I can't explain why one solder pot would be lower in tin than another,
but I can explain why the tin content would drop: dross is mostly
solder mixed with a little tin oxide, not the combined oxides of tin
and lead. The more dross that forms, the more the tin concentration
drops. Since the formation of dross also removes about a hundred
times as much solder (as solder) as it does tin (as oxide), and since
solder is always added to replace that lost to dross, the rate of loss
of tin is slow.
In my opinion it's not worth getting a solder pot analyzed month after
month. The most practical way to tell if the contamination level is
too high is just to look at a quickly-frozen solder connection. With
pure eutectic solder, such a connection will be "smooth and shiny", as
the specs used to demand. The first effect of contaminants is to make
the connection look gritty. (Some use the term "grainy", but this term
applied to surface appearance has three different meanings and so is
ambiguous). The second effect (higher concentration) is to strengthen
the connection somewhat (the particles reinforce the solder, making it
more resistant to creep). The last effect (higher concentration yet)
is to restrict the flow of solder (because the contaminants are now
present as solid particles and so make it sluggish). Concentrations
this high almost never occur in practice. It is fair to say that of
all the possible causes of solder defects (defect meaning a condition
of a connection that renders it unreliable), solder composition is at
the bottom of the list.
Technet has been carrying a discussion on how to remove the most
common contaminant, copper, virtually for free, from a wave solder
pot, just by letting the solder stand undisturbed at a temperature
just above its melting temperature, where the solubility of copper in
molten solder is low.
The visual effect of solder in a solder pot being low in tin (compared
to the eutectic composition) is to increase, in the wave-soldered
connection, the amount of lead that freezes before the tin starts to
freeze. If the solder freezes slowly, this lead will be observable as
many small protrusions on the surface. These protrusions are the ends
of lead dendrites that formed during the early stages of freezing.
Because solder contracts about 4 percent during freezing, the last
liquid in the connection to freeze has receded, leaving the ends of
the dendrites exposed. When the solder freezes quickly, this all
takes place so fast that the lead dendrites that form are too small to
be noticeable at the surface.
(It is interesting to note that even eutectic solder does not freeze
instantly, although this is sometimes asserted. It does not even
freeze at the eutectic temperature. The temperature drops below 183 C
by dozens of degrees (a phenomenon called "undercooling": Spontaneous-
ly forming crystal nuclei necessarily start out very small, and very
small nuclei have a lower melting temperature than big crystals), and
then lead (Pb) starts to precipitate. This causes the tin concentra-
tion in the remaining melt to rise. The temperature rises, too, due
to release of the heat of fusion. Eventually, tin also starts to
freeze along with the lead, and finally the temperature starts to drop
again.)
The practical effect of solder being low in tin is nil, unless the tin
concentration has dropped to the point where the liquidus temperature
approaches the solder temperature (in which case, flow is restricted,
due to premature freezing of solder in the connection).
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