Soldering Connector & Cable Assembly

Standard Washers

If you are using individual washers in your process, there are several things to keep in mind:

• The ID (inner diameter) of the washer will be the most critical dimension. It needs to fit over the pin. If your washers are flux-coated, be sure to allow for the added flux in your calculation.
• Some IDs are too small for flux coating as the flux coating can easily obscure the ID and make it difficult to smoothly place a washer over a pin.
• When you are flux coating your washers, less is more. In other words, 0.5% to 1.5% flux by weight is sufficient to reduce the surface oxides and prepare the surface for wetting.
• Solder volume can be adjusted by adjusting the thickness. Contact us to help determine the best inner and outer dimensions for your application. Next we'll need to know the board thickness, hole size, and pin size. Then we can recommend the proper thickness for your washer.
• Here are some common washer sizes:
  • 0.020" x 0.031"
  • 0.022" x 0.050"
  • 0.025" x 0.040"
  • 0.027" x 0.043"

  • 0.030" x 0.049"
  • 0.032" x 0.052"
  • 0.033" x 0.060"
  • 0.035" x 0.060"

  • 0.043" x 0.058"
  • 0.045" x 0.060"
  • 0.045" x 0.080"
  • 0.060" x 0.100"
• Contact us if these sizes do not work for your application

Washers are available in a variety of alloys, including indium-based alloys which allow for soldering to ceramics or other non-metallics.

Solder Tubes

Solder Tubes – Precise Solder for Connector and Wire Splice Applications

Indium Corporation’s Solder Tubes provide a precise, controlled amount of solder for heat shrink electrical joint termination within solder sleeves.

While Solder Tubes are similar in shape to standard washers, the tight wall-to-height/thickness ratios of 3 or more is a key distinguishing feature. Solder Tubes can be customized to meet your heat shrink solder sleeve requirements and are ideal for a number of applications including:

• Radio systems
• Wire harness
• EMI shield to ground termination
• Wire to wire splicing, and more

Flux Coating

Flux coating is available to facilitate the soldering process. Typically, flux coatings can be applied in the range of 0.5%–2% by weight and are available in no-clean, RMA, and RA. For more information, contact Tyler Hutchinson via email or +1 315 853 4900 to learn more about flux technologies used with Solder Tubes.

Visual Reflow Indicators

There are two options available for visual verification that the reflow temperature for the solder has been reached:

• Thermochromic indicator dye which disappears when the proper temperature has been reached. This dye is added to the flux coating and does not interfere with reflow.
• External indicator ring which is made of an alloy that melts at a higher temperature than the base tube. Once the outer ring is reflowed, it is an indication that the base tube has also reflowed.

Features:

• Wall-to-height/thickness ratios of 3 or more
• Visual reflow verification
• Flux coatings can be applied in the range of 0.5%-2% by weight
• Available in the most frequently used solder alloys, including:
  • SAC alloys
  • SnAg
  • Sn63
  • Sn62
  • Sn10
• Non-standard alloys are also available, depending on the alloy.

For more information, contact Tyler Hutchinson via email or +1 315 853 4900.