SAE AS 4461C-2016 Assembly and Soldering Criteria for High Quality High Reliability Soldering Wire and Cable Termination in Aerospace Vehicles.pdf

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1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref

2、rom, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2016 SAE InternationalAll rights reserved. No part of this publi

3、cation may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE.TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada)Tel: +1 724-776-4970 (out

4、side USA)Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visithttp:/www.sae.org/technical/standards/AS4461CAEROSPACESTANDARDAS4461 REV. CIssued 1991-11Reaffirmed 2004-12Revised 2016-07Supersedi

5、ng AS4461BAssembly and Soldering Criteria for High Quality/High ReliabilitySoldering Wire and Cable Termination in Aerospace VehiclesRATIONALEChange needed to clarify Flux requirements in 4.7.2.TABLE OF CONTENTS1. SCOPE 31.1 Applicability 31.1.1 Safety Considerations . 31.1.2 Strain Relief. 31.1.3 S

6、older Joint Protection 32. REFERENCES 32.1 SAE Publications. 32.2 American National Standard . 42.3 ASTM Publications 42.4 U.S. Government Publications 42.4.1 Specifications 42.4.2 Standards 52.4.3 Handbooks 53. DEFINITIONS . 53.1 Terms and Definitions . 54. GENERAL REQUIREMENTS . 54.1 Conflict 54.1

7、.1 Line Drawings 54.2 Acceptance Criteria. 54.3 Visual Inspection . 54.4 Electrostatic Discharge . 54.5 Solderability. 64.6 Facilities and Equipment . 64.6.1 The Soldering Facility 64.6.2 Conductor Preparation Tools 64.6.3 Soldering Equipment. 74.7 Materials 94.7.1 Solder 94.7.2 Flux 94.7.3 Cleaning

8、 Solvents . 10SAE INTERNATIONAL AS4461C Page 2 of 384.7.4 Tin Whisker Growth 11 4.8 Preparation for Soldering 11 4.8.1 Insulation Removal 11 4.8.2 Preparation of Gold Plated Areas 13 4.8.3 Preparation of Solder Cups. 14 4.8.4 Tinning of Stranded Wire 14 4.8.5 Preparation of Shielded Wire 15 4.8.6 Pr

9、ecleaning . 15 4.8.7 Handling and Storage of Parts 15 4.8.8 Component Workmanship 15 4.9 Manual Soldering 15 4.10 Soldering by Use of Controlled Soldering Devices 17 4.10.1 Preparation and Assembly 18 4.10.2 Heat Application 18 4.11 Post Soldering Operations 20 4.11.1 Rework of Unsatisfactory Solder

10、 Connections 20 4.11.2 Cleaning 20 4.12 Workmanship 20 5. DETAIL REQUIREMENTS 21 5.1 Inspection Criteria for Manually Soldered Connections 21 5.1.1 Finish. 21 5.1.2 Wetting and Filleting 21 5.1.3 Coverage. 21 5.1.4 Insulation Clearance 21 5.1.5 Physical Attributes. 21 5.1.6 Criteria for Specific App

11、lications . 22 5.2 Inspection Criteria for Controlled Soldering Devices. 22 5.2.1 Finish. 22 5.2.2 Wetting and Filleting 22 5.2.3 Criteria for Specific Applications . 23 6. NOTES 386.1 Revision Indicator 38FIGURE 1 TYPICAL THERMAL STRIPPER (SEE 4.6.2.1) . 7 FIGURE 2 AS5756 MECHANICAL HAND WIRE STRIP

12、PER (SEE 4.6.2.2) 8 FIGURE 3 INSULATION STRIPPING EXAMPLES 12 FIGURE 4 SOLDER APPLICATION AND BRIDGING (SEE 4.9.5) 17 FIGURE 5 CUP TYPE TERMINALS (SEE 4.9.5.1) 18 FIGURE 6 PREFILLING HOLLOW CYLINDRICAL TERMINALS (SEE 4.9.5.1) . 19 FIGURE 7 SOLDERING OF HOLLOW CYLINDRICAL CONNECTIONS (SEE 4.9.5.1) .

13、19 FIGURE 8 HOOK TERMINAL, SOLDER CONNECTION (SEE 5.1.6.1) 23 FIGURE 9 HOOK TERMINAL, WIRE CONNECTION METHODS (SEE 5.1.6.1) 24 FIGURE 10 CUP TERMINAL, WIRE INSERTION (SEE 5.1.6.2). 26 FIGURE 11 CUP TERMINAL, SOLDER CONNECTION (SEE 5.1.6.2).28 FIGURE 12 WIRE AND LEAD SOLDERING TO CONTACTS (SEE 5.1.6.

