In the manufacturing process of LED freezer lights, welding technology is a critical factor affecting product lifespan. During customer complaint handling, we’ve found that the most prevalent issue is cold solder joints, which result in half of the lamp being lit while the other half remains unlit. This article focuses on key nodes throughout the welding process, providing Q&A analysis to offer practical optimization solutions for lighting manufacturers.
1. What are the two basic requirements for personnel involved in welding operations?
- Wearing a work permit.
- Wearing an antistatic wrist strap.
2. What is the correct moisture state of the sponge used for welding?
When pressed with a finger, moisture seeps out and is absorbed by the sponge upon release; it should not reach the point of dripping when held in the hand.
3. What is the recommended soldering iron temperature range for new employees during welding?
330℃ to 370℃. Although higher temperatures enable faster welding compared to lower ones, they accelerate the oxidation of the soldering iron tip. Oxidation at temperatures above 470℃ is twice as fast as at 380℃.
4. What is the requirement for the dwell time of the soldering iron tip on the pad during high-temperature welding?
No more than 3 seconds to prevent pad detachment.
5. What is the correct method for cleaning the soldering iron tip?
Clean the oxidized residue on the tinned part of the soldering iron tip in the sponge, ensuring that the entire tip is thoroughly wiped clean before applying fresh solder.
6. What are the welding time requirements for new and experienced employees?
Entire process: 5-6 seconds for new employees, and no less than 3 seconds for experienced employees.
7. What are the steps for welding?
Prepare the solder wire and soldering iron. Heat the pad with the soldering iron first, then feed in the solder wire. Withdraw the solder wire and soldering iron. Heat the solder joint with the soldering iron first, then feed in the wire core. Withdraw the soldering iron and place it back on the soldering iron stand.
8. What are the core basic requirements for a qualified solder joint?
- The solder joint is full and rounded.
- It completely wraps around the copper wire of the conductor.
- There are no burrs or cracks.
- The amount of solder covers the pad without overflowing.
- The distance between the solder joint and the LED is greater than 0.5mm.
- There is no exposed wire core between the insulation and the solder joint.
9. What are the common causes of cold solder joints?
Low soldering iron temperature, short heating time, and wire movement during welding.
10. What are the hazards of cold solder joints?
Cold solder joints lack effective metallic connections. Initially, they may temporarily conduct electricity, but later, factors such as vibration and temperature changes can lead to poor contact and disconnection. When applied in electronic components and circuit connections, this can result in equipment failure, functional ineffectiveness, and even more serious problems, such as short circuits and board burning.
11. What are the welding precautions?
- Cut off the power supply to the soldering iron when it is not in use for an extended period to prevent dry burning and potential fires.
- Replace damaged or aged soldering iron cords promptly to prevent electric shock and short circuits.
- Do not touch the soldering iron tip or other heated parts during use to avoid burns.
- When replacing the soldering iron tip during use, first turn off the power and wait 10-15 minutes to confirm that it has cooled to room temperature before replacement.
- Do not swing the soldering iron around during use to prevent solder splashes from burning people or materials; instead, collect them uniformly in a waste bin.
- When using the soldering iron, place the soldering iron stand on a stable table to ensure its stability and prevent tipping, which could cause burns or fires.
- Do not continuously feed solder to the soldering iron tip to prevent solder splashing.
For other questions about LED lights, please visit our website.https://www.laidishine.com/category/faq/
