Electrical wires are part of every electrical circuit. They carry current (in the form of electrons) that power all electrical and electronic devices we use today.

But, why is solder used for joining electrical wires? Solder is used in joining electrical wires to create a permanent bond between them Also, solder is made of a conducting material that allows current to flow between electrical wires. There are many different types of electrical wire, as well as solder that is used to join them. 

Main purpose why solder is used for joining electrical wires

Electricity (electrical current) is the flow of electrons in an electrical circuit. It is what powers every electrical device from Lights, Motors, Microwaves, Televisions etc.

This flow of electrons requires a path to travel in a circuit to get from one component/device to the next. However, electrons can only flow through conducting materials like metals. An insulator like plastic will inhibit the flow of current. 

Electrical wires are composed of conducting materials that allow electrons flow in a circuit. 

There are many different types of electrical wires that range in materials, core diameter, and number of strands. 

Where does solder play its part?

Some of the time you will need to join two pieces of electrical wires to complete the path to allow current to flow. 

Solder is used to create a permanent connection between these two wires while allowing current to still flow.

A deeper look at solder

So, what is solder?

Solder is a material that in most cases is an alloy which has the ability of joining electrical wires. 

A soldering iron is needed to metal the solder that can then adhere to the pieces of electrical wire being joined together.

Different types of solder used for joining electrical wires

There are many different types of solder available, that are made using a number of different conducting materials. 

Traditional solder was lead based (made with lead). However, the use of lead based solder proved very dangerous as it creates fumes that are detrimental to a person’s health.

It can cause health problems that relate to the reproductive system, digestion, memory, and muscle/joint pain.

Due to this, regulations have been put in place to replace lead based solders with Lead-Free solders. 

These lead-free solders contain materials such as Antimony, Bismuth, Brass, Copper, Indium, Tin and Silver. 

They come in a variety of diameters as well. The larger diameters are better for larger joints, while smaller diameters are suitable for smaller hard to get joints. 

Is solder used to join wires in electronic applications as well?

Electronics is a sub-category of Electrical Engineering which also deals with the flow of currents. 

Electrical applications are of higher voltages and currents, electronic applications deal with lower voltage and current applications. 

While the wires used in electronics might vary due to the lower currents, solder is still used as a bonding agent to join wires. 

The only thing that will vary will be the type of solder used.

Best solder for joining electrical wires?

Since there are so many different types of solder available, which is the best for joining electrical wire.

The most commonly used is a lead-free rosin core solder which is typically a Tin/Copper alloy. 

If you opt to use a lead based solder, the 60/40 (60% tin, 40% lead) rosin core solder is your best option. 

However, when using lead based solders, remember to follow safety practices such as having proper ventilation, and wearing a face mask.

Other considerations to make when choosing solder to join wires, is to make sure they are not acid core as they can damage your circuit and components. 

Is there a substitute for solder to join electrical wires?

There might be instances where you have run out of solder, and need to join two electrical wires. 

Is it possible to join two wires without using solder?

Yes. You can join electrical wires if you do not have solder. 

Common ways to do so are:

• Twist the stripped ends of wires together or
• Use electrical tape to create a bond between the stripped ends. 

However, if the electrical wires carry high currents, it is not advisable to make bonds using the methods mentioned above. 

These should only be used for temporary purposes only, like if you are testing the functionality of the circuit. 

They should never be used as a permanent solution. 

Advantages of using solder to join electrical wires

The most common advantages of using solder to join electrical wires is that it creates a long lasting bond, and it allows current to flow as it is a conducting material. 

It is a better option compared to the alternatives that I mentioned above (twisting the wires and electrical tape). Using these temporary methods does not create a good connection between wires and has the potential of falling apart. 

Using solder will avoid these downfalls.

It also has many other advantages which include:

• Low power required
• Low process temperature 
• No thermal distortions and residual stresses in the joint parts
• High variety of materials may be joined
• Low level of skill required 

What is used to melt solder to join electrical wires?

So, solder is the ‘glue’ that is used to connect electrical wires together. But,what is the process of joining wires?

Soldering is the process that is used to join electrical wires. The solder needs to be melted in order to join two pieces of electrical wire. It needs to be heated up to temperatures around  441 degrees fahrenheit ( 227 degrees celsius). 

The way it is heated to these temperatures so it can melt is by using something known as a soldering iron. A soldering iron is a very useful tool used a lot in the Electrical and Electronic Field. 

Is solder only used for joining electrical wires?

You might assume that solder and soldering is only used for joining electrical wires and wiring components in electrical and electronics applications. 

While it’s mainly used in these fields, solder and soldering is very versatile and can be used in other applications as well. 

