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Wave Soldering Process & Equipment

Wave soldering process is used for mass soldering of electronic components to PCB.

Wave Soldering Process is used for Mass Soldering of Electronic Components to PCB. Wave of Molten Solder is Used in the Process, hence the name wave soldering.

Wave soldering is the most widely used method in electronics industry for large scale mass soldering of through-hole electronic components to the PCB.

Components glued to the bottom of a mixed-technology PCB require wave soldering, although the required wave geometry is different from that for through-hole electronic components. In the most common wave soldering process, the dual-wave type, one wave is turbulent and the other wave is smooth, as in conventional technology soldering.

Wave Soldering Machine

Wave Soldering Machine

The need for wave soldering equipment can also be met by simply retrofitting the conventional solder pot with the dual pot for dip soldering – at a small fraction of the cost of a new machine. A completely new machine is not necessary.

Another wave geometry for PCB Assembly that is popular for surface mounting in Surface Mount Technology (SMT) is a vibrating single wave known as the omega wave. Like the dual wave geometry, it helps in reducing solder defects. The agitation provided by the dual or vibrating wave dislodges trapped flux gas that forms during wave contact and forces solder into areas with poor wetting angles. Proper component orientation is also very important.

Wave Soldering Process Steps

  • Step-1: Fluxing
  • Step-2: Preheating
  • Step-3: Wave Solder
  • Step-4: Cleaning

Video: Wave Soldering Process

Wave Soldering in SMT

Some electronic companies have successfully used drag soldering equipment and techniques. Ideally, the wave or drag soldering process should be limited to soldering ceramic surface mount resistors and SMD capacitors. Small outline transistor (SOT) components are difficult to wave or drag solder.

Wave and foam fluxers are generally used to apply flux to the board. Spray Fluxers are being used to apply very controlled amounts of flux, especially when no-clean fluxes are used. The development of an appropriate solder profile is important for best results.

Read: SMD Soldering Guide

Wave Soldering Defects

Wave Soldering Defects: Pin hole and Blow hole

Wave Soldering Defects: Pin hole and Blow hole

Pin hole or blow hole defects are major problem during wave soldering. Both these defects are generally associated with thickness of copper plating. Moisture in the board escapes through either thin copper plating or voids in the plating and forms Pin Hole or Blow Hole Defects.

Read: Pin Hole and Blow Hole Soldering Defects

PCB Assembly Process Flow Chart (PCBA Process)

PCB Assembly Process Flow Chart (PCBA Process)

PCB Assembly Process Flow Chart (PCBA Process)

FAQs: Wave Soldering for PCB Assembly

The primary equipment used in wave soldering includes a conveyor system to move the PCBs, a solder wave generator that maintains molten solder, preheating zones to prepare the PCB for soldering, flux applicators to clean surfaces, and sometimes an automated component insertion system.

Flux is used in wave soldering to remove oxides from the surfaces of the PCB and components, ensuring proper wetting and solder joint formation. It also helps to prevent oxidation during the soldering process.

Wave soldering offers several advantages, including fast and efficient soldering of through-hole components, consistent solder joint quality, reduced labor requirements compared to manual soldering, and the ability to process multiple PCBs simultaneously.

Challenges in wave soldering include the potential for solder bridging between closely spaced pins, thermal stress on components due to the high temperatures involved, the need for proper flux application and management, and potential damage to heat-sensitive components. Careful process optimization and control are essential to mitigate these challenges.

Read: Lead-Free Soldering: A Safer Approach to PCB Assembly

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Santosh Das

Santosh, founder of this Electronics Tutorial Website, is an Electronics Geek, Blogger and Young Entrepreneur. He possesses vast experience in the field of electronics, electronic components, PCB, Soldering, SMT, Telecommunication, ESD Safety, and PCB Assembly Tools, Equipment and Consumables. Keep visiting for daily dose of Tips and Tutorials.

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25 Responses

  1. November 27, 2013

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    […] are designed to provide the highest level of performance and reliability in its class. Specific wave solder flux products are formulated to offer a safer and more environmentally friendly alternative to […]

  5. February 27, 2019

    […] Pin hole or blow hole defects are the same problem caused by the printed board outgassing during wave soldering. Pin hole and blow hole formation during wave soldering is generally associated with thickness of copper plating. Moisture in the board escapes through either thin copper plating or voids in the plating. The plating in the through hole should be a minimum of 25um to stop the moisture in the board turning to water vapor and gassing through the copper wall during wave soldering. […]

  6. March 4, 2019

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    […] Wave Soldering: Wave soldering is done for mass production. Equipment and raw materials needed for wave soldering are – wave soldering machine, solder bar, flux, reflow checkers, dip tester, spray fluxers, flux controller. […]

  17. April 24, 2019

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  19. August 4, 2019

    […] Wave Soldering Machine: This is the main machine for any Automatic PCB Assembly Line for Mass Production. This Huge Machine is again divided into following sections: – Conveyor Belt – Fluxer or Flux Sprayer – Preheater or Preheating PAD – A Pan of Molten Solder that Produces Solder Waves with the Help of a Pump. – ERSA is a Leading Wave Soldering Manufacturer and Exporter.Read More on: Wave Soldering Process […]

  20. August 11, 2019

    […] and in various diameters ranging from 0.2 to 1.5mm. It is basically used in hand soldering or wave soldering and rework / […]

  21. August 18, 2019

    […] or Mixed PCB Assembly) are soldered either by automated Through Hole Soldering Technology like Wave Soldering or Automated Surface Mount Technology (SMT) like Reflow Soldering. Hand Soldering can also be […]

  22. August 24, 2019

    […] With double-sided PCBs, the reflow soldering process is repeated using either solder paste or glue to hold the components in place. If glue is used then the parts must be soldered later using wave soldering process. […]

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