14、3) 29 FIGURE 13 CONTROLLED SOLDERING DEVICE SHIELD TERMINATION (SEE 4.10 AND 5.2.3.2) 30 FIGURE 14 CONTROLLED SOLDERING DEVICE ROUND WIRE SPLICE (SEE 4.10 AND 5.2.3.3) . 32 FIGURE 15 CONTROLLED SOLDERING DEVICE SOLDER CONTACT (SEE 4.10 AND 5.2.3.4) . 34 FIGURE 16 CONTROLLED SOLDERING DEVICE SHIELD B

15、RAID SPLICE (SEE 4.10 AND 5.2.3.5) 37 TABLE 1 ACCEPTABLE SOLVENTS AND CLEANERS . 10 TABLE 2 MAXIMUM ALLOWABLE NICKED AND BROKEN STRANDS (SEE 4.8.1). 13 TABLE 3 SOLDER BATH MAXIMUM CONTAMINANT LEVELS 14 SAE INTERNATIONAL AS4461C Page 3 of 381. SCOPE1.1 ApplicabilityThis standard is applicable to manu

16、al soldering and machine soldering processes utilizing controlled soldering devices, for electrical connections for wiring and cabling used in aerospace vehicles. Description of a component or device herein is not to be construed as authorizing the use of the component or device.1.1.1 Safety Conside

17、rationsThis standard may involve hazardous materials, operations, and equipment. This standard does not purport to address all of the safety problems associated with its use. It is the responsibility of users of this standard to comply with appropriatesafety and health practices and regulatory limit

18、ations.1.1.2 Strain ReliefThe use of solder devices for wire or cable terminations in aircraft requires strain relief in all applications or designs with no strain on the solder terminations. Soldered wire or cable terminations may separate under physical load. The separation time is function of the

19、 ambient and electrical temperatures.1.1.3 Solder Joint ProtectionSealing protection for solder terminations is recommended when a potential electrical overload could cause the solder to melt and short adjacent terminations.2. REFERENCESThe following publications form a part of this document to the

20、extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In theevent of conflict between the text of this document and references cited herein, the text of this document takes

21、 precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.2.1 SAE PublicationsAvailable from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970

22、(outside USA), www.sae.org.ARP1931 Glossary of Terms with Specific Reference to Electrical Wire and CableAIR5444 Investigation of Whisker Formation on Tin Plated ConductorsAS5768 Tool, Stripper, Electrical Insulation, General Specification ForAS81824 Splice, Electric, Crimp, Copper, Environment Resi

23、stant, General Specification ForAS83519 Shield Termination, Solder Style, Insulated, Heat-Shrinkable, Environment ResistantSAE INTERNATIONAL AS4461C Page 4 of 382.2 American National StandardAvailable from Institute for Interconnecting and Packaging Electronic Circuits (IPC), 7380 N. Lincoln Avenue,

24、 Lincolnwood, IL 60646, www.ipc.org.J-STD-004 Requirements for Soldering FluxesJ-STD-005 Soldering Pastes Requirements forJ-STD-006 Requirements for Electronic Grade Solder Alloys and Fluxed and Non-Fluxed Solid Solders for Electronic Soldering Applications2.3 ASTM PublicationsAvailable from ASTM In

25、ternational, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ASTM D235 Specification for Mineral Spirits (Petroleum Spirits) (Hydrocarbon Drycleaning Solvents)ASTM D1007 Specification for Sec-Butyl AlcoholASTM D1193 Standard Specification for R

26、eagent WaterASTM D3622 Specification for n-Propyl Alcohol (1-Propanol)2.4 U.S. Government PublicationsCopies of Military documents are available online at http:/quicksearch.dla.mil. Copies of Code of Federal Regulations (CFR) may be obtained from the Superintendent of Documents, U.S. Government Prin

27、ting Office, Washington DC, 20402Specifications, standards, and handbooks2.4.1 Specifications2.4.1.1 FederalO-M-232 Methanol (Methyl Alcohol)TT-I-735 Isopropyl Alcohol27 CFR 21.36 Alcohol, Denatured27 CFR 20.113 Alcohol, Denatured27 CFR 20.112 Alcohol, DenaturedSAE INTERNATIONAL AS4461C Page 5 of 38

28、2.4.2 Standards2.4.2.1 MilitaryMIL-STD-202 Test Methods for Electronic and Electrical Component PartsMIL-STD-1686 Electrostatic Discharge Control Program for Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)2.4.3 Handbooks2.4

29、.3.1 MilitaryMIL-HDBK-263 Electrostatic Discharge Control Handbook for Protection of Electrical and Electronic Parts, Assemblies, and Equipment (Excluding Electrically Initiated Explosive Devices)3. DEFINITIONS3.1 Terms and DefinitionsThe definitions applicable to this standard shall be in accordanc

30、e with ARP1931.A Procuring Activity is a User activity (Government Air Framer, etc.) that procuring the finial soldered assembly.A Supplier is a manufacturer soldering the component.A terminal is a solder joint holding two or more electrical components together (i.e., solder cups, hooks, etc.).4. GE

31、NERAL REQUIREMENTS4.1 ConflictIn the event of conflict between the requirements of this standard and the applicable procuring activity approved assembly drawing(s), the requirements of the assembly drawing(s) shall govern.4.1.1 Line DrawingsLine drawings, illustrations, and photographs depicted here

