The Innovation of Using Lead-Free Stained Glass Solders: Personal experiences of using lead-free solders using copper foil.

We all recognize the environmental advantages of lead-free solders. Since January 1999, Hirsch Metals has been developing "easy to use" lead-free alloys for use with copper foil technology that have the additional advantages of greater strength and superior finish. Once development was completed, I had to persuade the stained glass artists to at least try these new alloys. I found that this could be a "hard sell" because of the unhappy experiences of using other lead free systems.

First I felt that I should gain some personal and practical experience in the use of these materials and I enrolled in a class given by Bob and Evelyn at "Glass by Design". I soon found that it was not as easy as it looked, but it was not long before I had my design assembled and the copper foil fitted ready to solder.

I had to learn the "tricks of the trade" but then progressed quickly. I found out for example that the iron had to run at a higher temperature, (the lead-free solder melts at 630F instead of the 374F for the usual 60/40 lead based solder). I had to feed the solder smoothly to the iron tip, and form a continuous bead of solder rather than attempting to smooth it out later.

At first I was concerned that when the solder solidified, about 2 inches from the iron, it had a frosty appearance, but soon learned that this was the flux crystallizing on the surface, and after cleaning and waxing it had a brilliant smooth finish.

I was excited, and my classmates were eager to see the results. They had heard so much against lead-free alloys, and were surprised at how simple this was to use, and how excellent were the results. I experimented with different finishes and patinas, such as the black and pewter finishes but I personally prefer the beautiful smooth shine of the natural finish. The absence of lead of course also allows the use of these alloys for products that may come in contact with food or drink.

I would like to thank all of the many artists who helped me in the development and introduction of these alloys. Unfortunately space only allows me to pass on a few of their comments.

Bob & Evelyn of Glass by Design said, "Hirsch silver lead-free flowed like the Porsche of lead free solders. Evelyn made a candle shelter that looked like the crown jewels."

Jeremy Pitz of Centerville Architectural Glass comments, "Filled gaps without any flow through. We were impressed by its strength and luster. We totally underestimated how far the solder would go."

Nancy Grant of Stained Glass Kaleidoscope states, "It was not prone to run through as regular solder. Nowhere as difficult as I anticipated. I have no problem in recommending the silver solder."

Sandy Seff of Colorful Vision said, "Very excited about the lead free silver solder, smooth running with a nice shiny finish. Not only user friendly but the additional strength will be a real benefit with some of the sculptural pieces we do."

Jo Stanley of The Stained Web remarked, "Either the lead free silver solder goes further than 60/40 or I'm a better solderer than I thought. Great to work with."

Carol Shrout Stain Glass commented, "Did not like it - could not get the solder to flow easily, but would like to try it again."

Gloria Fohr of Expressions in Stained Glass stated, "Your lead free silver solder works like a charm. Knowing there is a workable lead free is a wonderful thing."

Carolyn of Carolyn's Creations said, "Quite workable with absolutely no ripple effect, flowed best with higher temperature setting."

Dale Riddle of Stained Glass Concepts remarked, "Flows a little different but seems fine." (Dale evaluated various blends of solder for strength and appearance)

Ray Crawford of Accent in Glass admits, "Works well during tacking. At first tricky but the results are worth it. Solder is very strong and polishes to a silver sheen."

David and Gloria Lieb contacted me saying they were impressed with the solder and sent a three piece candle shelter that emphasized the beauty of the solder and their work.

Rick Wolf of Seattle Stained Glass revealed, "Ran smooth and evenly on every seam. I would definitely recommend the solder for any copper foil project."

Michael Straub of Ambient Stained Glass commented, "The solder has some fabulous potential. Thank you for developing new products for our industry."

In summary, I found the lead free silver solder easy to use, even for a novice. It certainly requires adapting to the higher soldering iron temperature, and different rate of melting, but this did not prove at all difficult and the advantages of a beautiful finish and greater joint strength made it well worth the effort. I had no difficulty in using any flux, and carried out all my work with a 100watt iron.

The success of the Hirsch Wizard A/G solder has led to the development of a new version of this product containing a core of water soluble flux.

I wish to thank Lisa Swiman of Venture Tape for donating copper foil for these tests, and to Jack Spangler of Esico Triton for the soldering irons that were used. These excellent products were invaluable for our testing and evaluation.