In
metallurgy
Metallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their inter-metallic compounds, and their mixtures, which are known as alloys.
Metallurgy encompasses both the sc ...
, a flux () is a chemical
cleaning agent
Cleaning agents or hard-surface cleaners are substances (usually liquids, powders, sprays, or granules) used to remove dirt, including dust, stains, bad smells, and clutter on surfaces. Purposes of cleaning agents include health, beauty, removin ...
, flowing agent, or purifying agent. Fluxes may have more than one function at a time. They are used in both
extractive metallurgy
Extractive metallurgy is a branch of metallurgical engineering wherein process and methods of extraction of metals from their natural mineral deposits are studied. The field is a materials science, covering all aspects of the types of ore, wash ...
and
metal joining.
Some of the earliest known fluxes were
sodium carbonate
Sodium carbonate, , (also known as washing soda, soda ash and soda crystals) is the inorganic compound with the formula Na2CO3 and its various hydrates. All forms are white, odourless, water-soluble salts that yield moderately alkaline solutions ...
,
potash
Potash () includes various mined and manufactured salts that contain potassium in water-soluble form. ,
charcoal
Charcoal is a lightweight black carbon residue produced by strongly heating wood (or other animal and plant materials) in minimal oxygen to remove all water and volatile constituents. In the traditional version of this pyrolysis process, cal ...
,
coke,
borax
Borax is a salt (ionic compound), a hydrated borate of sodium, with chemical formula often written . It is a colorless crystalline solid, that dissolves in water to make a basic solution. It is commonly available in powder or granular form, ...
,
lime
Lime commonly refers to:
* Lime (fruit), a green citrus fruit
* Lime (material), inorganic materials containing calcium, usually calcium oxide or calcium hydroxide
* Lime (color), a color between yellow and green
Lime may also refer to:
Botany ...
,
lead sulfide Lead sulfide refers to two compounds containing lead and sulfur:
* Lead(II) sulfide, PbS, containing lead in the +2 oxidation state, naturally occurring as the mineral galena
*Lead(IV) sulfide
Lead(IV) sulfide is a chemical compound with the formu ...
and certain minerals containing
phosphorus
Phosphorus is a chemical element with the symbol P and atomic number 15. Elemental phosphorus exists in two major forms, white phosphorus and red phosphorus, but because it is highly reactive, phosphorus is never found as a free element on Ear ...
. Iron ore was also used as a flux in the
smelting
Smelting is a process of applying heat to ore, to extract a base metal. It is a form of extractive metallurgy. It is used to extract many metals from their ores, including silver, iron, copper, and other base metals. Smelting uses heat and a ch ...
of copper. These agents served various functions, the simplest being a
reducing agent, which prevented
oxides
An oxide () is a chemical compound that contains at least one oxygen atom and one other element in its chemical formula. "Oxide" itself is the dianion of oxygen, an O2– (molecular) ion. with oxygen in the oxidation state of −2. Most of the E ...
from forming on the surface of the molten metal, while others absorbed
impurities into the
slag
Slag is a by-product of smelting (pyrometallurgical) ores and used metals. Broadly, it can be classified as ferrous (by-products of processing iron and steel), ferroalloy (by-product of ferroalloy production) or non-ferrous/base metals (by-prod ...
, which could be scraped off the molten metal.
Fluxes are also used in
foundries
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals pr ...
for removing impurities from molten
nonferrous metal
In metallurgy, non-ferrous metals are metals or alloys that do not contain iron (allotropes of iron, ferrite, and so on) in appreciable amounts.
Generally more costly than ferrous metals, non-ferrous metals are used because of desirable proper ...
s such as
aluminium
Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. I ...
, or for adding desirable
trace element
__NOTOC__
A trace element, also called minor element, is a chemical element whose concentration (or other measure of amount) is very low (a "trace amount"). They are classified into two groups: essential and non-essential. Essential trace elements ...
s such as
titanium
Titanium is a chemical element with the symbol Ti and atomic number 22. Found in nature only as an oxide, it can be reduced to produce a lustrous transition metal with a silver color, low density, and high strength, resistant to corrosion in ...
.
As cleaning agents, fluxes facilitate
soldering
Soldering (; ) is a process in which two or more items are joined by melting and putting a filler metal (solder) into the joint, the filler metal having a lower melting point than the adjoining metal. Unlike welding, soldering does not involv ...
,
brazing
Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, with the filler metal having a lower melting point than the adjoining metal.
Brazing differs from we ...
, and
welding
Welding is a fabrication (metal), fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing Fusion welding, fusion. Welding is distinct from lower ...
by removing
oxidation
Redox (reduction–oxidation, , ) is a type of chemical reaction in which the oxidation states of substrate change. Oxidation is the loss of electrons or an increase in the oxidation state, while reduction is the gain of electrons or a d ...
from the metals to be joined. In some applications molten flux also serves as a heat-transfer medium, facilitating heating of the joint by the soldering tool or molten solder.
Uses
Metal joining
In high-temperature metal joining processes (
welding
Welding is a fabrication (metal), fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing Fusion welding, fusion. Welding is distinct from lower ...
,
brazing
Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, with the filler metal having a lower melting point than the adjoining metal.
Brazing differs from we ...
and
soldering
Soldering (; ) is a process in which two or more items are joined by melting and putting a filler metal (solder) into the joint, the filler metal having a lower melting point than the adjoining metal. Unlike welding, soldering does not involv ...
), flux is a substance that is nearly inert at room temperature, but which becomes strongly
reducing at elevated temperatures, preventing oxidation of the base and filler materials. The role of flux is typically dual: dissolving the oxides already present on the metal surface, which facilitates
wetting
Wetting is the ability of a liquid to maintain contact with a solid surface, resulting from intermolecular interactions when the two are brought together. This happens in presence of a gaseous phase or another liquid phase not miscible with th ...
by molten metal, and acting as an oxygen barrier by coating the hot surface, preventing its oxidation.
For example, tin-lead solder attaches very well to copper, but poorly to the various oxides of copper, which form quickly at soldering temperatures. By preventing the formation of metal oxides, flux enables the solder to adhere to the clean metal surface, rather than forming beads, as it would on an oxidized surface.
Soldering
In soldering of metals, flux serves a threefold purpose: it removes any oxidized metal from the surfaces to be soldered, seals out air thus preventing further oxidation, and by facilitating amalgamation, improves
wetting
Wetting is the ability of a liquid to maintain contact with a solid surface, resulting from intermolecular interactions when the two are brought together. This happens in presence of a gaseous phase or another liquid phase not miscible with th ...
characteristics of the liquid solder. Some fluxes are
corrosive
A corrosive substance is one that will damage or destroy other substances with which it comes into contact by means of a chemical reaction.
Etymology
The word ''corrosive'' is derived from the Latin verb ''corrodere'', which means ''to gnaw'', ...
, so the parts have to be cleaned with a damp sponge or other absorbent material after soldering to prevent damage. Several types of flux are used in electronics.
A number of standards exist to define the various flux types. The principal standard is J-STD-004.
Various tests, including the
ROSE test, may be used after soldering to check for the presence of ionic or other contaminants that could cause short circuits or other problems.
Brazing and silver soldering
Brazing
Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, with the filler metal having a lower melting point than the adjoining metal.
Brazing differs from we ...
(sometimes known as
silver soldering or
hard soldering) requires a much higher temperature than soft soldering, sometimes over 850 °C. As well as removing existing oxides, rapid oxidation of the metal at the elevated temperatures has to be avoided. This means that fluxes need to be more aggressive and to provide a physical barrier.
Traditionally
borax
Borax is a salt (ionic compound), a hydrated borate of sodium, with chemical formula often written . It is a colorless crystalline solid, that dissolves in water to make a basic solution. It is commonly available in powder or granular form, ...
was used as a flux for brazing, but there are now many different fluxes available, often using active chemicals such as
fluoride
Fluoride (). According to this source, is a possible pronunciation in British English. is an inorganic, monatomic anion of fluorine, with the chemical formula (also written ), whose salts are typically white or colorless. Fluoride salts typ ...
s
as well as wetting agents. Many of these chemicals are toxic and due care should be taken during their use.
Smelting
In the process of
smelting
Smelting is a process of applying heat to ore, to extract a base metal. It is a form of extractive metallurgy. It is used to extract many metals from their ores, including silver, iron, copper, and other base metals. Smelting uses heat and a ch ...
, inorganic chlorides, fluorides (see
fluorite
Fluorite (also called fluorspar) is the mineral form of calcium fluoride, CaF2. It belongs to the halide minerals. It crystallizes in isometric cubic habit, although octahedral and more complex isometric forms are not uncommon.
The Mohs sca ...
