The Solder Wire Lead Roll 60/40 1.6mm per meter (1.6mm Extra-Heavy Gauge / Sold Per Meter) is a heavy-duty electrical soldering alloy offered in custom linear lengths for low-volume industrial repairs, high-current electrical terminations, DIY battery building, and prototyping tasks that do not require a full spool. Formulated with the standard 60% Tin (Sn) and 40% Lead (Pb) metallurgical ratio, it features a low melting range (183°C–190°C) with a narrow plastic transition phase, ensuring rapid liquefaction, smooth capillary wetting, and strong mechanical bonding. Featuring an integrated, non-corrosive multi-channel rosin flux core (1.8%–2.2%), its heavy 1.6mm gauge delivers substantial solder volume per feed stroke, making it ideal for large wire splices, high-power battery lugs, solid copper busbars, and motor rewinding.

Specifications

• Alloy Composition: 60% Tin (Sn) / 40% Lead (Pb)
• Wire Diameter: 1.6 mm (±0.05 mm / Extra-Heavy Industrial Gauge)
• Unit of Sale: Per Meter (Continuous linear length cut to order)
• Weight per Meter: Approx. 17.0 g to 17.5 g per meter
• 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 ambient conditions
• Packaging: Coiled bundle in sealed protective zip-lock / poly bag

Features

• Cost-Effective Per-Meter Option: Allows technicians, hobbyists, and students to purchase only the exact length required for specific heavy-duty projects without investing in bulk 1kg spools.
• Extra-Heavy 1.6mm Gauge: Dispenses high solder volume rapidly in a single feed motion, minimizing heating dwell time on high-dissipation joints and heavy metal connectors.
• Low Melting Point & Fast Capillary Action: Liquefies cleanly at ~185°C to flood stranded wire cores, large grounding straps, and heavy sheet metal joints without scorching adjacent insulation.
• Continuous Multi-Channel Rosin Core: Formulated with deoxidizing rosin flux that cleans surface oxides on copper, brass, tin, and nickel plating on contact without requiring external paste flux.
• Robust Mechanical & Vibration Resistance: Solidifies into thick, crack-resistant, shiny fillets with high shear strength and low contact resistance.

Common Applications

• Heavy Battery & Inverter Wiring: Splicing and tinning 4 AWG to 8 AWG power cables, off-grid solar battery lugs, and high-current terminal connections.
• High-Power Connectors: Soldering high-current XT90/EC5 plugs, Anderson Powerpole contacts, heavy banana plugs, and ground binding posts.
• Electric Motor & Transformer Repair: Terminating thick magnet wire coils, stator leads, and heavy transformer winding taps.
• Industrial Power Switchgear: Soldering solid copper busbars, heavy grounding rods, knife switches, and industrial contactor terminals.
• Stained Glass & Sheet Metal Work: 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 mass of the target joints, use a high-power soldering iron or station rated at 80W to 150W+ (or direct mains heavy irons) fitted with a wide chisel or wedge tip (5mm–10mm).
• Temperature Setting: Maintain soldering tip temperatures between 360°C and 390°C to ensure fast liquefaction and uniform capillary flow into thick stranded wire bundles.
• Feeding Technique: Pre-heat the terminal and wire bundle together for 2–4 seconds until hot, then feed the 1.6mm solder directly into the joint junction until the strands are completely wetted and saturated.
• Flux Residue Cleaning: The rosin residue is electrically non-conductive and protective, but can be removed for aesthetic cleanliness using Isopropyl Alcohol (IPA ≥ 99%) with a stiff bristle brush.
• Safety & Ventilation:
  • Soldering heavy joints with 1.6mm wire produces visible flux fumes; always work in a well-ventilated space or use an active benchtop fume extractor.
  • Contains lead; wash hands thoroughly with soap and water after handling, and avoid eating or drinking in the workspace.