Buying thin solder wire for electronics – the best diameter?

For electronics soldering, a rosin flux core solder wire is recommended as it combines flux and solder, facilitating the soldering process. Lead-tin alloys, particularly eutectic 63% tin and 37% lead solder, are preferred due to their lower melting point (~183°C) and better flow characteristics compared to lead-free alternatives. Traditional 60/40 solder is also commonly used with similar effectiveness. The optimal solder wire diameter depends on the application: approximately 0.5 mm is ideal for fine electronics work, while 0.8 mm to 1.0 mm suits general through-hole components and wire soldering. Smaller diameters are better for surface mount devices (SMD), but thinner solder is consumed faster on larger leads. It is advisable to have multiple diameters available for different tasks. Avoid low-quality solder, especially some Chinese brands that do not melt or flow properly and may leave excessive rosin residue. Proper soldering equipment includes a temperature-controlled iron (around $12 or more), a small tip for precision, and tip cleaning tools such as a metal sponge or wet sponge. Solder wick is useful for cleaning excess solder, especially on SMD parts. Kester is a noted brand offering high-quality rosin core solder wire in various diameters (0.5 mm to 2.0 mm) and compositions (63/37). Flux types include rosin core, no-clean flux, and aqueous-cleanable flux, with rosin flux requiring cleaning after soldering.
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