),
limestone
Limestone ( calcium carbonate ) is a type of carbonate sedimentary rock which is the main source of the material lime. It is composed mostly of the minerals calcite and aragonite, which are different crystal forms of . Limestone forms whe ...
and other materials are designated as "fluxes" when added to the contents of a
smelting furnace or a
cupola
In architecture, a cupola () is a relatively small, most often dome-like, tall structure on top of a building. Often used to provide a lookout or to admit light and air, it usually crowns a larger roof or dome.
The word derives, via Italian, from ...
for the purpose of purging the metal of chemical impurities such as phosphorus, and of rendering
slag
Slag is a by-product of smelting (pyrometallurgical) ores and used metals. Broadly, it can be classified as ferrous (by-products of processing iron and steel), ferroalloy (by-product of ferroalloy production) or non-ferrous/base metals (by-prod ...
more liquid at the smelting temperature. The slag is a liquid mixture of
ash
Ash or ashes are the solid remnants of fires. Specifically, ''ash'' refers to all non-aqueous, non- gaseous residues that remain after something burns. In analytical chemistry, to analyse the mineral and metal content of chemical samples, ash ...
, flux, and other impurities. This reduction of slag viscosity with temperature, increasing the flow of slag in smelting, is the origin of the word ''flux'' in metallurgy.
The flux most commonly used in iron and
steel
Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant ty ...
furnaces is
limestone
Limestone ( calcium carbonate ) is a type of carbonate sedimentary rock which is the main source of the material lime. It is composed mostly of the minerals calcite and aragonite, which are different crystal forms of . Limestone forms whe ...
, which is charged in the proper proportions with the iron and
fuel
A fuel is any material that can be made to react with other substances so that it releases energy as thermal energy or to be used for work. The concept was originally applied solely to those materials capable of releasing chemical energy but ...
.
Drawbacks
Fluxes have several serious drawbacks:
* Corrosivity, which is mostly due to the aggressive compounds of the activators;
hygroscopic
Hygroscopy is the phenomenon of attracting and holding water molecules via either absorption or adsorption from the surrounding environment, which is usually at normal or room temperature. If water molecules become suspended among the substance ...
properties of the flux residues may aggravate the effects
* Interference with test equipment, which is due to the insulating residues deposited on the test contacts on electronic circuit boards
* Interference with
machine vision
Machine vision (MV) is the technology and methods used to provide imaging-based automatic inspection and analysis for such applications as automatic inspection, process control, and robot guidance, usually in industry. Machine vision refers to ...
systems when the layer of flux or its remains is too thick or improperly located
* Contamination of sensitive parts, e.g. facets of laser diodes, contacts of connectors and mechanical switches, and
MEMS
Microelectromechanical systems (MEMS), also written as micro-electro-mechanical systems (or microelectronic and microelectromechanical systems) and the related micromechatronics and microsystems constitute the technology of microscopic devices, ...
assemblies
* Deterioration of electrical properties of printed circuit boards, as soldering temperatures are above the
glass transition temperature
The glass–liquid transition, or glass transition, is the gradual and reversible transition in amorphous materials (or in amorphous regions within semicrystalline materials) from a hard and relatively brittle "glassy" state into a viscous or rubb ...
of the board material and flux components (e.g. glycols, or chloride and bromide ions) can diffuse into its matrix; e.g. water-soluble fluxes containing
polyethylene glycol
Polyethylene glycol (PEG; ) is a polyether compound derived from petroleum with many applications, from industrial manufacturing to medicine. PEG is also known as polyethylene oxide (PEO) or polyoxyethylene (POE), depending on its molecular we ...
were demonstrated to have such impact
* Deterioration of high-frequency circuit performance by flux residues
* Deterioration of
surface insulation resistance, which tends to be as much as three orders of magnitude lower than the bulk resistance of the material
*
Electromigration and growth of
whiskers
Vibrissae (; singular: vibrissa; ), more generally called Whiskers, are a type of stiff, functional hair used by mammals to sense their environment. These hairs are finely specialised for this purpose, whereas other types of hair are coarse ...
between nearby traces, aided by ionic residues, surface moisture and a bias voltage
* The fumes liberated during soldering have adverse health effects, and
volatile organic compounds
Volatile organic compounds (VOCs) are organic compounds that have a high vapour pressure at room temperature
Colloquially, "room temperature" is a range of air temperatures that most people prefer for indoor settings. It feels comfortable to a ...
can be outgassed during processing
* The solvents required for post-soldering cleaning of the boards are expensive and may have adverse environmental impact
In special cases the drawbacks are sufficiently serious to warrant using fluxless techniques.
Dangers
Acid flux types (not used in electronics) may contain
hydrochloric acid
Hydrochloric acid, also known as muriatic acid, is an aqueous solution of hydrogen chloride. It is a colorless solution with a distinctive pungent smell. It is classified as a strong acid
Acid strength is the tendency of an acid, symbol ...
,
zinc chloride
Zinc chloride is the name of inorganic chemical compounds with the formula ZnCl2 and its hydrates. Zinc chlorides, of which nine crystalline forms are known, are colorless or white, and are highly soluble in water. This salt is hygroscopic and ev ...
or
ammonium chloride, which are harmful to humans. Therefore, flux should be handled with gloves and goggles, and used with adequate ventilation.
Prolonged exposure to rosin fumes released during soldering can cause
occupational asthma
Occupational asthma is new onset asthma or the recurrence of previously quiescent asthma directly caused by exposure to an agent at workplace. It is an occupational lung disease and a type of work-related asthma. Agents that can induce occupational ...
(formerly called ''colophony disease'' in this context) in sensitive individuals, although it is not known which component of the fumes causes the problem.
While molten solder has low tendency to adhere to organic materials, molten fluxes, especially of the resin/rosin type, adhere well to fingers. A mass of hot sticky flux can transfer more heat to skin and cause more serious
burn
A burn is an injury to skin, or other tissues, caused by heat, cold, electricity, chemicals, friction, or ultraviolet radiation (like sunburn). Most burns are due to heat from hot liquids (called scalding), solids, or fire. Burns occur mainl ...
s than a comparable particle of non-adhering molten metal, which can be quickly shaken off. In this regard, molten flux is similar to molten
hot glue.
Fluxless techniques
In some cases the presence of flux is undesirable; flux traces interfere with e.g. precision optics or
MEMS
Microelectromechanical systems (MEMS), also written as micro-electro-mechanical systems (or microelectronic and microelectromechanical systems) and the related micromechatronics and microsystems constitute the technology of microscopic devices, ...
assemblies. Flux residues also tend to
outgas
Outgassing (sometimes called offgassing, particularly when in reference to indoor air quality) is the release of a gas that was dissolved, trapped, frozen, or absorbed in some material. Outgassing can include sublimation and evaporation (which ...
in vacuum and space applications, and traces of water, ions and organic compounds may adversely affect long-term reliability of non-hermetic packages. Trapped flux residues are also the cause of most voids in the joints. Flux-less techniques are therefore desirable there.
For successful soldering and brazing, the oxide layer has to be removed from both the surfaces of the materials and the surface of the filler metal preform; the exposed surfaces also have to be protected against oxidation during heating. Flux-coated preforms can also be used to eliminate flux residue entirely from the soldering process.
Protection of the surfaces against further oxidation is relatively simple, by using vacuum or inert atmosphere. Removal of the native oxide layer is more troublesome; physical or chemical cleaning methods have to be employed and the surfaces can be protected by e.g. gold plating. The gold layer has to be sufficiently thick and non-porous to provide protection for reasonable storage time. Thick gold metallization also limits choice of soldering alloys, as tin-based solders dissolve gold and form brittle
intermetallic
An intermetallic (also called an intermetallic compound, intermetallic alloy, ordered intermetallic alloy, and a long-range-ordered alloy) is a type of metallic alloy that forms an ordered solid-state compound between two or more metallic eleme ...
s, embrittling the joint. Thicker gold coatings are usually limited to use with indium-based solders and solders with high gold content.
Removal of the oxides from the solder preform is also troublesome. Fortunately some alloys are able to dissolve the surface oxides in their bulk when superheated by several degrees above their melting point; the Sn-Cu
1 and Sn-Ag
4 require superheating by 18–19 °C, the Sn-Sb
5 requires as little as 10 °C, but the Sn-Pb
37 alloy requires 77 °C above its melting point to dissolve its surface oxide. The self-dissolved oxide degrades the solder's properties and increases its viscosity in molten state, however, so this approach is not optimal.
Solder preforms are preferred to be with high volume-to-surface ratio, as that limits the amount of oxide being formed. Pastes have to contain smooth spherical particles, preforms are ideally made of round wire. Problems with preforms can be also sidestepped by depositing the solder alloy directly on the surfaces of the parts or substrates, by chemical or electrochemical means for example.
