I don't know the specifics involved in tip fabrication, only what I've
learned from tip manufacturers' information regarding their product
reliability and durability.

I'm not sure why iron plating became common with soldering tips. I'm fairly
certain it's beneficial to durability, possibly because copper is so soft.
Iron and steel aren't as good at heat condction as copper is, so the reasons
are for other characteristics.

As for the nickel plating, again, I don't know about the specifics, but
there are two processes IIRC, one being electroplating, and the other being
electroless.

You're at a good advantage by having metalworking capabilities in-house. I
have metalworking machines, and it's often difficult to imagine alternatives
for others.

Another possibility for tips could be some alloys of stainless steel. Some
300 and 400 series are relatively easy to machine (avoid the work-hardening
alloys), although I'm not sure which alloys are easily tinned.
Stainless alloys will most likely require a highly active flux to tin them,
but after they're tinned that flux can be removed.
Stainless can erode like other metals, particularly at elevated temps, as
can be seen on the stainless covers of soldering iron heaters, but the
heater sections are typically hotter than the tip's working temp.
Fluxes for stainless are available from Harris (StaBrite product line) and
other sources.

I should've mentioned that I don't know much about the newer lead-free
solders or how they work (or don't work) with conventional tip plating
materials. I don't do servicing work anymore, and I still use lead alloy
solders for everything.

--
Cheers,
WB
..............


"Smitty Two" wrote in message
news
In article ,

Thanks for the deets. The actual fabrication of the tip will be
relatively painless since we have a machine shop in-house. And, I think
the volume of work to be done is such that a reasonably well-made tip
will last the length of the task. If not, I'd think it wouldn't require
more than 3 copies.

Do you see any significant advantage to copper--iron--copper--nickel
over just copper--nickel? Do you know how thick the nickel plating
should be?