Strain Gage Soldering Techniques: Strain Gages and Instruments
Strain Gage Soldering Techniques: Strain Gages and Instruments
Strain Gage Soldering Techniques: Strain Gages and Instruments
Solder Selection
The Micro-Measurements Division stocks a broad range of solder types to meet various installation and test require m ents.While solders are sometimes selected to provide specific electrical or mechanical properties, the most common basis for selection is simply the meltingtemperature range. Low-melting-point solders, for example, are generally used for strain gage installations on nonmetallic test parts to avoid damaging the gage, bonding adhesive, or test material due to overheating. In contrast, high-temperature solders are normally selected only when necessary to satisfy elevated-tem p erature testing requirements. These solders are somewhat more difficult to handle because the higher working tem p erature
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rapidly vaporizes the f lux, and oxidizes the soldering tip, both of which tend to impede the soldering process. Specially designed soldering tips are recommended for high-temperature use. For routine applications, where test conditions do not dictate the use of either a low- or high-temperature solder, an alloy with an intermediate melting temperature is the normal selection. The 63/37 tin-lead alloy ( Type 361A20R) is an excellent choice for general-purpose strain gage soldering. As an eutectic alloy, it has a sharply defined melting tem p erature a characteristic that largely eliminates cold solder joints. The addition of a trace of antimony provides superior performance when the soldered connections will be exposed to very low (cryogenic) temperatures for long periods of time. The general-purpose solders are supplied with a core of activated rosin f lux.This makes soldering much more con venient, and is particularly useful in field applications where accessory liquid rosin flux (M-Flux AR) may not be available. Solid-wire solder, with externally applied acid flux (M-Flux SS), is recommended for making soldered connections to Micro-Measurements K- and D-alloy (modified Karma and isoelastic) strain gages. Rosin-core solders should not be used in conjunction with acid flux. Silver solder ( Type 1240-FPA) is available for applica tions where leadwire connections will be exposed to temperatures above about +550F (+290C ). This solder, in paste form, is not suitable for attaching wires directly to strain gage solder tabs or to bondable terminals, but is intended for connecting instrument leads to preattached strain gage leads, as with WK-Series gages using a special resistance soldering unit. Techniques for making leadwire connections with silver solder are described in MicroMeasurements Application Note TT-602, Silver Soldering Technique for Attachment of Leads to Strain Gages. When tinning bare (without soldering options) solder tabs of Micro-Measurements K- and D-alloy strain gages, a liquid acid flux (M-Flux SS) is recommended. After the tinning operation, the residual flux must be completely neutralized within one to two minutes; and then the leadwire joint can be completed using the same solder and M-Flux AR rosin flux or a rosin-cored solder.
Soldering Flux
The function of a soldering flux is to remove oxidation from the members being joined (solder tabs, terminals, leadwires), and to prevent further oxidation during soldering. For making leadwire splices, or soldering directly to constantan foil or copper terminals, the flux contained in a rosin-core solder is usually sufficient. With higher temperature solders, however, it may be necessary to supply additional flux. A liquid activatedrosin flux such as M-Flux AR is recommended for this purpose. Acid fluxes should never be used on constantan strain gages or copper terminals, or for splicing copper leadwires; and paste f luxes, containing chlorides, should not be used under any circumstances for strain gage soldering.
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3. Wipe the excess solder from the tinned tip with a dry gauze sponge. For severely oxidized tips, it may be necessary to repeat this operation several times to obtain a properly tinned surface. The soldering tip should never be filed or sanded, since this may remove the plating on the tip, accelerating the oxidation and leading to the early deterioration of the tip. After the cleaning operation, remove excess solder, re-tin and clean the tip several times, using rosin-core solder, or solid-wire solder withM-Flux AR. M-Flux AR to the tab or terminal (this step can be omitted if a rosin-core solder is used). When soldering directly to bare Karma or isoelastic foil, use M-Flux SS on the gage tabs only. Hold the soldering pencil in a nearly horizontal position (<30), with the flat surface of the tip parallel to the solder tab or terminal. Place the solder wire flat on the gage tab, and press firmly with the tinned hot soldering tip for about one to two seconds, while adding approximately 1/8 in (3 mm) of fresh solder at the edge of the tip. This procedure assures that there is sufficient solder and flux for effective tinning. Simultaneously lift both the soldering pencil and solder wire from the tab area. OTE: Lifting the soldering iron before lifting the solder N may result in the end of the solder wire becoming attached to the tab; lifting them in the reverse order can leave a jagged (spike) solder deposit on the tab. When the operation is performed properly, it will produce a small, smoothly tinned area on the tab or terminal. If M-Flux AR or a rosin-core solder is used in the tinning, it is not necessary to remove the residual soldering flux at this time. However, when M-Flux SS is employed to tin the bare solder tabs of K- or D-alloy gages, the acidic flux residue must be removed immediately following the tinning operation. To remove the residue, apply M-Prep Conditioner A liberally, and wash the area with a soft brush; then blot dry with a clean gauze sponge. Next, wash again with freely applied M-Prep Neu tralizer 5A, and blot dry with a clean gauze sponge. OTE: Special procedures for tinning and wiring strain N gages supplied with preattached solder dots are described in Micro-Measurements Application Note TT-606, Soldering Techniques for Lead Attachment to Strain Gages with Solder Dots.