32、in are provided as aids for determining compliance with the written requirements and shall not take precedence over the written requirements.4.2 Acceptance CriteriaAcceptance requirements and illustrations for use as comparison criteria for soldering shall be as specified herein. The written require

33、ments shall take precedence over the illustrations.4.3 Visual InspectionOne hundred percent inspection of all soldered connections and assemblies shall be performed using the magnification aids of 4.6.1.3. The soldered connections and assemblies shall conform to the requirements specified herein. Sa

34、mpling may be used in lieu of 100% inspection when performed as part of a statistical process control system approved by the procuring activity.4.4 Electrostatic DischargeWhere applicable, electrostatic discharge control criteria for the protection of electrical and electronic parts, components, ass

35、emblies, and equipment shall be in accordance with MIL-STD-1686 and MIL-HDBK-263.SAE INTERNATIONAL AS4461C Page 6 of 384.5 SolderabilityAll surfaces to be soldered shall be tested no more than 120 days prior to soldering for conformance to the requirements of MIL-STD-202, Test Method 208, except tha

36、t 1 hour steam aging with insulation removed shall be required for wires and cables not having silver plated conductors or shields. Items not meeting these requirements shall be tinned prior to termination. Tin plated conductor and to some extent nickel plated conductor surfaces oxidizes over time w

37、ith a non-conductive coatings. An active flux is typically required for these platings, but may be restricted by the governing activity (see 4.7.2) 4.6 Facilities and Equipment4.6.1 The Soldering Facility4.6.1.1 Environmental ConditionsAssemblies containing electrostatic discharge (ESD) sensitive de

38、vices shall be processed in accordance with MIL-STD-1686.4.6.1.2 CleanlinessWork areas shall be maintained in a clean and orderly condition. All visible dirt, grease, flux, solder spatter, chips, and other foreign objects or debris (FOD) shall be promptly removed. Eating, smoking, or drinking at the

39、 soldering work station shall not be permitted.4.6.1.3 Magnification Aids and LightingMagnification aids and lighting used for assembly and inspection shall be commensurate with the size of the item being processed and conform to the following requirements:a. Shall be suitable to permit inspection o

40、f each solder connection in its entirety.b. The optical system shall have a magnification power not less than 2X nor more than 4X, and shall be capable of rendering appropriate contrast, proportional dimensions, and adequate resolution.c. Light source for no shadow illumination of the area being vie

41、wed.4.6.2 Conductor Preparation Tools4.6.2.1 Thermal StrippersThermal strippers utilized to remove insulation from stranded and solid conductor wires shall be of a type that can be regulated to provide the required temperature (see Figure 1). Temperature controls shall be sufficient to prevent damag

42、e to the wire or unstrapped insulation.SAE INTERNATIONAL AS4461C Page 7 of 38Figure 1 - Typical thermal stripper (see 4.6.2.1)4.6.2.2 Mechanical StrippersMechanical strippers utilized to remove insulation from stranded or solid conductor wires may be of the hand operated or automatic high volume mac

43、hine type. Hand operated strippers shall be of a fixed die configuration in accordance with AS5768 (see Figure 2). Automatic high volume machine strippers shall be of a type utilizing either fixed dies, dies adjustable to calibrated stops, or roller cutters adjustable to calibrated stops. Dies, whet

44、her adjustable or fixed, shall beproperly maintained to assure consistently sharp and even cuts without damage to the wires or un-stripped insulation.4.6.2.3 Wire and Lead Cutting ToolsCutters shall be of a shear type, designed to cut squarely without leaving burrs, excessive ridges, or sharp points

45、.4.6.2.4 Bending ToolsBending tools used for wire or lead bending may be automatic or hand implements and shall be of a material that will not cut, nick, or otherwise damage solid or stranded wires, leads, integral insulation, or any other insulation or insulators added prior to the bending operatio

46、n.4.6.3 Soldering EquipmentSoldering equipment shall not produce levels of electromagnetic, electrostatic, electromechanical, electrical or other forms of energy which will be detrimental to the item(s) being soldered. Protective devices to prevent potential differences greater than 2 mV rms measure

47、d between 50 to 500 Hz shall be used when voltage sensitive devices are being soldered. Transformer type soldering guns shall not be used.SAE INTERNATIONAL AS4461C Page 8 of 38Figure 2 - AS5756 mechanical hand wire stripper (see 4.6.2.2)4.6.3.1 Soldering IronsSoldering irons shall be of the temperat

48、ure controlled type, controllable within 10 F (5.5 C) of the preselected idling temperature unless it can be demonstrated to the procuring activity that uncontrolled soldering irons are essential for a particular application. The size and shape of the soldering iron and tip shall permit soldering wi

49、th maximum ease and control without causing damage to adjacent areas or connections. The soldering iron or resistance heating element shall heat the connection area rapidly and maintain proper soldering temperature at the connection throughout the soldering operation, and shall have a thermal capacity adequate to make a solder connection in not more than 5 seconds.4.6.3.2 Soldering Iron TipsThe soldering iron tips or resis