How can you replace the headlight professionally?
Sometimes there are cases when the impact breaks off "ears" from the headlight or the so-called mounts and the first thing that comes to mind is the idea of replacing the headlight.
However, with the help of a regular RoHS Solder iron, mesh and a small set of tools, this situation can be corrected.
What tools do you need to RoHS Solder the headlight mounts?
To work, you will also need napkins, solvent, pliers and two types of nippers. You will also need scissors, and the mesh, who does not have one, can be used from an old sports filter. First you need to decide how and where the part itself goes, how tightly it fits.
The main thing is to fit it so that it is fixed very tightly. It is necessary to fit all the joints that we will solder. In our case, you can see that we have a little plastic left, a little further than we need. Therefore, first we solder the small pieces that are easy to reach, because if you solder a large part right away, it will be difficult to solder behind the face.
What preparatory work we carry out before soldering?
We take a napkin and wipe the edges very well, where we will be RoHS Soldered. Because if salt, dirt or dust has accumulated there, then the soldering may be of poor quality. To do this, you need to degrease and clean everything well.
You can also immediately degrease the part itself. We use a heated soldering iron and solder it carefully, without going to the part where the crack was. Solder the part that is visible, first melt both sides of the plastic and then melt them together.
What is the most important thing to consider while RoHS Solder?
The most important thing when soldering the headlight is that the joints themselves look nice and even, because if you open the hood, they will be visible first. Since during such work it is not particularly necessary to use putty, it is advisable to do everything the first time and well.
We also RoHS Solder the second part, first as deep as possible, but a little more than the thickness of the plastic. We give it a flat surface. You need to let it cool down for a while.
You've probably already noticed that we have new soldering irons. They have become much more convenient; the tip has become even thinner - which means you can solder even more accurately!
An important RoHS Solder iron tip?
The soldering iron has a tip - cone "DSS" (Long Service Life), which has a long service life thanks to a special coating. The tip is removable - you can change it if necessary. Heating time to maximum temperature: 4 minutes.
The cord has a length of 1.5 meters, which will be more than enough to use it at a work table. A power of 30 W will be enough for both RoHS Soldering and desoldering the elements. The maximum temperature for heating the tip is 400 degrees.
MIG soldering - what is it? Why should I use it?
It is known that during MIG or GMA welding (arc, metal consumable electrode in an inert gas atmosphere), galvanized steel loses its properties due to overheating. In particular, corrosion resistance suffers.
Manufacturers are trying to solve this problem by using MIG brazing, and also complement the process with spot seam and random seam methods. The scope of this method is limited by the technology of manufacturers.
With MIG brazing, a minimum amount of zinc is burned due to the lower temperature, providing protection against corrosion.
The image shows the heat propagation zone. Left - for MIG brazing, right - wider exposure area for GMA (MIG) welding.
What should be the heating temperature of the MIG electrode?
The average heating temperature of the MIG electrode is higher than the evaporation temperature of zinc, which is 910 ° C. Therefore, zinc evaporates in and around the weld zone.
However, with a decrease in the welding temperature, the amount of evaporated zinc near the weld will decrease, and the zinc that has already been released in the process will "return".
In addition to protecting the electroplated coating, lowering the temperature during MIG brazing reduces the negative impact on the strength properties of the steel.
What are the features of MIG brazing?
The features of MIG brazing include:
- Reduced metal spatter. The material is not short-circuited, so the arc is practically spatter-free.
- Simplified finishing of the weld.
- Less plane deformation.
- The probability of burn through is lower.
- Good tightness of the seam along the entire length. Cathodic corrosion protection is formed
What is the adhesion against welding?
During GMA / MIG welding at a temperature of about 1'650 ° C, both the metal itself and the filler melt. When brazing, the temperature is much lower and amounts to 1'060 ° C - only the filler wire melts.
The surrounding material is not susceptible to melting; the RoHS solder lies on top and does not penetrate into the base metal.
Recommended rohs solder additives:
For brazing, it is recommended to use copper wire (CuSi3), which is used for welding sheet metal, or bronze solder (CuAl8 and CuSn6). This material should be handled like aluminum wire. The additive must be smooth and free from damage. Smooth semi-circular rollers are used to feed the wire. The guides can be Teflon coated, made of graphite plastic or carbon. Pure argon is recommended as a shielding gas.
Installations:
The most common mistake is setting the voltage too high during MIG / GMA RoHS soldering, resulting in overheating. When brazing, use a low filler wire feed speed similar to steel wire. Use less voltage (shorter arc length). The power source must provide a stable arc in the low power range.
When welding at low temperatures, the seam is not flat. Unlike welding steel, this is permissible. Do not try to change the heat settings to obtain a smoother and flatter weld, as the increase in temperature will nullify the benefits of GMA / MIG brazing.
Rohs solder Testing:
The quality of the MIG braze is checked in the same way as the quality of the GMA / MIG welding. When welded correctly, the gap will go along the seam. Destructive tests are similar to those conducted in the I-CAR courses.
