Affordable Alternatives to Silver Solder for Heating Element Joining

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Discussion Overview

The discussion centers on finding affordable alternatives to silver solder for joining heating elements on copper pipes, particularly in contexts where high temperatures and pressures are involved. Participants explore various soldering materials and methods suitable for these applications.

Discussion Character

  • Exploratory, Technical explanation, Debate/contested

Main Points Raised

  • One participant suggests using tin-copper solder or tin-lead solder as alternatives, noting their lower melting points and the importance of clean surfaces and good flux.
  • Another participant mentions the use of standard 95/5 plumbing solder for lower pressure and temperature applications, while highlighting that silver solder is necessary for higher pressures and temperatures, particularly in HVAC work.
  • A later reply acknowledges the high temperatures of the fin heaters being used and expresses concern about the safety of using lead-based solders.
  • Some participants mention the historical use of cadmium in soldering, noting its current restrictions in Europe.
  • There is a suggestion that mechanical contacts with thermal paste could be an alternative for lower temperature applications.

Areas of Agreement / Disagreement

Participants express differing views on the suitability of various soldering materials based on temperature and pressure requirements. There is no consensus on a single best alternative to silver solder, and the discussion remains unresolved regarding the most effective and safe options.

Contextual Notes

Limitations include the specific temperature and pressure requirements of the heating elements, as well as the potential health and safety concerns associated with lead and cadmium solders.

Who May Find This Useful

Individuals involved in plumbing, HVAC work, or DIY projects related to heating elements may find this discussion relevant.

math111
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Right now I am using silver solder to combine heating elements on a copper pipe. This is becoming very expensive. Any other means/materials I could use that could get the similar results as the silver without the high cost!
 
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Silver solder resists higher temperatures. If you don't need them, just take tin-copper solder used for electronics presently, or the better tin-lead that was used previously (forbidden in Europe now). Their melting point is like +200°C and +180°C. Clean surfaces and good flux are important.

Available from plumbers and their shops.

Other compositions exist(ed) which I haven't used, like cadmium. Must be forbidden in Europe meanwhile.

At maximum +150°C, you can make a mechanical contact, with thermal paste between the parts. Press seriously with screws the precisely matched surfaces.
 
As a plumber, we use standard 95/5 plumbing solder (available at home centers and plumbing supply houses). It is used on water and heating copper with pressures below 125 PSI and temps below 210 deg F.

For pressures and temps above those levels we use Silver Solder. And yes Silver Solder is expensive. I do HVAC work and it is the only approved joining material for R-410a refrigerant due to the high pressures.
 
Thanks for the replies. The fin heaters we use get pretty hot with the amount of 1 to 6 Kw supplied quickly passing 212F+. I'll keep at it I guess. Lead is good but needed major protection so I am sure it will not be the best bet.
 

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