The Solder Wire Lead Roll 60/40 1.6mm 1Kg High Quality (1.6mm Extra-Heavy Gauge / 1kg Bulk Industrial Spool) is an industrial-grade, heavy-duty electrical soldering alloy engineered for extreme thermal mass joints, massive copper busbars, heavy motor rewinding, industrial power terminations, and continuous high-volume assembly lines. Formulated with the classic 60% Tin (Sn) and 40% Lead (Pb) metallurgical ratio, it features a low melting range (183°C–190°C) with a narrow plastic transition zone, providing rapid liquefaction, aggressive capillary action, and high structural joint strength. Incorporating an integrated, non-corrosive multi-channel rosin flux core (typically 1.8%–2.2%), its extra-thick 1.6mm gauge feeds high solder volume rapidly per stroke, while the commercial 1kg bulk spool provides maximum wire capacity to eliminate frequent line changeovers in heavy electrical workshops and manufacturing plants.

Specifications

• Alloy Composition: 60% Tin (Sn) / 40% Lead (Pb)
• Wire Diameter: 1.6 mm (±0.05 mm / Extra-Heavy Industrial Gauge)
• Net Solder Weight: 1000 g / 1.0 kg (Gross spool weight approx. 1080 g to 1150 g)
• Flux Type / Core: Continuous Integrated Rosin Activated (RA) / Mildly Activated (RMA) Core
• Flux Content / Percentage: 1.8% to 2.2% (By weight)
• Melting Temperature Range:
  • Solidus: 183°C (361°F)
  • Liquidus: 190°C (374°F)
• Recommended Iron Tip Temperature: 350°C to 400°C (662°F to 752°F)
• Density: Approx. 8.5 g/cm³
• Electrical Conductivity: Approx. 11.5% to 12% IACS
• Flux Residue Characteristics: Light amber, transparent, non-conductive, non-corrosive under normal operating conditions
• Spool Dimensions: Approx. 90 mm to 100 mm Flange Diameter × 80 mm to 90 mm Overall Height
• Spool Hub Hole Diameter: Approx. 20 mm to 25 mm (Fits heavy benchtop spindle dispenser racks)

Features

• Extra-Heavy 1.6mm Diameter: Delivers massive solder volume in a single feed motion, drastically reducing contact dwell time on high-dissipation joints and heavy metal assemblies.
• Low Melting Point & Fast Wetting: Liquefies cleanly at ~185°C to flood stranded wire cores, large grounding straps, and heavy sheet metal joints without heat damage to adjacent wire jackets.
• Continuous Multi-Channel Rosin Core: Formulated with aggressive deoxidizing rosin flux that strips oxidation from raw copper, tin, brass, and bronze surfaces on contact without needing separate paste flux.
• Heavy Mechanical & Fatigue Strength: Solidifies into thick, crack-resistant, shiny fillets with high shear resistance and exceptional tolerance against continuous mechanical vibrations.
• 1kg Bulk Industrial Spool: Maximizes efficiency on production lines and service stations by drastically minimizing spool changes and reducing packaging waste.

Common Applications

• Heavy Battery & Power Cabling: Soldering large 4 AWG to 8 AWG inverter cables, commercial battery bank lugs, and starter motor cables.
• Electric Motor & Transformer Manufacturing: Splicing heavy stator winding taps, large armature coils, commutator bars, and distribution transformer leads.
• Industrial Power Switchgear: Soldering solid copper busbars, heavy grounding rods, knife switches, and industrial contactor terminals.
• Automotive, Marine & Solar Installations: Terminating heavy DC disconnects, alternator harnesses, off-grid solar combiners, and boat battery isolator switches.
• Stained Glass & Sheet Metal Seaming: Rapid filling and soldering of wide lead came channels, zinc border came, brass sheet fabrications, and copper heat exchangers.

Usage Tips

• Soldering Iron Power Requirement: Due to the large 1.6mm wire diameter and massive thermal load, use a high-power soldering iron or station rated at 100W to 200W+ (or direct heavy mains irons) equipped with a broad copper chisel or wedge tip (5mm–10mm).
• Temperature Setting: Maintain soldering tip temperatures between 360°C and 390°C to ensure immediate liquefaction and uniform capillary flow into thick stranded wire bundles.
• Feeding Technique: Pre-heat the heavy terminal and wire bundle together for 3–5 seconds, then feed the 1.6mm solder directly into the joint junction until the strands are completely wetted and saturated.
• Flux Residue Cleaning: While the rosin flux residue is non-conductive and provides a mild protective seal, it can be removed for clean inspection or potting using Isopropyl Alcohol (IPA ≥ 99%) with a stiff bristle brush.
• Safety & Ventilation:
  • Soldering heavy joints with 1.6mm wire generates significant flux vapor; always operate under an active industrial fume extraction hood or in a well-ventilated open area.
  • Contains lead; wash hands thoroughly with soap and water after handling, and do not handle food or drinks in the work area.