A protective atmosphere with chemically reducing properties can be beneficial in some cases. Molecular
hydrogen
Hydrogen is the chemical element with the symbol H and atomic number 1. Hydrogen is the lightest element. At standard conditions hydrogen is a gas of diatomic molecules having the formula . It is colorless, odorless, tasteless, non-toxic, an ...
can be used to reduce surface oxides of tin and indium at temperatures above 430 and 470 °C; for zinc the temperature is above 500 °C, where zinc is already becoming volatilized. (At lower temperatures the reaction speed is too slow for practical applications.) Very low partial pressures of oxygen and water vapor have to be achieved for the reaction to proceed.
Other reactive atmospheres are also in use. Vapors of
formic acid
Formic acid (), systematically named methanoic acid, is the simplest carboxylic acid, and has the chemical formula HCOOH and structure . It is an important intermediate in chemical synthesis and occurs naturally, most notably in some ants. Es ...
and
acetic acid
Acetic acid , systematically named ethanoic acid , is an acidic, colourless liquid and organic compound with the chemical formula (also written as , , or ). Vinegar is at least 4% acetic acid by volume, making acetic acid the main component ...
are the most commonly used.
Carbon monoxide
Carbon monoxide (chemical formula CO) is a colorless, poisonous, odorless, tasteless, flammable gas that is slightly less dense than air. Carbon monoxide consists of one carbon atom and one oxygen atom connected by a triple bond. It is the simple ...
and halogen gases (for example
carbon tetrafluoride
Tetrafluoromethane, also known as carbon tetrafluoride or R-14, is the simplest perfluorocarbon ( C F4). As its IUPAC name indicates, tetrafluoromethane is the perfluorinated counterpart to the hydrocarbon methane. It can also be classified as a ...
,
sulfur hexafluoride
Sulfur hexafluoride or sulphur hexafluoride (British spelling) is an inorganic compound with the formula SF6. It is a colorless, odorless, non- flammable, and non-toxic gas. has an octahedral geometry, consisting of six fluorine atoms attached ...
, or
dichlorodifluoromethane) require fairly high temperatures for several minutes to be effective.
Atomic hydrogen is much more reactive than molecular hydrogen. In contact with surface oxides it forms hydroxides, water, or hydrogenated complexes, which are volatile at soldering temperatures. A practical dissociation method is an electrical discharge. Argon-hydrogen gas compositions with hydrogen concentration below the low flammable limit can be used, eliminating the safety issues. The operation has to be performed at low pressure, as the stability of atomic hydrogen at atmospheric pressure is insufficient. Such hydrogen plasma can be used for fluxless reflow soldering.
Active atmospheres are relatively common in furnace brazing; due to the high process temperatures the reactions are reasonably fast. The active ingredients are usually carbon monoxide (possibly in the form of combusted fuel gas) and hydrogen. Thermal dissociation of ammonia yields an inexpensive mixture of hydrogen and nitrogen.
Bombardment with atomic particle beams can remove surface layers at a rate of tens of nanometers per minute. The addition of hydrogen to the plasma augments the removal efficiency by chemical mechanisms.
Mechanical agitation is another possibility for disrupting the oxide layer. Ultrasound can be used for assisting tinning and soldering; an ultrasonic transducer can be mounted on the soldering iron, in a solder bath, or in the wave for
wave soldering
Wave soldering is a bulk soldering process used for the manufacturing of printed circuit boards. The circuit board is passed over a pan of molten solder in which a pump produces an upwelling of solder that looks like a standing wave. As the ci ...
. The oxide disruption and removal involves
cavitation
Cavitation is a phenomenon in which the static pressure of a liquid reduces to below the liquid's vapour pressure, leading to the formation of small vapor-filled cavities in the liquid. When subjected to higher pressure, these cavities, cal ...
effects between the molten solder and the base metal surface. A common application of ultrasound fluxing is in tinning of passive parts (active parts do not cope well with the mechanical stresses involved); even aluminium can be tinned this way. The parts can then be soldered or brazed conventionally.
Mechanical rubbing of a heated surface with molten solder can be used for coating the surface. Both surfaces to be joined can be prepared this way, then placed together and reheated. This technique was formerly used to repair small damages on aluminium aircraft skins.
A very thin layer of zinc can be used for joining aluminium parts. The parts have to be perfectly machined, or pressed together, due to the small volume of filler metal. At high temperature applied for long time, the zinc diffuses away from the joint. The resulting joint does not present a mechanical weakness and is corrosion-resistant. The technique is known as diffusion soldering.
Fluxless brazing of copper alloys can be done with self-fluxing filler metals. Such metals contain an element capable of reaction with oxygen, usually
phosphorus
Phosphorus is a chemical element with the symbol P and atomic number 15. Elemental phosphorus exists in two major forms, white phosphorus and red phosphorus, but because it is highly reactive, phosphorus is never found as a free element on Ear ...
. A good example is the family of copper-phosphorus alloys.
Properties
Fluxes have several important properties:
* Activity – the ability to dissolve existing oxides on the metal surface and promote wetting with solder. Highly active fluxes are often acidic or corrosive in nature.
* Corrosivity – the promotion of corrosion by the flux and its residues. Most active fluxes tend to be corrosive at room temperatures and require careful removal. As activity and corrosivity are linked, the preparation of surfaces to be joined should allow use of milder fluxes. Some water-soluble flux residues are
hygroscopic
Hygroscopy is the phenomenon of attracting and holding water molecules via either absorption or adsorption from the surrounding environment, which is usually at normal or room temperature. If water molecules become suspended among the substance ...
, which causes problems with electrical resistance and contributes to corrosion. Fluxes containing halides and mineral acids are highly corrosive and require thorough removal. Some fluxes, especially those based on borax used for brazing, form very hard glass-like coatings that are difficult to remove.
* Cleanability – the difficulty of removal of flux and its residues after the soldering operation. Fluxes with higher content of solids tend to leave larger amount of residues; thermal decomposition of some vehicles also leads to formation of difficult-to-clean, polymerized and possibly even charred deposits (a problem especially for hand soldering). Some flux residues are soluble in
organic solvent
A solvent (s) (from the Latin '' solvō'', "loosen, untie, solve") is a substance that dissolves a solute, resulting in a solution. A solvent is usually a liquid but can also be a solid, a gas, or a supercritical fluid. Water is a solvent for p ...
s, others in water, some in both. Some fluxes are no-clean, as they are sufficiently volatile or undergo thermal decomposition to volatile products, that they do not require the cleaning step. Other fluxes leave non-corrosive residues that can be left in place. However, flux residues can interfere with subsequent operations; they can impair adhesion of
conformal coating
Conformal coating is a protective coating of thin polymeric film, applied to printed circuit boards (PCB). The coating is named conformal since it ''conforms'' to the contours of the PCB. Conformal coatings are typically applied at 25-250 μm to ...
s, or act as undesired insulation on connectors and
contact pad
Contact pads or bond pads are designated surface areas of a printed circuit board (PCB) or die of an integrated circuit.
Possibilities to contact to pads include soldering, wirebonding, flip chip
Flip chip, also known as controlled collapse ...
s for test equipment.
* Residue tack – the stickiness of the surface of the flux residue. When not removed, the flux residue should have smooth, hard surface. Tacky surfaces tend to accumulate dust and particulates, which causes issues with electrical resistance; the particles themselves can be conductive or they can be hygroscopic or corrosive.
* Volatility – this property has to be balanced to facilitate easy removal of solvents during the preheating phase but to not require too frequent replenishing of solvent in the process equipment.
* Viscosity – especially important for
solder paste
Solder paste is used in the manufacture of printed circuit boards to connect surface mount components to pads on the board. It is also possible to solder through-hole pin in paste components by printing solder paste in and over the holes. The ...
s, which have to be easy to apply but also thick enough to stay in place without spreading to undesired locations. Solder pastes may also function as a temporary adhesive for keeping electronic parts in place before and during soldering. Fluxes applied by e.g. foam require low viscosity.
* Flammability – relevant especially for glycol-based vehicles and for organic solvents. Flux vapors tend to have low
autoignition temperature
The autoignition temperature or kindling point of a substance is the lowest temperature in which it spontaneously ignites in a normal atmosphere without an external source of ignition, such as a flame or spark. This temperature is required to su ...
and present a risk of a
flash fire
A flash fire is a sudden, intense fire caused by ignition of a mixture of air and a dispersed flammable substance such as a solid (including dust), flammable or combustible liquid (such as an aerosol or fine mist), or a flammable gas. It is charact ...
when the flux comes in contact with a hot surface.