Other soldering applications include:

• Plumbing
• Jewelry
• Sheet Metal work
• Stained glass work

Since the sole purpose of solder is to be the ‘glue’ between two pieces of metal, applications where metal pieces need to be joined together can use solder.

Can solder be used for welding applications?

I mentioned above that solder can be used for applications where metal pieces need to be joined. 

However, this is only applicable for smaller pieces of metal. 

There are instances where larger pieces of metal need to be connected. Solder will not be suitable for these applications. 

This requires a process known as welding. Welding is similar to soldering in its processes. It uses a filler bonding material (similar to solder) and high heat to melt it to join two pieces of metal together. The main distinction is that welding uses higher temperatures and melts the base metal as well. 

Is solder used for DC and AC applications when joining wires?

We now know that solder helps create strong bonds and help current flow between two wires that are joined together. 

But, there are two types of current used to power devices ; Alternating Current (AC) , and Direct Current (DC).

Alternating current is charge that changes its directions periodically. It is most commonly found in electrical applications. 

Direct current, on the other hand, is a charge that only travels in one direction. It is commonly found in electronic applications. 

Solder can be used in joining wires that carry both AC and DC types currents. 

The only considerations that need to be taken into account is how much current travels through these wires. Higher currents will require larger diameter wires. Therefore, larger diameter solder will be needed to create a stronger bond, and be able to handle these high currents. 

Is the bond of solder permanent when joining electrical wires?

Solder is used to create a ‘permanent’ bond between electrical wires. But, is this bond really permanent?

The bond that is created by solder between electrical wires is permanent but reversible. 

The removal of solder between electrical wires and components is known as Desoldering. 

There might be a faulty wiring in a circuit, or you might have soldered the wrong wires together. You do not have to worry as you can remove the solder and start again.

Tools used to desolder include:

• Solderwick
• Desoldering pump

For a comprehensive guide on how to desolder check this article.

Tips and Tricks on how to solder electrical wires

Using solder to join electrical wires can be cumbersome and annoying at times. But, there are tips and tricks you can use to make the process less stressful. 

These tips and tricks will also help you create stronger bonds that will last longer and let current flow better.

Check the video below on how to solder electrical wires.

The post why is solder used for joining electrical wires? appeared first on Electronic Guidebook.

I get asked many times if I can rewire the wiring in their house, and when I try to tell them that I cannot be because I am an Electronics Engineer, they think that I am just trying to get out of doing work (which is not the case!).

The main reason is that I am not trained or educated at rewiring a house. That is the job of an Electrician. 

There is a lot of confusion between Electronics and Electrical Engineering. Many people assume that they are the same thing, and while they have similarities and crossovers, they are quite different.

Also, it does not help that the degree is named “Bachelors of Electrical and Electronics”. Which is probably why most people get confused.

In this article I will cover the difference, as well as the similarities between Electronics and Electrical Engineering.

But, before we dive straight into the facts, let us take a step back and look at the basics of Electronics vs Electrical engineering.

Basics of Electronics Engineering

The modern world and all its advancements would not be possible without Electronics engineering (also known as just electronics).

The awesome power of electronics can be found in many (if not most) everyday devices from the mobile phone, home appliances, medical equipment, automobiles etc.

So what is it?

Electronics is a form of science (mainly physics) which is concerned with the flow and control of electrons through vacuum and matter.

The flow and control of electrons is achieved by active devices through amplification and rectification.

Electronics utilizes semiconductors as the main avenue for the flow of electronics. 

An electronic system can be broken down into three parts; An input, signal processing, and output.

The first part is where real world data is gathered via sensors. This data is collected in analog form (voltage and electrical signals). Real world data can range from temperature, force, humidity and many more.

Signal processing comes next. This part of the system has the job of  taking this real world data (voltage and electrical signals) and processing it in accordance with the end goal of the system. 

The final part of the system is the output. The output is the physical manifestation and the end result depending on the signal processing. This can be a display, motor, LED etc.

An example of an electronic system could be displaying temperature on an LCD. The input would gather temperature readings, the signal processing circuitry can interpret and manipulate this data accordingly and finally output this information on an LCD.

Brief History

The dawn of electronics began with the vacuum diode. A man by the name of J.A. Fleming was noted for inventing it in 1897. 

Later on after the vacuum diode, the vacuum triode was created by Lee De Forest to amplify electrical signals. 

The next step was the transistor. The junction transistor was invented in 1948. These transistors were created using germanium and silicon semiconductors. 

The creation of the Integrated Circuit was the next big breakthrough in electronics. This saw entire electronic circuits being embedded onto a single chip. This was possible as many electronic components considerably reduced in size (enough to fit onto a single chip).