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Figure 1 Gage grid and upper portion of solder tabs masked with drafting tape.
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wire end before starting to tin, and proceed in the same manner. This will produce a smooth, shiny coating of solder over the bare wire. For applications employing bondable terminal strips and stranded instrumentation wire, it may be convenient to use a single strand of the wire as a jumper between the terminal and the strain gage solder tab. In such cases, the single wire strand should be separated out before twisting and tinning the remaining strands (see Micro-Measurements Application Note TT-603, The Proper Use of Bondable Terminals in Strain Gage Applications). Leadwires should be formed and routed to the strain gage or terminal strip, then firmly anchored to the test-part surface with drafting tape before making the soldered connection. Attempting to route the leadwires after completing the solder joint will often result in damage to the gage or terminals. Routing into the connection area should be along a minimum strain direction (such as the Poisson direction in a uniaxial stress field) particularly for high elongation or dynamic tests. The tinned leadwire end should be trimmed short enough so that it will not protrude through the connection area, and cannot inadvertently make electrical contact with the test-part surface or adjacent solder connections. Figure 2 illustrates this stage in the procedure. In the final preparatory step, bend the leadwire end slightly to form a spring-like loop, and tape the wire firmly in place over the connection area, using PDT-1 drafting tape. The tape should be within about 1/8 in (3 mm) of the connection area, as shown in Figure 3. Clean and re-tin the soldering iron tip with fresh solder. The temperature of the iron should be adjusted so that the solder is easily melted, without rapidly vaporizing the flux. If the iron temperature is either too low or too high, it may cause poor solder connections, or it may damage the strain
gage, terminal, or bonding adhesive. Apply a small amount of M-Flux AR to the joint area and, holding the soldering pencil nearly horizontal, firmly press the flat surface of the tip on the junction for about one second; then lift the tip from the soldered joint. If needed, additional flux can be provided during the joining operation by feeding a little fresh solder into the joint from a spool of rosin-core solder. This procedure should result in a smooth, hemispherical solder joint, without any peaks or jagged areas. If the solder joints are not smooth and uniform in size, repeat the soldering procedure, using additional flux and/or solder as necessary.
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should be smooth, shiny, and uniform in appearance. Any soldered joints that look questionable should be re-soldered, and flux removed. Check the resistance-toground of the completed gage installation, using the Model 1300 Gage Installation Tester. Low or marginal resistance readings suggest a leakage path between the soldered connections and the test-part surface. This condition usually results from residual soldering flux, or from bare leadwire conductors partially shorting the gage tabs or terminals to the test part. Soldered joints should not be tested by pulling on the leadwire, or by probing at the joint area. These practices frequently cause lifting or tearing of the solder tab from the gage backing material. professional soldering equipment which is specially designed for making soldered connections in strain gage circuits. The soldering pencil should be lightweight, with a flat chisel or screwdriver tip, and it should be connected to the soldering station with a very flexible power cord. Requirements for the soldering station include low-voltage operation of the soldering pencil, and provision for temperature adjustment to suit the type of solder and the application conditions. The equipment should not generate electrical interference that could affect sensitive measuring instrumentation. Solder selection is based primarily on the expected operating temperature range of the strain gage installation; and all solder tabs, bondable terminals, and leadwire ends should be tinned before soldering the joints. Soldered joints should always be smooth and shiny, with no jagged or irregular edges, and all traces of residual flux must be thoroughly removed prior to the application of protective coating. Use of the recommended materials and techniques, with careful attention to detail, will result in consistently proper and reliable soldered connections.
Summary
The ability to make consistently good soldered joints is essential for precision strain gage measurements. The techniques described here are straightforward and easily mastered, but they are most effective when used with
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