* Solids – the percentage of solid material in the flux. Fluxes with low solids, sometimes as little as 1–2%, are called low solids flux, low-residue flux, or no clean flux. They are often composed of weak organic acids, with addition of small amount of rosin or other resins.
* Conductivity – some fluxes remain conductive after soldering if not cleaned properly, leading to random malfunctions on circuits with high impedances. Different types of fluxes are differently prone to cause these issues.
Composition
Fluxes for metal joining
The composition of fluxes is tailored for the required properties - the base metals and their surface preparation (which determine the composition and thickness of surface oxides), the solder (which determines the wetting properties and the soldering temperature), the corrosion resistance and ease of removal, and others.
Fluxes for soft soldering are typically of organic nature, though inorganic fluxes, usually based on halogenides or acids, are also used in non-electronics applications. Fluxes for brazing operate at significantly higher temperatures and are therefore mostly inorganic; the organic compounds tend to be of supplementary nature, e.g. to make the flux sticky at low temperature so it can be easily applied.
The surface of the tin-based solder is coated predominantly with tin oxides; even in alloys the surface layer tends to become relatively enriched by tin. Fluxes for indium and zinc based solders have different compositions than fluxes for ordinary tin-lead and tin-based solders, due to different soldering temperatures and different chemistry of the oxides involved.
Organic fluxes are unsuitable for flame soldering and flame brazing, as they tend to char and impair solder flow.
Some metals are classified as "unsolderable" in air, and have to be either coated with another metal before soldering or special fluxes or protective atmospheres have to be used. Such metals are
beryllium
Beryllium is a chemical element with the symbol Be and atomic number 4. It is a steel-gray, strong, lightweight and brittle alkaline earth metal. It is a divalent element that occurs naturally only in combination with other elements to form mi ...
,
chromium
Chromium is a chemical element with the symbol Cr and atomic number 24. It is the first element in group 6. It is a steely-grey, lustrous, hard, and brittle transition metal.
Chromium metal is valued for its high corrosion resistance and hardne ...
,
magnesium
Magnesium is a chemical element with the symbol Mg and atomic number 12. It is a shiny gray metal having a low density, low melting point and high chemical reactivity. Like the other alkaline earth metals (group 2 of the periodic ta ...
,
titanium
Titanium is a chemical element with the symbol Ti and atomic number 22. Found in nature only as an oxide, it can be reduced to produce a lustrous transition metal with a silver color, low density, and high strength, resistant to corrosion in ...
, and some
aluminium alloy
An aluminium alloy (or aluminum alloy; see spelling differences) is an alloy in which aluminium (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon, tin, nickel and zinc. There are two principal ...
s.
Fluxes for high-temperature soldering differ from the fluxes for use at lower temperatures. At higher temperatures even relatively mild chemicals have sufficient oxide-disrupting activity, but the metal oxidation rates become fairly high; the barrier function of the vehicle therefore becomes more important than the fluxing activity. High molecular weight hydrocarbons are often used for this application; a diluent with a lower molecular weight, boiling off during the preheat phase, is usually used to aid application.
Common fluxes are
ammonium chloride or
resin acids Resin acid refers to mixtures of several related carboxylic acids, primarily abietic acid, found in tree resins. Nearly all resin acids have the same basic skeleton: three fused rings having the empirical formula C19H29COOH. Resin acids are tacky, ...
(contained in
rosin
Rosin (), also called colophony or Greek pitch ( la, links=no, pix graeca), is a solid form of resin obtained from pines and some other plants, mostly conifers, produced by heating fresh liquid resin to vaporize the volatile liquid terpene comp ...
) for soldering
copper
Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pinkis ...
and
tin
Tin is a chemical element with the symbol Sn (from la, stannum) and atomic number 50. Tin is a silvery-coloured metal.
Tin is soft enough to be cut with little force and a bar of tin can be bent by hand with little effort. When bent, t ...
;
hydrochloric acid
Hydrochloric acid, also known as muriatic acid, is an aqueous solution of hydrogen chloride. It is a colorless solution with a distinctive pungent smell. It is classified as a strong acid
Acid strength is the tendency of an acid, symbol ...
and
zinc chloride
Zinc chloride is the name of inorganic chemical compounds with the formula ZnCl2 and its hydrates. Zinc chlorides, of which nine crystalline forms are known, are colorless or white, and are highly soluble in water. This salt is hygroscopic and ev ...
for soldering
galvanized
Galvanization or galvanizing ( also spelled galvanisation or galvanising) is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The most common method is hot-dip galvanizing, in which the parts are submerged ...
iron
Iron () is a chemical element with symbol Fe (from la, ferrum) and atomic number 26. It is a metal that belongs to the first transition series and group 8 of the periodic table. It is, by mass, the most common element on Earth, right in f ...
(and other
zinc
Zinc is a chemical element with the symbol Zn and atomic number 30. Zinc is a slightly brittle metal at room temperature and has a shiny-greyish appearance when oxidation is removed. It is the first element in group 12 (IIB) of the periodi ...
surfaces); and
borax
Borax is a salt (ionic compound), a hydrated borate of sodium, with chemical formula often written . It is a colorless crystalline solid, that dissolves in water to make a basic solution. It is commonly available in powder or granular form, ...
for
brazing
Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, with the filler metal having a lower melting point than the adjoining metal.
Brazing differs from we ...
, braze-welding
ferrous
In chemistry, the adjective Ferrous indicates a compound that contains iron(II), meaning iron in its +2 oxidation state, possibly as the divalent cation Fe2+. It is opposed to "ferric" or iron(III), meaning iron in its +3 oxidation state, such a ...
metals, and
forge welding
Forge welding (FOW), also called fire welding, is a solid-state welding process that joins two pieces of metal by heating them to a high temperature and then hammering them together. It may also consist of heating and forcing the metals together ...
.
Organic fluxes
Organic fluxes typically consist of four major components:
* Activators – chemicals disrupting/dissolving the metal oxides. Their role is to expose unoxidized, easily wettable metal surface and aid soldering by other means, e.g. by exchange reactions with the base metals.
** Highly active fluxes contain chemicals that are corrosive at room temperature. The compounds used include metal
halide
In chemistry, a halide (rarely halogenide) is a binary chemical compound, of which one part is a halogen atom and the other part is an element or radical that is less electronegative (or more electropositive) than the halogen, to make a fluor ...
s (most often
zinc chloride
Zinc chloride is the name of inorganic chemical compounds with the formula ZnCl2 and its hydrates. Zinc chlorides, of which nine crystalline forms are known, are colorless or white, and are highly soluble in water. This salt is hygroscopic and ev ...
or
ammonium chloride),
hydrochloric acid
Hydrochloric acid, also known as muriatic acid, is an aqueous solution of hydrogen chloride. It is a colorless solution with a distinctive pungent smell. It is classified as a strong acid
Acid strength is the tendency of an acid, symbol ...
,
phosphoric acid
Phosphoric acid (orthophosphoric acid, monophosphoric acid or phosphoric(V) acid) is a colorless, odorless phosphorus-containing solid, and inorganic compound with the chemical formula . It is commonly encountered as an 85% aqueous solution, w ...
,
citric acid
Citric acid is an organic compound with the chemical formula HOC(CO2H)(CH2CO2H)2. It is a colorless weak organic acid. It occurs naturally in citrus fruits. In biochemistry, it is an intermediate in the citric acid cycle, which occurs in t ...
, and
hydrobromic acid
Hydrobromic acid is a strong acid formed by dissolving the diatomic molecule hydrogen bromide (HBr) in water. "Constant boiling" hydrobromic acid is an aqueous solution that distills at and contains 47.6% HBr by mass, which is 8.77 mol/L. H ...
. Salts of
mineral acid
A mineral acid (or inorganic acid) is an acid derived from one or more inorganic compounds, as opposed to organic acids which are acidic, organic compounds. All mineral acids form hydrogen ions and the conjugate base when dissolved in water.
Cha ...
s with
amine
In chemistry, amines (, ) are compounds and functional groups that contain a basic nitrogen atom with a lone pair. Amines are formally derivatives of ammonia (), wherein one or more hydrogen atoms have been replaced by a substituen ...
s are also used as aggressive activators. Aggressive fluxes typically facilitate
corrosion
Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...
, require careful removal, and are unsuitable for finer work. Activators for fluxes for soldering and
brazing
Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, with the filler metal having a lower melting point than the adjoining metal.
Brazing differs from we ...
aluminium often contain
fluoride
Fluoride (). According to this source, is a possible pronunciation in British English. is an inorganic, monatomic anion of fluorine, with the chemical formula (also written ), whose salts are typically white or colorless. Fluoride salts typ ...
s.