As the years went by we saw further growth in the field with devices such as JFETs and MOSFETs (which are electronic switches). This then led to the development of the Microprocessor and Microcontroller.

Analog vs Digital

There are two main branches of electronics; Analog and Digital.

Analog electronics is concerned with a continuous range of voltage. Some circuits that include analog electronics are transistor amplifiers, operational amplifiers and oscillators.

Devices that utilize analog circuitry can range from radio receivers, mixers, modulators etc.

With Digital electronics, the differing factor is that voltage levels are discrete (either 0 or 1). A 0 can be viewed as no voltage present, while a 1 can represent the max voltage the system is running. 

They can be seen as a physical representation of Boolean Algebra. 

Computers, calculators, digital clocks are some of the many devices that have digital circuitry.

Application of Electronics

In this day and age, you would find it hard to go a day without using or seeing a device that did not have some sort of electronics. 

There are a plethora of applications that electronics lends its helpful hand to.

Consumer Electronics

Consumer electronics are devices that are used on a everyday basis.

Devices like calculators, printers, computers, telephone for use in the office.

Microwaves, coffee machines, ovens, toasters to help you in your kitchen.

Televisions, mobile phones, gaming consoles, home theater systems, headphones to keep you entertained for an eternity (or until the battery runs out).

Medical Electronics

Medical applications of electronics serve a greater purpose to that of consumer electronics. 

Many operations and procedures would not be possible without electronics. Also, devices to detect and prevent life threatening diseases exist because of electronic devices.

A few life saving devices include the defibrillator, MRI machine, glucose meter, and pacemaker.

Industrial Electronics

Industrial electronics and its application feature things like automation, motion control, robotics.

As we all know the fear of having robots replace the human worker. But, many robots conduct tasks that would not be able to be done by humans. Also, they do them at a much higher efficiency. 

Aerospace and Aeronautics

Man landing on the moon, exploring the depths of the universe, flying from continent to continent would not be achievable without the discovery of the field of electronics. 

Rockets and Airplanes all contain complex electronic systems that help them succeed the amazing feat of flight.

Basics of Electrical Engineering

As we saw earlier, electronics engineering deals with the flow of electrons through semiconductors.

Electrical engineering is related more to the transmission and distribution of electrical energy to houses, factories, buildings, etc. It’s primary concern is the operating and producing electricity.

There are many branches of electrical engineering which include, power generation, transmission systems, motors, batteries and control systems.

Design, construction and manufacturing devices that serve a useful purpose was made possible because of Michael Faraday’s law of induction which stated that voltage through a circuit is directly proportional to the rate of change of a magnetic field through that circuit.

Things like electric generators, motors and transformers make use of this law.

Brief history

Electrical engineering can be seen to date as far back as 1864. We can thank one James Clerk Maxwell from Scotland who managed to summarize the basic laws of electricity in a mathematical formula.

He also showed us that electromagnetic radiation travels through space at the speed of light. 

The earliest known practical application of electricity was the telegraph invented by Samuel F.B. Morse in 1837. 

Next came the telephone created by Alexander Graham Bell in 1876. Due to the telephone, the field of electrical engineering was born.

The biggest breakthrough however, was the incandescent light bulb invented by Thomas Edison in 1878. As the light bulb spread across homes in the United States of America, there was a need for transmission systems as well power generating plants. This in turn increased the need for electrical engineers. 

Another prominent figure in the field of electricity was Nikola Tesla who discovered Alternating Current (AC).

Application of Electrical Engineering

Just like Electronics Engineering, Electrical Engineering has a vast array of applications.

You wake up in the morning to your alarm clock, turn on the light, use the electric kettle to heat the water for your cup of coffee, make some toast, sit down turn on your television to watch your favorite TV show while having breakfast. 

All this was made possible because of power generation, distribution and transmission of electricity thanks to the design, implementation and construction of systems made possible by electrical engineering.

Other than just distribution and transmission of electricity, electrical engineering sees itself in the development of electrical systems for electric motors, machinery controls, lighting/ wiring in buildings and radar/navigation systems.

Electronics vs Electrical Engineer

Now that we have covered the basics of Electronics and Electrical Engineering, let us take a look at what the engineers of each field are involved in. 

Education

When it comes to education and the degree, as I mentioned above most universities/colleges have a Bachelors of Electrical and Electronics. The course runs on average for four years. 

The reason that they are grouped together as one degree is because they are quite similar in theories and fundamentals.

The first year usually covers the general aspects of electronic and electrical theory. Then, depending on what you choose the second, third, and fourth year branches out further into your field of choice.

