Since OA flux residues are corrosive if not removed, how does one handle
soldering rework wires to boards?

*The short answer is - you don't.  At least with an OA.

Won't the flux wick under the insulationand cause a problem?

*Yup.  That's why you don't do it.

Assume I do not have the option of using a no clean flux.

*And why would I be making such an assumption?  A low solids flux is your
best answer.

Is my only choice an RMA chemistry with local cleaning (which is an
option I have available if needed)? Any other ideas?

*Well, why not start with telling us all the constraints you are under
first?  Then we might make better suggestions.  In general, most flux
residue will get under insulation on wires, especially if you are using
stranded wires.  Forget trying to clean it out with anything.  Once in, it
stays in.  You might strip back the insulation farther and use a heat
shrinkable sleeve to replace the insulation.

Doug Pauls
Rockwell Collins

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