** Milder activators begin to react with oxides only at elevated temperature. Typical compounds used are
carboxylic acid
In organic chemistry, a carboxylic acid is an organic acid that contains a carboxyl group () attached to an R-group. The general formula of a carboxylic acid is or , with R referring to the alkyl, alkenyl, aryl, or other group. Carboxylic ...
s (e.g.
fatty acid
In chemistry, particularly in biochemistry, a fatty acid is a carboxylic acid with an aliphatic chain, which is either saturated or unsaturated. Most naturally occurring fatty acids have an unbranched chain of an even number of carbon atoms, fr ...
s (most often
oleic acid
Oleic acid is a fatty acid that occurs naturally in various animal and vegetable fats and oils. It is an odorless, colorless oil, although commercial samples may be yellowish. In chemical terms, oleic acid is classified as a monounsaturated omega ...
and
stearic acid
Stearic acid ( , ) is a saturated fatty acid with an 18-carbon chain. The IUPAC name is octadecanoic acid. It is a waxy solid and its chemical formula is C17H35CO2H. Its name comes from the Greek word στέαρ "''stéar''", which means tallow. ...
),
dicarboxylic acids) and sometimes
amino acid
Amino acids are organic compounds that contain both amino and carboxylic acid functional groups. Although hundreds of amino acids exist in nature, by far the most important are the alpha-amino acids, which comprise proteins. Only 22 alpha am ...
s. Some milder fluxes also contain halides or
organohalide
Halocarbon compounds are chemicals in which one or more carbon atoms are linked by covalent bonds with one or more halogen atoms (fluorine, chlorine, bromine or iodine – ) resulting in the formation of organofluorine compounds, organochlori ...
s.
* Vehicles – high-temperature tolerant chemicals in the form of non-volatile liquids or solids with suitable melting point; they are generally liquid at soldering temperatures. Their role is to act as an oxygen barrier to protect the hot metal surface against oxidation, to dissolve the reaction products of activators and oxides and carry them away from the metal surface, and to facilitate heat transfer. Solid vehicles tend to be based on natural or modified
rosin
Rosin (), also called colophony or Greek pitch ( la, links=no, pix graeca), is a solid form of resin obtained from pines and some other plants, mostly conifers, produced by heating fresh liquid resin to vaporize the volatile liquid terpene comp ...
(mostly
abietic acid
Abietic acid (also known as ''abietinic acid'' or ''sylvic acid'') is an organic compound that occurs widely in trees. It is the primary component of resin acid, is the primary irritant in pine wood and resin, isolated from rosin (via isomerizat ...
,
pimaric acid
Pimaric acid is a carboxylic acid from the resin acid group, often found in the oleoresins of pine trees. It can be prepared by dehydration of abietic acid, which it usually accompanies in mixtures like rosin. It is soluble in alcohols, acetone, a ...
, and other
resin acid Resin acid refers to mixtures of several related carboxylic acids, primarily abietic acid, found in tree resins. Nearly all resin acids have the same basic skeleton: three fused rings having the empirical formula C19H29COOH. Resin acids are tack ...
s) or natural or synthetic
resin
In polymer chemistry and materials science, resin is a solid or highly viscous substance of plant or synthetic origin that is typically convertible into polymers. Resins are usually mixtures of organic compounds. This article focuses on natu ...
s. Water-soluble organic fluxes tend to contain vehicles based on high-boiling
polyol
In organic chemistry, a polyol is an organic compound containing multiple hydroxyl groups (). The term "polyol" can have slightly different meanings depending on whether it is used in food science or polymer chemistry. Polyols containing two, thr ...
s -
glycol
A diol is a chemical compound containing two hydroxyl groups ( groups). An Aliphatic compound, aliphatic diol is also called a glycol. This pairing of functional groups is pervasive, and many subcategories have been identified.
The most common ...
s,
diethylene glycol
Diethylene glycol (DEG) is an organic compound with the formula (HOCH2CH2)2O. It is a colorless, practically odorless, and hygroscopic liquid with a sweetish taste. It is a four carbon dimer of ethylene glycol. It is miscible in water, alcohol, ...
and higher polyglycols, polyglycol-based
surfactant
Surfactants are chemical compounds that decrease the surface tension between two liquids, between a gas and a liquid, or interfacial tension between a liquid and a solid. Surfactants may act as detergents, wetting agents, emulsifiers, foaming ...
s and
glycerol
Glycerol (), also called glycerine in British English and glycerin in American English, is a simple triol compound. It is a colorless, odorless, viscous liquid that is sweet-tasting and non-toxic. The glycerol backbone is found in lipids known ...
.
* Solvents – added to facilitate processing and deposition to the joint. Solvents are typically dried out during preheating before the soldering operation; incomplete solvent removal may lead to boiling off and spattering of solder paste particles or molten solder.
* Additives – numerous other chemicals modifying the flux properties. Additives can be
surfactant
Surfactants are chemical compounds that decrease the surface tension between two liquids, between a gas and a liquid, or interfacial tension between a liquid and a solid. Surfactants may act as detergents, wetting agents, emulsifiers, foaming ...
s (especially nonionic),
corrosion inhibitor
In chemistry, a corrosion inhibitor or anti-corrosive is a chemical compound that, when added to a liquid or gas, decreases the corrosion rate of a material, typically a metal or an alloy, that comes into contact with the fluid. The effectiveness ...
s,
stabilizers and
antioxidant
Antioxidants are compounds that inhibit oxidation, a chemical reaction that can produce free radicals. This can lead to polymerization and other chain reactions. They are frequently added to industrial products, such as fuels and lubricant ...
s,
tackifier
Tackifiers are chemical compounds used in formulating adhesives to increase the tack, the stickiness of the surface of the adhesive. They are usually low-molecular weight compounds with high glass transition temperature. At low strain rate, they p ...
s,
thickener
A thickening agent or thickener is a substance which can increase the viscosity of a liquid without substantially changing its other properties. Edible thickeners are commonly used to thicken sauces, soups, and puddings without altering their t ...
s and other
rheological
Rheology (; ) is the study of the flow of matter, primarily in a fluid (liquid or gas) state, but also as "soft solids" or solids under conditions in which they respond with plastic flow rather than deforming elastically in response to an appli ...
modifiers (especially for
solder paste
Solder paste is used in the manufacture of printed circuit boards to connect surface mount components to pads on the board. It is also possible to solder through-hole pin in paste components by printing solder paste in and over the holes. The ...
s),
plasticizer
A plasticizer ( UK: plasticiser) is a substance that is added to a material to make it softer and more flexible, to increase its plasticity, to decrease its viscosity, and/or to decrease friction during its handling in manufacture.
Plasticiz ...
s (especially for flux-cored solders), and
dyes.
Inorganic fluxes
Inorganic fluxes contain components playing the same role as in organic fluxes. They are more often used in brazing and other high-temperature applications, where organic fluxes have insufficient thermal stability. The chemicals used often simultaneously act as both vehicles and activators; typical examples are
borax
Borax is a salt (ionic compound), a hydrated borate of sodium, with chemical formula often written . It is a colorless crystalline solid, that dissolves in water to make a basic solution. It is commonly available in powder or granular form, ...
,
borate
A borate is any of several boron oxyanions, negative ions consisting of boron and oxygen, such as orthoborate , metaborate , or tetraborate ; or any salt with such anions, such as sodium metaborate, and disodium tetraborate . The name also refe ...
s,
fluoroborate
Tetrafluoroborate is the anion . This tetrahedral species is isoelectronic with tetrafluoroberyllate (), tetrafluoromethane (CF4), and tetrafluoroammonium () and is valence isoelectronic with many stable and important species including the perchl ...
s,
fluoride
Fluoride (). According to this source, is a possible pronunciation in British English. is an inorganic, monatomic anion of fluorine, with the chemical formula (also written ), whose salts are typically white or colorless. Fluoride salts typ ...
s and
chloride
The chloride ion is the anion (negatively charged ion) Cl−. It is formed when the element chlorine (a halogen) gains an electron or when a compound such as hydrogen chloride is dissolved in water or other polar solvents. Chloride salts ...
s. Halogenides are active at lower temperatures than borates, and are therefore used for brazing of aluminium and magnesium alloys; they are however highly corrosive.
Behavior of activators
The role of the activators is primarily disruption and removal of the oxide layer on the metal surface (and also the molten solder), to facilitate direct contact between the molten solder and metal. The reaction product is usually soluble or at least dispersible in the molten vehicle. The activators are usually either acids, or compounds that release acids at elevated temperature.
