Soldering Process of a HTS Cable Step by Step
Description: Soldering Process of a HTS Cable Step by Step Instruction as done by Irfan Özen Note: Even if this instruction gives all steps, the used amount of flux, solder and performed pressure is all done by hand and therefore also up to experience.
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slide1. Soldering Process of a HTS Cable Step by Step Instruction as done by Irfan Özen
Note: Even if this instruction gives all steps, the used amount of flux, solder and performed pressure is all done by hand and therefore also up to experience. 08/02/2023 Christian von Byern 1<br>
slide2. Pictures of the assembly frame 08/02/2023 Christian von Byern 2 Heater cables for end region/central region Assembly Frame Copper Endblocks (Cu-blocks) Aluminium
U-profile (Al-U) HTS Tapes Aluminium pressure plate (APP)<br>
slide3. Preparation Pretinning of HTS Tape.
InSn solder, 160°C.
Cut the tapes to their individual lengths.
Solder Aluminium-U-profile (Al-U) and Copper end blocks (Cu-block) together.
SnPb solder, 220°C.
Soldering in the solder frame.
Al-U is orientated and fixed with weigth, Cu-blocks are fixed with screws.
Cool down, get off frame, clean with Isopropanol.
Insert again in Frame.
Whenever the cable is inserted in the frame, the Cu-Blocks are fixed with screws.
Pretin the Cu-blocks with InSn.
Cleaning process, c.f. step 4.
Cut Al foil to the correct length (length of the Al-U), 2 pieces. 08/02/2023 Christian von Byern 3<br>
slide4. Adding the layers Put one Al foil in the centre of the Al-U.
Take the first (shortest) HTS tape and lay it in the Al-U. It shall be centred in terms of length as well as width. Carefully fix the ends with Kapton.
Repeat step 10 for the layers 2 to 5.
Add the second Al foil layer, centred in the sample. Again the length is the same as the Al-U.
Repeat step 10 for the layers 6 to 10.
Put the whole sample back in the frame.
Put flux between the tapes and the Al-U.
Use a syringe for that.
Heat the frame.
Central heaters up to 110°C.
Heaters in the Cu-block regions up to 50°C 08/02/2023 Christian von Byern 4<br>
slide5. Soldering the cable Fix the central region of the cable with a solder iron (210°C).
Start with the iron in the centre of the cable, go about 6cm to the left. While doing so, carefully press the iron on the tape and add more InSn while doing so.
Repeat on the right side of the centre.
Let everything cool down.
Carefully remove the Kapton which fixes the tapes on the ends.
Add Flux btween tapes and Cu-blocks.
Heat up everything to 110°C, this time including the end regions.
Solder the remaining parts of the tapes.
Continue at the already soldered part and push outwards with the solder iron (210°C). Add more InSn in front of the iron and press down the tape behind the iron. For this use either Teflon or Kapton.
Cool down to around 40°C to 50°C and clean everything (still in the frame) 08/02/2023 Christian von Byern 5<br>
slide6. Improving the soldering Add additional flux on the cable.
Put the Aluminium pressure plate (APP) weight with Teflon below on top.
Add some additional Kapton on the ends to reduce the height difference caused by the tape steps.
Heat everything to 160°C, keep for 1 minute.
Carefully press on the APP with your hands.
Put additional weights on the APP and keep for 1 minute.
Cool everything down.
Remove APP when around 100°C to 110°C. If colder the flux will behave like glue.
When at 60°C to 80°C clean everything with Isopropanol. 08/02/2023 Christian von Byern 6<br>
slide7. Last steps and cleaning. Optional: If the tapes at the Cu-blocks are not soldered from the side, these sides can be soldered to prevent moisture getting in between.
Add flux on the Cu-blocks
Heat one(!) Cu block to 110°C.
Solder the sides of the tapes on the warm side of the cable with a solder iron (210°C) and InSn solder.
Cool down and clean around 70°C to 80°C.
Repeat on the other side of the cable.
Get the cable off the frame and let it completely cool down.
Clean the cable with isopropanol.
