So we found a place to weld an aluminum wire to an aluminum enclosure (19mm diameter tube). Now we are trying to figure out an economical way to connect that wire to a PCB.
The suggestion we have is to nickel plate the end of an aluminum wire so it can be soldered to copper.
Any other ideas for this?
So we found a place to weld an aluminum wire to an aluminum enclosure (19mm diameter tube). Now we are trying to figure out an economical way to connect that wire to a PCB.
The suggestion we have is to nickel plate the end of an aluminum wire so it can be soldered to copper.
Any other ideas for this?
Crimp a bootlace or ring ferrule onto the ali wire. Solder or screw that to the pcb.
JB
Crimp a ring connector onto the end of the wire (perhaps with a dab of Penetrox or NoAlOx) and then use a machine screw to attach the ring connector to a ground pad on the PCB (go through the PCB and into a threaded standoff post)?
On Fri, 14 Nov 2014 13:34:26 -0800, sms Gave us:
Nut. Bolt. Internal or external stainless star washer. Locktite. Anti-oxidant paste. Done.
The washer goes at the interface, and makes a bunch of little 'gas-tight' 'connections' which can carry high current.
It solves single point of failure and current capacity and long term integrity all in one. Use two stars if you want the bolt/PCB interface on the bottom side to 'bite' better. Anti-oxidant on those electrical mates.
On Fri, 14 Nov 2014 21:40:32 -0000, "JB" Gave us:
"Screw that"
Hehehe... Good answer, JB.
You should have heard Sigourney say it.
BRL!!
On Fri, 14 Nov 2014 14:34:47 -0800 (PST), snipped-for-privacy@gmail.com Gave us:
Do you even know how a PCB is constructed, you stupid f*ck?
On Fri, 14 Nov 2014 16:18:08 -0800, DecadentLinuxUserNumeroUno Gave us:
On Friday, November 14, 2014 7:34:06 PM UTC-5, DecadentLinuxUserNumeroUno w rote:
Get lost, idiot. Brazing is not soldering, you don't even know what the bra zing process is. And the liquidus of the alloy is just over 1000oF, not 220
0o. Then you're confused about temperature and heat. There are even process es for welding PCBs which is even more transformative than brazing.
Poke it into a Mill-Max type of spring socket.
That suggestion says it all, you're a pathetic idiot. And you're "done" alright.
These are cheap and CU9AL
-as an example.
Can you get them to weld copper or steel wire instead?
The maker of my last car's starter spot welded the copper braid from the brushes to the aluminium field windings. the spot weld outlasted the brushes.
Lugs are not practical. This is PCB that is about 15mm wide and maybe
25mm long. And brazing with a filler metal onto a small copper pad is not practical.The problem is that aluminum really can only have aluminum welded to it.
I am thinking of trying copper clad aluminum wire and scraping or sanding off the cladding off the end that will be welded to the aluminum enclosure. See . If it works it will be easier that finding a place to nickel plate 2mm of a 2 cm, 22AWG, aluminum wire.
We started this project with steel enclosures but those didn't work for reasons I can't go into at this time. The aluminum works fine except for the grounding issue.
You could solder a copper wire (or spad lug) onto the aluminum.
George H.
o
Why don't you use copper wire from the PCB to the aluminum chassis? Certain ly you can find space on the chassis for a conversion lug. Then the board c onnection is a standard solder joint, and the chassis connection of the ste el lug is a standard steel/aluminum weld or even a threaded mechanical atta chment.
On Sat, 15 Nov 2014 04:21:05 -0800, sms Gave us:
Why not simply switch the wire over to SPC and be done?
On Sat, 15 Nov 2014 04:21:05 -0800, sms Gave us:
SPC wire. Solder to board. Crimp AL lug onto the chassis attach end with AO paste and seal with HV heat shrink. Weld THAT to the chassis. Done.
Hi, George -
You may recall that I got some of the solder to which you referred. Now I would like some hints on how to get familiar with it. Can I solder to kitchen aluminum foil? If not, what do I look for around the shop to practice with? I do have some angle Al, about .06 thick.
Thanks for your help. John
Disregard, George. No hints needed. I am able to solder to aluminum kitchen foil easily. I might have used too much heat the first time, but it worked as easily as soldering to copper.
Thanks again for the recommendation.
Cheers, John
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