When you encounter a broken resistor, you're typically soldering a new wire or the broken lead back onto the remaining stub attached to the resistor body, rather than repairing the internal resistance element itself. The process involves carefully preparing the connection points and using your soldering iron to create a strong bond.
Here's how to solder a broken lead or wire onto a resistor, based on the provided reference:
The Simple Soldering Process
Repairing a broken resistor lead involves a few straightforward steps to ensure a solid electrical connection. The key is proper preparation and temperature control.
- Tin the Components Separately: Start by applying a small amount of solder to both the small piece of the lead or wire you intend to attach and the remaining small stub or piece left on the resistor. This process, called tinning, coats the surfaces with solder, making it easier to join them cleanly.
- Prepare Your Soldering Iron Tip: Apply a bit of solder directly to the tip of your soldering iron. This creates a "wet" tip, which transfers heat efficiently and helps melt the pre-tinned surfaces together smoothly.
- Join and Heat: Bring the tinned lead/wire and the tinned resistor stub together in the desired position. Use the wet tip of your soldering iron to heat both tinned surfaces simultaneously. The solder on the tip and on the components will melt, flowing together and forming a connection. Once the solder flows and creates a shiny, solid joint, remove the soldering iron.
- Cool and Inspect: Allow the joint to cool undisturbed for a few seconds. The solder should harden and form a solid, bright connection. Inspect the joint to ensure it looks mechanically sound and the solder has flowed properly.
This technique is effective for reattaching leads or wires securely to electronic components like resistors.