Use compressed air to remove the remaining Isopropanol from the cable.
Only go in one direction.
Heat the empty frame to 70°C to 80°C and clean it. 08/02/2023 Christian von Byern 7<br>
Note: Even if this instruction gives all steps, the used amount of flux, solder and performed pressure is all done by hand and therefore also up to experience. 08/02/2023 Christian von Byern 1<br>
slide2. Pictures of the assembly frame 08/02/2023 Christian von Byern 2 Heater cables for end region/central region Assembly Frame Copper Endblocks (Cu-blocks) Aluminium
U-profile (Al-U) HTS Tapes Aluminium pressure plate (APP)<br>
slide3. Preparation Pretinning of HTS Tape.
InSn solder, 160°C.
Cut the tapes to their individual lengths.
Solder Aluminium-U-profile (Al-U) and Copper end blocks (Cu-block) together.
SnPb solder, 220°C.
Soldering in the solder frame.
Al-U is orientated and fixed with weigth, Cu-blocks are fixed with screws.
Cool down, get off frame, clean with Isopropanol.
Insert again in Frame.
Whenever the cable is inserted in the frame, the Cu-Blocks are fixed with screws.
Pretin the Cu-blocks with InSn.
Cleaning process, c.f. step 4.
Cut Al foil to the correct length (length of the Al-U), 2 pieces. 08/02/2023 Christian von Byern 3<br>
slide4. Adding the layers Put one Al foil in the centre of the Al-U.
Take the first (shortest) HTS tape and lay it in the Al-U. It shall be centred in terms of length as well as width. Carefully fix the ends with Kapton.
Repeat step 10 for the layers 2 to 5.
Add the second Al foil layer, centred in the sample. Again the length is the same as the Al-U.
Repeat step 10 for the layers 6 to 10.
Put the whole sample back in the frame.
Put flux between the tapes and the Al-U.
Use a syringe for that.
Heat the frame.
Central heaters up to 110°C.
Heaters in the Cu-block regions up to 50°C 08/02/2023 Christian von Byern 4<br>
slide5. Soldering the cable Fix the central region of the cable with a solder iron (210°C).
Start with the iron in the centre of the cable, go about 6cm to the left. While doing so, carefully press the iron on the tape and add more InSn while doing so.
Repeat on the right side of the centre.
Let everything cool down.
Carefully remove the Kapton which fixes the tapes on the ends.
Add Flux btween tapes and Cu-blocks.
Heat up everything to 110°C, this time including the end regions.
Solder the remaining parts of the tapes.
Continue at the already soldered part and push outwards with the solder iron (210°C). Add more InSn in front of the iron and press down the tape behind the iron. For this use either Teflon or Kapton.
Cool down to around 40°C to 50°C and clean everything (still in the frame) 08/02/2023 Christian von Byern 5<br>
slide6. Improving the soldering Add additional flux on the cable.
Put the Aluminium pressure plate (APP) weight with Teflon below on top.
Add some additional Kapton on the ends to reduce the height difference caused by the tape steps.
Heat everything to 160°C, keep for 1 minute.
Carefully press on the APP with your hands.
Put additional weights on the APP and keep for 1 minute.
Cool everything down.
Remove APP when around 100°C to 110°C. If colder the flux will behave like glue.
When at 60°C to 80°C clean everything with Isopropanol. 08/02/2023 Christian von Byern 6<br>
slide7. Last steps and cleaning. Optional: If the tapes at the Cu-blocks are not soldered from the side, these sides can be soldered to prevent moisture getting in between.
Add flux on the Cu-blocks
Heat one(!) Cu block to 110°C.
Solder the sides of the tapes on the warm side of the cable with a solder iron (210°C) and InSn solder.
Cool down and clean around 70°C to 80°C.
Repeat on the other side of the cable.
Get the cable off the frame and let it completely cool down.
Clean the cable with isopropanol.
Use compressed air to remove the remaining Isopropanol from the cable.
Only go in one direction.
Heat the empty frame to 70°C to 80°C and clean it. 08/02/2023 Christian von Byern 7<br>