The general reaction of oxide removal is:
:Metal oxide + Acid → Salt + Water
Salts are ionic in nature and can cause problems from metallic leaching or
dendrite
Dendrites (from Greek δένδρον ''déndron'', "tree"), also dendrons, are branched protoplasmic extensions of a nerve cell that propagate the electrochemical stimulation received from other neural cells to the cell body, or soma, of the n ...
growth, with possible product failure. In some cases, particularly in high-
reliability
Reliability, reliable, or unreliable may refer to:
Science, technology, and mathematics Computing
* Data reliability (disambiguation), a property of some disk arrays in computer storage
* High availability
* Reliability (computer networking), a ...
applications, flux residues must be removed.
The activity of the activator generally increases with temperature, up to a certain value where activity ceases, either due to thermal decomposition or excessive volatilization. However the oxidation rate of the metals also increases with temperature.
At high temperatures, copper oxide reacts with hydrogen chloride to water-soluble and mechanically weak copper chloride, and with rosin to salts of copper and abietic acid which is soluble in molten rosin.
Some activators may also contain metal ions, capable of exchange reaction with the underlying metal; such fluxes aid soldering by chemically depositing a thin layer of easier solderable metal on the exposed base metal. An example is the group of fluxes containing
zinc
Zinc is a chemical element with the symbol Zn and atomic number 30. Zinc is a slightly brittle metal at room temperature and has a shiny-greyish appearance when oxidation is removed. It is the first element in group 12 (IIB) of the periodi ...
, tin or cadmium compounds, usually chlorides, sometimes fluorides or fluoroborates.
Inorganic activators
Common high-activity activators are
mineral acid
A mineral acid (or inorganic acid) is an acid derived from one or more inorganic compounds, as opposed to organic acids which are acidic, organic compounds. All mineral acids form hydrogen ions and the conjugate base when dissolved in water.
Cha ...
s, often together with halides, amines, water or alcohols:
*
hydrochloric acid
Hydrochloric acid, also known as muriatic acid, is an aqueous solution of hydrogen chloride. It is a colorless solution with a distinctive pungent smell. It is classified as a strong acid
Acid strength is the tendency of an acid, symbol ...
, most common
*
phosphoric acid
Phosphoric acid (orthophosphoric acid, monophosphoric acid or phosphoric(V) acid) is a colorless, odorless phosphorus-containing solid, and inorganic compound with the chemical formula . It is commonly encountered as an 85% aqueous solution, w ...
, less common, use limited by its polymerization at higher temperatures
Inorganic acids are highly corrosive to metals even at room temperature, which causes issues during storage, handling and applications. As soldering involves high temperatures, compounds that decompose or react, with acids as products, are frequently used:
*
zinc chloride
Zinc chloride is the name of inorganic chemical compounds with the formula ZnCl2 and its hydrates. Zinc chlorides, of which nine crystalline forms are known, are colorless or white, and are highly soluble in water. This salt is hygroscopic and ev ...
, which at high temperatures reacts with moisture, forming
oxychloride
In chemistry, molecular oxohalides (oxyhalides) are a group of chemical compounds in which both oxygen and halogen atoms are attached to another chemical element A in a single molecule. They have the general formula , where X = fluorine (F), chlor ...
and
hydrochloric acid
Hydrochloric acid, also known as muriatic acid, is an aqueous solution of hydrogen chloride. It is a colorless solution with a distinctive pungent smell. It is classified as a strong acid
Acid strength is the tendency of an acid, symbol ...
*
ammonium chloride, thermally decomposing to ammonia and hydrochloric acid
*
amine
In chemistry, amines (, ) are compounds and functional groups that contain a basic nitrogen atom with a lone pair. Amines are formally derivatives of ammonia (), wherein one or more hydrogen atoms have been replaced by a substituen ...
hydrochloride
In chemistry, a hydrochloride is an acid salt resulting, or regarded as resulting, from the reaction of hydrochloric acid with an organic base (e.g. an amine). An alternative name is chlorhydrate, which comes from French. An archaic alternative n ...
s, decomposing to the amine and hydrochloric acid
Rosin fluxes
The terms resin flux and rosin flux are ambiguous and somewhat interchangeable, with different vendors using different assignments. Generally, fluxes are labeled as rosin if the vehicle they are based on is primarily natural
rosin
Rosin (), also called colophony or Greek pitch ( la, links=no, pix graeca), is a solid form of resin obtained from pines and some other plants, mostly conifers, produced by heating fresh liquid resin to vaporize the volatile liquid terpene comp ...
. Some manufactures reserve "rosin" designation for military fluxes based on rosin (R, RMA and RA compositions) and label others as "resin".
Rosin has good flux properties. A mixture of organic acids (
resin acid Resin acid refers to mixtures of several related carboxylic acids, primarily abietic acid, found in tree resins. Nearly all resin acids have the same basic skeleton: three fused rings having the empirical formula C19H29COOH. Resin acids are tack ...
s, predominantly
abietic acid
Abietic acid (also known as ''abietinic acid'' or ''sylvic acid'') is an organic compound that occurs widely in trees. It is the primary component of resin acid, is the primary irritant in pine wood and resin, isolated from rosin (via isomerizat ...
, with
pimaric acid
Pimaric acid is a carboxylic acid from the resin acid group, often found in the oleoresins of pine trees. It can be prepared by dehydration of abietic acid, which it usually accompanies in mixtures like rosin. It is soluble in alcohols, acetone, a ...
,
isopimaric acid
Isopimaric acid (IPA) is a toxin which acts as a large conductance Ca2+-activated K+ channel (BK channel) opener.
Sources
IPA originates from many sorts of trees, especially conifers.
Chemistry
IPA is one of the members of the resin acid group ...
,
neoabietic acid,
dihydroabietic acid, and
dehydroabietic acid), rosin is a glassy solid, virtually nonreactive and noncorrosive at normal temperature, but liquid, ionic and mildly reactive to metal oxides at molten state. Rosin tends to soften between 60–70 °C and is fully fluid at around 120 °C; molten rosin is weakly acidic and is able to dissolve thinner layers of surface oxides from copper without further additives. For heavier surface contamination or improved process speed, additional activators can be added.
There are several possible activator groups for rosins:
* halide activators (organic halide salts, e.g.
dimethylammonium chloride and
diethylammonium chloride)
* organic acids (monocarboxylic, e.g.
formic acid
Formic acid (), systematically named methanoic acid, is the simplest carboxylic acid, and has the chemical formula HCOOH and structure . It is an important intermediate in chemical synthesis and occurs naturally, most notably in some ants. Es ...
,
acetic acid
Acetic acid , systematically named ethanoic acid , is an acidic, colourless liquid and organic compound with the chemical formula (also written as , , or ). Vinegar is at least 4% acetic acid by volume, making acetic acid the main component ...
,
propionic acid
Propionic acid (, from the Greek words πρῶτος : ''prōtos'', meaning "first", and πίων : ''píōn'', meaning "fat"; also known as propanoic acid) is a naturally occurring carboxylic acid with chemical formula CH3CH2CO2H. It is a liq ...
, and dicarboxylic, e.g.
oxalic acid
Oxalic acid is an organic acid with the systematic name ethanedioic acid and formula . It is the simplest dicarboxylic acid. It is a white crystalline solid that forms a colorless solution in water. Its name comes from the fact that early inve ...
,
malonic acid
Malonic acid (IUPAC systematic name: propanedioic acid) is a dicarboxylic acid with structure CH2(COOH)2. The ionized form of malonic acid, as well as its esters and salts, are known as malonates. For example, diethyl malonate is malonic acid' ...
,
sebacic acid
Sebacic acid is a naturally occurring dicarboxylic acid with the chemical formula . It is a white flake or powdered solid. ''Sebaceus'' is Latin for tallow candle, ''sebum'' is Latin for tallow, and refers to its use in the manufacture of candles. ...
)
There are three types of rosin: gum rosin (from pine tree
oleoresin Oleoresins are semi-solid extracts composed of resin and essential or fatty oil, obtained by evaporation of the solvents used for their production. The oleoresin of conifers is known as crude turpentine or gum turpentine, which consists of oil of ...
), wood rosin (obtained by extraction of tree stumps), and tall oil rosin (obtained from
tall oil, a byproduct of
kraft paper
Kraft paper or kraft is paper or paperboard (cardboard) produced from chemical pulp produced in the kraft process.
Sack kraft paper (or just sack paper) is a porous kraft paper with high elasticity and high tear resistance, designed for packag ...
process). Gum rosin has a milder odor and lower tendency to crystallize from solutions than wood rosin, and is therefore preferred for flux applications. Tall oil rosin finds increased use due to its higher thermal stability and therefore lower tendency to form insoluble thermal decomposition residues. The composition and quality of rosin differs by the tree type, and also by location and even by year. In Europe, rosin for fluxes is usually obtained from a specific type of Portuguese pine, in America a North Carolina variant is used.
