the tip in a Lead Free environment.

Wettable Area
Chrome

Copper

Iron
Cross section LT1S 150µm Fe

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 Tip Lifetime

Relationship between Iron Thickness and Performance - Comparison of an LTA with

200µm and 400µm Iron layer
Comparison LTA 200 / LTA 400 Performance test

400

350

300

250
Temperatur °C

200µm Iron 400µm Iron

LTA 400µm
200 137sec. 174sec
LTA 200µm

150

100 More Iron = longer life

= reduced performance.
50

0
0 20 40 60 80 100 120 140 160 180 200
Ze it se c.

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 Tip Lifetime

Tip Life Comparison Showing the Impact of the

Solder Alloy Used

Comparison
ComparisonSnAgCu
SnAgCu- -SnCu
SnCu- -SnAg
SnAgatat725°F
725°F • The wear process is also dependent on the
kind of solder alloy that’s used.
4000
4000 • Comparison between three common alloys.
3368
3368
3500
3500 • Sn 95,8 Ag 3,5 Cu 0,7 (SAC)
3000
3000 2478 • Sn 99,3 Cu 0,7 (SC)
2478
2500
2500 2163 SAC
2163 SAC • Sn 96,5 Ag 3,5 (SA)
ZZy yk klelenn

2000
2000 SC
SC • Compared to a SAC alloy, the Tin -Copper
1500 SA
SA
1500 and Tin-Silver alloys reduce the lifetime by:
1000
1000 • SC - 25%
500
500 • SA - 35%
00
HT2 Soldering tip / 725°F SAC
SAC/ /SC
SC/ /SA
SA

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 Tip Lifetime

Lifetime Comparison Showing the Impact of Tip

Temperature

Cycles
Cyclesatatdifferent
differenttemperatures
temperatureswith
withSnCu
SnCualloy
alloy

Cycles20000
Cycles 20000 • Tip temperature has a significant influence
on the tip lifetime.
15000
15000 • The corrosion and migration rates increase
disproportionately.

10000 • By using a Sn Cu alloy at 770°F versus

10000 19000
19000 680°F the durability decreases by about 60%
13850
13850
5000
5000 7450
7450

00
680°F
680°F 725°F
725°F 770°F
770°F

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 Tip Lifetime

Impact of the Solder Alloy and Tip Temperature

Comparison
ComparisonSnCu
SnCu- -SnAgCu
SnAgCualloy
alloy The influence of the temperature also differs
with the solder alloy. We compared Sn Cu to
35000 31953
31953 SAC solder alloy.
35000
30000
30000 • SC solder at 770 °F---lasted for 7450 cycles
25000 SnCu
SnCuLot
Lotbei
bei360°
360° • SC solder at 680 °F---lasted for 19000 cycles
25000 19000
19000
CCy yc cleles s

20000
20000 SnCu
SnCuLot
Lotbei
bei410°
410° • SAC solder at 770 °F---lasted for 8390 cycles
15000 SnAgCu
15000 SnAgCuLot
Lotbei
bei410°
410° • SAC solder at 680 °F---lasted for 31953 cycles
7450 8390
10000
10000 7450 8390 SnAgCu
SnAgCuLot
Lotbei
bei360°
360°
5000
5000 This equates to a 77% spread between best
00 and worst.
11
360°+410°
360°+410°SnCu
SnCu/ 410°+360°
/ 410°+360°SnAgCu
SnAgCu

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 Tip Lifetime

New Solder Alloys with Micro Additives have been developed to reduce Migration
from the Soldering Tip, Components and Boards

Erosion depending on flux content • Additives reduce the migration of the Iron layer
into the solder.
5000
• The additives are nickel, cobalt or rare earth in
4500 4300
very low percentages which do not change the
4000 physical characteristics of the solder.
3500
• Together with the new flux composition used in
3000 the micro alloys, the impact to tip lifetime is
Cycles

2610
2500 2250 significant ( up to 4 times ).
2000
• Rosin flux compositions (Kristall) create more
1500 1170 corrosion than halogen compositions (KS115).
1000

500
More info on the Weller blog in the article
titled: “Lead Free - What To Do?”
0
1 2 3 4

Solder material
w/o flowTin® with flowTin® w/o flowTin® with flowTin®
Kristall 2,2% Kristall 2,2% KS115 3% KS115 3%

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 Tip Lifetime

New Lead Free Flux with High Solids Content

• In many cases, rosin based flux is used with

a high percentage of solids content.
• A portion of the flux remains on the tip
and contaminates the surface.
• The tip can no longer be used since it is
non-wettable.
• The flux residues are highly aggressive and
create corrosion even when the soldering
Iron is in the stand.
• Proper cleaning is the most important part of tip
maintenance.

