How to Solder Copper to Copper

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Things You'll Need

  • Emery cloth

  • Pipe fitting brush

  • Silver solder

  • Lead-free flux and brush

  • Propane torch

  • Wet rag

  • Pencil eraser

  • Soldering iron

  • 60/40 rosin-core solder

Tip

Always heat the joint or connection; don't heat the solder directly. The best joints are the ones that melt the solder and pull the solder into the joint with flux. This provides a good mechanical and electrical bond.

Warning

Propane torches can start fires; be careful where you point them. If youare soldering in tight places near flammable materials, use a fabric heat shield available at most home centers in the plumbing department.

Soldering irons can get very hot. and given enough time, can start a fire if left in contact with flammable materials. Always use a soldering iron stand or station to keep the iron in when not in use.

Use a small iron for soldering circuit boards. Large, high wattage irons can damage a board and its components.

Soldered copper pipe connections

Copper pipes and other copper parts can be soldered using various metals with low melting points. Traditionally, lead alloys have been used for soldering copper, but these have fallen from favor in recent years due to lead poisoning concerns. Today, copper water pipes are soldered with lead-free flux and silver alloys. Lead alloys are still used for soldering wires, components on circuit boards and some other copper-joining applications. Regardless of the alloys used, the techniques remain basically the same.

Sweating Copper Pipe

Step 1

Clean the outside end of the copper pipe with a piece of emery cloth until it is shiny bright. Clean the inside of the copper fitting with the fitting brush.

Step 2

Brush generous amounts of flux onto the end of the copper pipe, coating the entire circumference. Repeat for the inside of the copper fitting, covering the entire surface the pipe fits inside of.

Step 3

Insert the pipe into the fitting. Light the torch and heat the fitting evenly. Occasionally touch the silver solder to the juncture of the fitting and the pipe. If it begins to melt, continue applying solder around the entire joint. Continue heating the joint for a few seconds.

Step 4

Turn the torch off and allow the joint to cool for a few seconds until the solder begins to harden. You'll see the solder change from a shiny surface to one that is duller and similar to the unused solder on the roll. Gently wipe the joint with the wet rag to remove the flux.

Soldering Copper Wire

Step 1

Clean solid wire with emery cloth and remove any enamel if it was used to coat the wire. Clean pads on a circuit board with a pencil eraser. Make the connection by twisting wires together or inserting the wire into a hole on a circuit board. Stranded wire can't be cleaned -- in this case, you'll need the soldering iron.

Step 2

Apply a small amount of rosin-core solder to the soldering iron tip. The iron is hot enough when the solder melts when you touch the solder to the tip. In the case of stranded wire, use the soldering iron to heat the strands and melt a little rosin-core solder on them to make a solid wire end in preparation for the connection. This is called tinning.

Step 3

Begin heating the connection with the soldering iron. Occasionally touch the solder to the connection; when it melts, continue applying a little solder until the connection is covered.

Step 4

Remove the iron from the connection and return the iron to the holder or stand. Let the connection cool entirely before touching the wires.

references & resources

Michael Logan

Michael Logan is a writer, editor and web page designer. His professional background includes electrical, computer and test engineering, real estate investment, network engineering and management, programming and remodeling company owner. Logan has been writing professionally since he was first published in "Test & Measurement World" in 1989.