Natural rosin can be used as-is, or can be chemically modified by e.g.
esterification
In chemistry, an ester is a compound derived from an oxoacid (organic or inorganic) in which at least one hydroxyl group () is replaced by an alkoxy group (), as in the substitution reaction of a carboxylic acid and an alcohol. Glycerides ar ...
,
polymerization
In polymer chemistry, polymerization (American English), or polymerisation (British English), is a process of reacting monomer, monomer molecules together in a chemical reaction to form polymer chains or three-dimensional networks. There are ...
, or
hydrogenation
Hydrogenation is a chemical reaction between molecular hydrogen (H2) and another compound or element, usually in the presence of a Catalysis, catalyst such as nickel, palladium or platinum. The process is commonly employed to redox, reduce or S ...
. The properties being altered are increased thermal stability, better cleanability, altered solution
viscosity
The viscosity of a fluid is a measure of its resistance to deformation at a given rate. For liquids, it corresponds to the informal concept of "thickness": for example, syrup has a higher viscosity than water.
Viscosity quantifies the inte ...
, and harder residue (or conversely, softer and more tacky residue). Rosin can be also converted to a water-soluble rosin flux, by formation of an
ethoxylated rosin
amine
In chemistry, amines (, ) are compounds and functional groups that contain a basic nitrogen atom with a lone pair. Amines are formally derivatives of ammonia (), wherein one or more hydrogen atoms have been replaced by a substituen ...
, an
adduct
An adduct (from the Latin ''adductus'', "drawn toward" alternatively, a contraction of "addition product") is a product of a direct addition of two or more distinct molecules, resulting in a single reaction product containing all atoms of all co ...
with a polyglycol and an amine.
One of the early fluxes was a mixture of equal amounts of rosin and
vaseline
Vaseline ()Also pronounced with the main stress on the last syllable . is an American brand of petroleum jelly-based products owned by transnational company Unilever. Products include plain petroleum jelly and a selection of skin creams, soa ...
. A more aggressive early composition was a mixture of saturated solution of zinc chloride, alcohol, and
glycerol
Glycerol (), also called glycerine in British English and glycerin in American English, is a simple triol compound. It is a colorless, odorless, viscous liquid that is sweet-tasting and non-toxic. The glycerol backbone is found in lipids known ...
.
Fluxes can be also prepared from synthetic resins, often based on esters of
polyol
In organic chemistry, a polyol is an organic compound containing multiple hydroxyl groups (). The term "polyol" can have slightly different meanings depending on whether it is used in food science or polymer chemistry. Polyols containing two, thr ...
s and
fatty acid
In chemistry, particularly in biochemistry, a fatty acid is a carboxylic acid with an aliphatic chain, which is either saturated or unsaturated. Most naturally occurring fatty acids have an unbranched chain of an even number of carbon atoms, fr ...
s. Such resins have improved fume odor and lower residue tack, but their fluxing activity and solubility tend to be lower than that of natural resins.
Rosin flux grades
Rosin fluxes are categorized by grades of activity: L for low, M for moderate, and H for high. There are also other abbreviations for different rosin flux grades:
* R (Rosin) – pure rosin, no activators, low activity, mildest
* WW (Water-White) – purest rosin grade, no activators, low activity, sometimes synonymous with R
* RMA (Rosin Mildly Activated) - contains mild activators, typically no halides
* RA (Rosin Activated) – rosin with strong activators, high activity, contains halides
* OA (Organic Acid) – rosin activated with organic acids, high activity, highly corrosive, aqueous cleaning
* SA (Synthetically Activated) – rosin with strong synthetic activators, high activity; formulated to be easily soluble in organic solvents (
chlorofluorocarbon
Chlorofluorocarbons (CFCs) and hydrochlorofluorocarbons (HCFCs) are fully or partly halogenated hydrocarbons that contain carbon (C), hydrogen (H), chlorine (Cl), and fluorine (F), produced as volatile derivatives of methane, ethane, and prop ...
s, alcohols) to facilitate cleaning
* WS (Water-Soluble) – usually based on inorganic or organic halides; highly corrosive residues
* SRA (Superactivated rosin) – rosin with very strong activators, very high activity
* IA (Inorganic Acid) – rosin activated with inorganic acids (usually hydrochloric acid or phosphoric acid), highest activities, highly corrosive
R, WW, and RMA grades are used for joints that can not be easily cleaned or where there is too high corrosion risk. More active grades require thorough cleaning of the residues. Improper cleaning can actually aggravate the corrosion by releasing trapped activators from the flux residues.
Special fluxes
Fluxes for soldering certain metals
Some materials are very difficult to solder. In some cases special fluxes have to be employed.
Aluminum and its alloys
Aluminium and its alloys are difficult to solder due to the formation of the passivation layer of aluminium oxide. The flux has to be able to disrupt this layer and facilitate wetting by solder. Salts or organic complexes of some metals can be used; the salt has to be able to penetrate the cracks in the oxide layer. The metal ions, more noble than aluminium, then undergo a redox reaction, dissolve the surface layer of aluminium and form a deposit there. This intermediate layer of another metal then can be wetted with a solder.
One example of such flux is a composition of
triethanolamine
Triethanolamine, or TEA is a viscous organic compound that is both a tertiary amine and a triol. A triol is a molecule with three alcohol groups. Approximately 150,000 tonnes were produced in 1999. It is a colourless compound although samples m ...
,
fluoroboric acid
Fluoroboric acid or tetrafluoroboric acid (archaically, fluoboric acid) is an inorganic compound with the chemical formula +BF4−], where H+ represents the solvated proton. The solvent can be any suitably Lewis-basic entity. For instance, in w ...
, and
cadmium fluoroborate. More than 1% magnesium in the alloy impairs the flux action, however, as the magnesium oxide layer is more refractory. Another possibility is an inorganic flux composed of
zinc chloride
Zinc chloride is the name of inorganic chemical compounds with the formula ZnCl2 and its hydrates. Zinc chlorides, of which nine crystalline forms are known, are colorless or white, and are highly soluble in water. This salt is hygroscopic and ev ...
or
tin(II) chloride
Tin(II) chloride, also known as stannous chloride, is a white crystalline solid with the formula . It forms a stable dihydrate, but aqueous solutions tend to undergo hydrolysis, particularly if hot. SnCl2 is widely used as a reducing agent (in aci ...
,
ammonium chloride, and a
fluoride
Fluoride (). According to this source, is a possible pronunciation in British English. is an inorganic, monatomic anion of fluorine, with the chemical formula (also written ), whose salts are typically white or colorless. Fluoride salts typ ...
(e.g.
sodium fluoride
Sodium fluoride (NaF) is an inorganic compound with the formula . It is used in trace amounts in the fluoridation of drinking water, in toothpaste, in metallurgy, and as a flux. It is a colorless or white solid that is readily soluble in water. I ...
). Presence of
silicon
Silicon is a chemical element with the symbol Si and atomic number 14. It is a hard, brittle crystalline solid with a blue-grey metallic luster, and is a tetravalent metalloid and semiconductor. It is a member of group 14 in the periodic tab ...
in the alloy impairs the flux effectivity, as silicon does not undergo the exchange reaction aluminium does.
Magnesium alloys
Magnesium alloy
Magnesium alloys are mixtures of magnesium (the lightest structural metal) with other metals (called an alloy), often aluminium, zinc, manganese, silicon, copper, rare earths and zirconium. Magnesium alloys have a hexagonal lattice structure, w ...
s. A putative flux for soldering these alloys at low temperature is molten
acetamide
Acetamide (systematic name: ethanamide) is an organic compound with the formula CH3CONH2. It is the simplest amide derived from acetic acid. It finds some use as a plasticizer and as an industrial solvent. The related compound ''N'',''N''-dimeth ...
. Acetamide dissolves surface oxides on both aluminium and magnesium; promising experiments were done with its use as a flux for a tin-indium solder on magnesium.
Stainless steel
Stainless steel
Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's corros ...
is material which is difficult to solder because of its stable, self-healing surface oxide layer and its low thermal conductivity. A solution of zinc chloride in hydrochloric acid is a common flux for stainless steels; it has however to be thoroughly removed afterwards as it would cause
pitting corrosion
Pitting corrosion, or pitting, is a form of extremely localized corrosion that leads to the random creation of small holes in metal. The driving power for pitting corrosion is the depassivation of a small area, which becomes anodic (oxidation re ...
. Another highly effective flux is phosphoric acid; its tendency to polymerize at higher temperatures however limits its applications.
