As a trusted lead free solder wire manufacturer in India, we follow a refined and efficient manufacturing process that ensures delivery of the highest quality lead free solder wire. With a strong focus on innovation, precision, and sustainability at every step, we consistently achieve excellence.
Raw Material Selection for Lead Free Wire: At Kothari Metsol, the process starts with selecting high-quality raw materials. We use eco-friendly, lead free solder material like tin, copper, and silver alloys. This ensures the final product is free from toxic lead content, making it safer for both users and the environment.
Alloy Formation and Melting:The chosen materials are carefully melted and blended to create a homogeneous alloy. For lead free solder, a common composition is tin combined with other metals like copper (Sn-Cu) or silver (Sn-Ag), which enhances performance and ensures compliance with environmental standards.
Wire Drawing Process: After forming the alloy, the next step is the wire drawing process. The molten solder alloy is drawn through a series of progressively smaller dies, reducing the diameter of the wire to the desired thickness. Lead free wire is drawn into various sizes, from 10 SWG to 22 SWG, to cater to different soldering applications.
Flux Core Insertion (for Flux-Cored Solder Wire): During this process, flux material is inserted into the hollow core of the solder wire. The flux helps improve solder flow, ensuring smooth, clean joints without the harmful effects of lead. This lead free wire is ideal for applications where precision and clean connections are essential, such as in the electronics and medical device industries.
Annealing for Flexibility:The lead free wire undergoes an annealing process where it is heated to a specific temperature in a controlled environment. This step softens the wire, making it more flexible and easier to handle during soldering.
Coating for Corrosion Resistance:Some lead free solder may be coated for added protection against corrosion. This ensures that the solder wire maintains its performance over time, especially in harsh environments like automotive or plumbing applications. The coating helps prevent oxidation, ensuring a longer shelf life and more reliable solder joints.
Spooling and Packaging:After the wire is drawn, annealed, and coated (if applicable), it is carefully wound onto spools of 500 gm, 3 kg. These spools are then packaged to protect the wire from moisture, which can cause oxidation. We ensure that each spool of lead free solder wire is packaged in a way that maintains its quality during storage and shipping.
Rigorous Quality Control and Testing:As a trusted lead free solder wire manufacturer in India, we apply stringent quality control measures throughout the manufacturing process. Every batch of wire undergoes extensive testing to check factors such as melting point, flow characteristics, and consistency. These tests ensure that our lead free solder wire provides reliable, consistent performance across a range of industries, including electronics, automotive, and electrical applications.
Final Inspection and Delivery:Before shipping, all spools of lead free wire are inspected one final time to ensure they meet our high standards. We carefully check for uniformity in diameter, flux distribution, and overall quality. Once approved, the wire is ready for delivery, ensuring that customers receive a top-quality, eco-friendly soldering solution.