It is broken down into these 5 subcategories; Power Engineer, Control Engineering, Computer Engineering, Telecommunications Engineering, and Embedded Systems Engineering. 

There are many other subcategories within those subcategories, but these are the most common.

My first year I studied electrical and electronics, the second year I chose electronics, then chose Embedded Digital Systems.and finally decided upon becoming an Embedded Systems Engineer.

As a school student if you are deciding on doing a Electrical and Electronics Engineering degree, you will need to take the appropriate subjects that will grant you the ability to get into it.

Subjects such as mathematics (Calculus) and science (Physics). Consult your school’s career counselor if you are unsure. 

There are many jobs available for Electrical and Electronics Engineers from, Embedded System, Aeronautical, Automation, Software, Aerospace and many more.

What can you do as an Electronics Engineer?

So what does an Electronics Engineer do? If you decide to choose the path of Electronics Engineering your options can look something like this.

Depending on your branch of electronics, you would have the opportunity to design electronic components, software products or systems for commercial, industrial, medical or scientific purposes.

If you chose to be a consultant, you would be in charge of analyzing customers needs and developing and implementing a system to meet their needs.

Or you could be tasked with evaluating systems and recommending design modifications and repair.

Maybe you might inspect electronic equipment and instrumentation to make certain they meet safety standards and regulations.

What can you do as an Electrical Engineer?

If however, you chose the path of an Electrical Engineer, the options available to you could look as follows.

Developing new ways that electric power is utilized by products. 

Designing new electrical systems and solving problems related to the generating and distribution of electrical power. This could be conventional energy or renewable energy sources. 

Planning the wiring and lighting of a new building under construction.

Working on motor control in Automation or Control system applications in the Industrial Factories or better motor efficiency in the Automobile Industry.

The Electrician

Now I get confused a lot for being an electrician and a lot of people assume I can carry out the duties of the Electrician.

However, there is a clear distinction between an Engineer and an Electrician. We just saw above what the Electrical and Electronics Engineer does, so what does an Electrician do?

The main job of the electrician is to install and maintain electrical and power systems in homes, businesses and factories. They are tasked with wiring of control equipment through which electricity flows.

Their primary concern is the construction and maintenance. 

The distinction between the Engineer and the Electrician is that the Engineer’s main duty is the design of new systems, whereas the Electrician is more concerned with installation and maintenance. 

While you need a degree to get a job in the Electronics and Electrical Engineering field, becoming an Electrician requires completing an apprenticeship which involves on the job paid training as well as classroom training. On average apprenticeships run for 4 years. 

Finally, just to clear things up, an Engineer cannot perform the duties (wiring, maintenance) of electrical systems in one’s home. You need to be a certified electrician.

The difference between Electronics vs Electrical engineering

So, we have covered the basics of what Electronics and Electrical Engineering, and also seen what the Engineers of both disciplines do.

One note to make is that Electronics is derivation of Electrical Engineering. This means it would not exist without the discovery of the field of electrical engineering. So there are a lot of similarities in the theories and applications.

Saying that, Electronics vs Electrical Engineering do have a couple differences

Theory

Electrical engineering in theory is the study of electricity as an energy source. It is not fully defined by voltages, currents or magnetic fields. 

Electronics engineering on the other hand is the theory and use of active devices such as vacuum tubes and semiconductors. It is more focused on the study of electrons in a circuit. So in essence electronics is the study of principles relating to electrons.

Scale 

Electrical Engineering is focused more on large scale electrical systems like power transmission to houses, businesses and factories. They deal with AC (alternating current) systems that consist of voltages in the range from 120 – 220 V and frequencies in the range of 50 – 60 Hz.

Electronics engineering is related more to smaller scale systems. These smaller scale systems tend to be DC (Direct current) and include devices such as the microprocessor and microcontroller. 

Another way to look at it is, that electrical engineering deals with “heavier currents” whereas electronics engineering deals with “lighter currents”. 

Application 

Another area that separates the two is their applications. 

As I mentioned earlier the differences in applications, depending on what the problem may be, or what the customers needs are, will call on the help of either electrical or electronics engineering.

If one requires the designing of the wiring and lighting of a new building then electrical engineering is the discipline that will be the best fit.

If the application requires the designing of the next best mobile phone, then electronics engineering is more suitable. 

Which is better?

There is no measuring stick to compare which one is better than the other. It all comes down to what the application demands. In the world we live in now, we wouldn’t be able to do without either of them.

So it just shows how important both are equally, and the need for them in our everyday life.

If you are someone who is deciding on whether to be an Electrical or Electronics Engineer, it all comes down to what you are passionate about. Do not let it be because you think one is better than the other. Let your passion be the defining factor.

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