Metal salts as flux in hot corrosion
Hot corrosion can affect
gas turbine
A gas turbine, also called a combustion turbine, is a type of continuous flow internal combustion engine. The main parts common to all gas turbine engines form the power-producing part (known as the gas generator or core) and are, in the directi ...
s operating in high salt environments (e.g., near the ocean). Salts, including
chloride
The chloride ion is the anion (negatively charged ion) Cl−. It is formed when the element chlorine (a halogen) gains an electron or when a compound such as hydrogen chloride is dissolved in water or other polar solvents. Chloride salts ...
s and
sulfate
The sulfate or sulphate ion is a polyatomic anion with the empirical formula . Salts, acid derivatives, and peroxides of sulfate are widely used in industry. Sulfates occur widely in everyday life. Sulfates are salts of sulfuric acid and many ar ...
s, are ingested by the turbines and deposited in the hot sections of the engine; other elements present in fuels also form salts, e.g.
vanadate
In chemistry, a vanadate is an anionic coordination complex of vanadium. Often vanadate refers to oxoanions of vanadium, most of which exist in its highest oxidation state of +5. The complexes and are referred to as hexacyanovanadate(III) and no ...
s. The heat from the engine melts these salts which then can flux the
passivating oxide layers on the metal components of the engine, allowing corrosion to occur at an accelerated rate.
List of fluxes
*
Borax
Borax is a salt (ionic compound), a hydrated borate of sodium, with chemical formula often written . It is a colorless crystalline solid, that dissolves in water to make a basic solution. It is commonly available in powder or granular form, ...
– for brazing
*
Beeswax
Beeswax (''cera alba'') is a natural wax produced by honey bees of the genus ''Apis''. The wax is formed into scales by eight wax-producing glands in the abdominal segments of worker bees, which discard it in or at the hive. The hive workers ...
*
Citric Acid
Citric acid is an organic compound with the chemical formula HOC(CO2H)(CH2CO2H)2. It is a colorless weak organic acid. It occurs naturally in citrus fruits. In biochemistry, it is an intermediate in the citric acid cycle, which occurs in t ...
- for soldering copper/electronics.
*
Tallow
Tallow is a rendering (industrial), rendered form of beef or mutton fat, primarily made up of triglycerides.
In industry, tallow is not strictly defined as beef or mutton fat. In this context, tallow is animal fat that conforms to certain techn ...
and lead
*
Paraffin wax
Paraffin wax (or petroleum wax) is a soft colorless solid derived from petroleum, coal, or oil shale that consists of a mixture of hydrocarbon molecules containing between 20 and 40 carbon atoms. It is solid at room temperature and begins to m ...
*
Palm oil
Palm oil is an edible vegetable oil derived from the mesocarp (reddish pulp) of the fruit of the oil palms. The oil is used in food manufacturing, in beauty products, and as biofuel. Palm oil accounted for about 33% of global oils produced from ...
*
Zinc chloride
Zinc chloride is the name of inorganic chemical compounds with the formula ZnCl2 and its hydrates. Zinc chlorides, of which nine crystalline forms are known, are colorless or white, and are highly soluble in water. This salt is hygroscopic and ev ...
("Killed Spirits")
* Zinc chloride and
Ammonium chloride
*
Olive oil
Olive oil is a liquid fat obtained from olives (the fruit of ''Olea europaea''; family Oleaceae), a traditional tree crop of the Mediterranean Basin, produced by pressing whole olives and extracting the oil. It is commonly used in cooking: f ...
and Ammonium chloride – for iron
*
Rosin
Rosin (), also called colophony or Greek pitch ( la, links=no, pix graeca), is a solid form of resin obtained from pines and some other plants, mostly conifers, produced by heating fresh liquid resin to vaporize the volatile liquid terpene comp ...
, tallow, olive oil, and zinc chloride - for aluminium
*
Cryolite
Cryolite ( Na3 Al F6, sodium hexafluoroaluminate) is an uncommon mineral identified with the once-large deposit at Ivittuut on the west coast of Greenland, mined commercially until 1987.
History
Cryolite was first described in 1798 by Danish vete ...
(Sodium hexafluoroaluminate)
* Cryolite and
phosphoric acid
Phosphoric acid (orthophosphoric acid, monophosphoric acid or phosphoric(V) acid) is a colorless, odorless phosphorus-containing solid, and inorganic compound with the chemical formula . It is commonly encountered as an 85% aqueous solution, w ...
* Phosphoric acid & alcohol
* Cryolite and
barium chloride
Barium chloride is an inorganic compound with the formula Ba Cl2. It is one of the most common water-soluble salts of barium. Like most other water-soluble barium salts, it is white, highly toxic, and imparts a yellow-green coloration to a flame. ...
*
Oleic acid
Oleic acid is a fatty acid that occurs naturally in various animal and vegetable fats and oils. It is an odorless, colorless oil, although commercial samples may be yellowish. In chemical terms, oleic acid is classified as a monounsaturated omega ...
*
Lithium chloride
Lithium chloride is a chemical compound with the formula Li Cl. The salt is a typical ionic compound (with certain covalent characteristics), although the small size of the Li+ ion gives rise to properties not seen for other alkali metal chlor ...
*
Magnesium chloride
Magnesium chloride is the family of inorganic compounds with the formula , where x can range from 0 to 12. These salts are colorless or white solids that are highly soluble in water. These compounds and their solutions, both of which occur in natu ...
*
Sodium chloride
Sodium chloride , commonly known as salt (although sea salt also contains other chemical salts), is an ionic compound with the chemical formula NaCl, representing a 1:1 ratio of sodium and chloride ions. With molar masses of 22.99 and 35.45 g ...
*
Potassium chloride
Potassium chloride (KCl, or potassium salt) is a metal halide salt composed of potassium and chlorine. It is odorless and has a white or colorless vitreous crystal appearance. The solid dissolves readily in water, and its solutions have a salt ...
*
Unslaked lime
Flux recovery
During the
submerged arc welding
Submerged arc welding (SAW) is a common arc welding process. The first SAW patent was taken out in 1935. The process requires a continuously fed consumable solid or tubular (metal cored) electrode. The molten weld and the arc zone are protec ...
process, not all flux turns into slag. Depending on the welding process, 50% to 90% of the flux can be reused.
Standards
Solder fluxes are specified according to several standards.
ISO 9454-1 and DIN EN 29454-1
The most common standard in Europe is
ISO
ISO is the most common abbreviation for the International Organization for Standardization.
ISO or Iso may also refer to: Business and finance
* Iso (supermarket), a chain of Danish supermarkets incorporated into the SuperBest chain in 2007
* Iso ...
9454-1 (also known as DIN EN 29454-1).
This standard specifies each flux by a four-character code: flux type, base, activator, and form. The form is often omitted.
Therefore, 1.1.2 means rosin flux with halides.
DIN 8511
The older German
DIN 8511 specification is still often in use in shops. In the table below, note that the correspondence between DIN 8511 and ISO 9454-1 codes is not one-to-one.
J-STD-004
One standard increasingly used (e.g. in the United States) is
J-STD-004. It is very similar to DIN EN 61190-1-1.
Four characters (two letters, then one letter, and last a number) represent flux composition, flux activity, and whether activators include halides:
* First two letters: Base
** RO: rosin
** RE: resin
** OR: organic
** IN: inorganic
* Third letter: Activity
** L: low
** M: moderate
** H: high
* Number: Halide content
** 0: less than 0.05% in weight (“halide-free”)
** 1: halide content depends on activity:
*** less than 0.5% for low activity
*** 0.5% to 2.0% for moderate activity
*** greater than 2.0% for high activity
Any combination is possible, e.g. ROL0, REM1 or ORH0.
J-STD-004 characterizes the flux by reliability of residue from a
surface insulation resistance (SIR) and
electromigration standpoint. It includes tests for electromigration and surface insulation resistance (which must be greater than 100 MΩ after 168 hours at elevated temperature and humidity with a DC bias applied).
MIL-F-14256 and QQ-S-571
The old
MIL-F-14256 and
QQ-S-571 standards defined fluxes as:
Any of these categories may be
no-clean, or not, depending on the chemistry selected and the standard that the manufacturer requires.
See also
*
Flux-cored arc welding Flux-cored arc welding (FCAW or FCA) is a semi-automatic or automatic arc welding process. FCAW requires a continuously-fed consumable tubular electrode containing a flux and a constant-voltage or, less commonly, a constant-current welding power ...
*
Gas metal arc welding
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) and metal active gas (MAG) is a welding process in which an electric arc forms between a consumable MIG wire electrode and the workpiece metal(s), which hea ...
*
Shielded metal arc welding
Shielded metal arc welding (SMAW), also known as manual metal arc welding (MMA or MMAW), flux shielded arc welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode covered with a flux to lay the we ...
References
External links
MetalShapers.OrgTips & Tricks from the Pros: 'Aluminum Welding"'' (includes Filler Metal chart)
Solder Fume and You
{{DEFAULTSORT:Flux (Metallurgy)
Metallurgy
Brazing and soldering