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 Tip Lifetime

Effects of operator habits on tip life

Sponge Cleaning of the Soldering Tip
• Thermal shock of a hot tip making contact with a
wet sponge may create minute fractures in the tip
plating, providing openings for the alloy and flux to
attack the Copper core
• Sponges remove more of the protective Tin
coating from the tip than when used with a WDC
Dry Tip Cleaner (sponges are better for Leaded
Solders / not as good for Lead Free alloys)
• Operators normally forget to re-Tin the tip after
wiping on the sponge
• Because of the cooling effect of a wet sponge,
flux residues are not effectively eliminated,
increasing the risk of oxidation and corrosion.
• Tap water can create non-wettable tips because
they contain mineral deposits. Use Distilled or De-
ionized water when using sponges.

Weller University | © 2007 Cooper Industries, Ltd. Proprietary CONFIDENTIAL | 26

 Tip Lifetime

Weller Dry Tip Cleaning

Solutions for extending tip life
• The risk of oxidation and flux
residues require an optimal cleaning
Metal wool procedure.
• Dry cleaning with metal wool (Weller
WDC & WDC2) is a significant
improvement over wet sponge cleaning.
• Flux residues are removed and some
solder remains on the tip surface after
cleaning. This reduces the risk of oxidation
and corrosion.
• To remove excessive solder on the tip, the
WDC also includes a Silicon Rubber Bar,
that can be used to gently tap off excess
Silicon solder.
rubber bar
• Always re-Tin the tip with a sufficient
amount of solder before placing the Iron
back into the tool holder.

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 Tip Lifetime

Accessories that can be used to Help Increase Tip Life

• Stop and Go Tool Holders (WDH10T & WDH20T) - switches on the soldering tool when
removed from the holder.
• WDC2 Dry Tip Cleaner is an optional accessory for all WDH series tool holders.
• WHP3000 Preheating Plate reduces the amount of heat required from the soldering tip by
heating up the PCB to a pre-selected temperature. A highly efficient IR heater with equal
heat distribution will improve the hand soldering process without the risk of partial over-
heat.
• Tip Activator can be used to rejuvenate oxidized or contaminated soldering tips.
• WPB1 Polishing bar cleans and renews soldering tips ( use only when tip is cold). Re-Tin
after use with Tip Activator at a low temperature to prevent oxidation.

WDC WDH10T / WDH20T WHP3000 WP80 Tip Activator and WPB1

Weller University | © 2007 Cooper Industries, Ltd. Proprietary CONFIDENTIAL | 28

 Tip Lifetime

WIIFYC & WIIFY

When visiting your customers, offer to help them solve their tip life
problems when using Lead-free solder. Here’s a quick summary:
• Choose the right solder tips…,the largest possible for the application. Larger tips provide better heat
transfer. Larger dimensioned tips have more Iron plating, which helps to extend tip life.
• Do not exceed 725°F. Lead-free solder does not require a higher soldering temperature. High
temperature increases tip plating erosion. Fluxes degrade faster at high temperatures and black residues
remain on the tip surface. Lowering the soldering temperature reduces oxidation and reduces flux
splattering.
• Chose the right solder alloy (SAC or Micro additive if possible) and flux to reduce wear of soldering tips.
• High powered soldering tools (80 - 150 Watts) with optimum temperature control can in most cases do the
job at lower temperatures. Weller WP 80 and WSP150 combine high power with optimized heat transfer.
• Dry cleaning with the Weller WDC keeps the tip wettable longer. Wet sponges cause thermal shock,
remove the majority of the Tinning and doesn’t properly remove flux residues.
• Always Tin the tip to prevent oxidation and surface contamination. Always apply a thin coating of
solder to the tip after cleaning, and before placing in the soldering tool holder.
• Use all available functions and accessories to reduce the tip temperature (Standby, Auto-
Off,Temperature Pre-sets, Stop and Go tool holders, etc.) or switch the soldering tools off during breaks.

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 Tip Lifetime

Competitor Claims and Positions

• OKI
– Auto-sleep work stands
• Both wet and dry cleaning offered
– Smart Heat Power Tip
• Increased Iron plating
• Green band around the tip to indicate Lead Free

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 Tip Lifetime

Competitor Claims and Positions

• Hakko
– First company to promote dry tip cleaning
– Nitrogen generator (which is not true Nitrogen
88 - 89 % efficient)
– Brass Tip Polisher
– Rotating V Groove Solder Cleaner to reduce
flux splatter

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 Tip Lifetime

Competitor Claims and Positions

• Pace
– Nitrogen generators (more efficient than
Hakko - 98 % efficient)
– Diamond soldering tips (no true advantage)
• JBC
– Increased Iron plating

Weller University | © 2007 Cooper Industries, Ltd. Proprietary CONFIDENTIAL | 32