Electronic – Soldered wires don’t last very long on PCB

solderingwire

I am having a very bad experience with soldering wires on my boards. The problem is I have tried wires from various manufactures and suppliers but when I solder them initially they appear good but overtime (within couple of days) the insulation near the solder point on PCB starts cracking or in some case the conductor itself starts breaking.

My soldering technique is

  1. Strip the wire end.
  2. Tin the wire with solder end and make sure no split ends.
  3. Solder the wire on the PCB and then cut the bits that might be sticking out.

Any ideas or wire makes that can solve this problem and make the solder last?

Best Answer

If you're trying to do this properly, then you probably want to use 'board-in' crimps. The wire is crimped to a little metal fitting, which is then soldered to the board.

For some examples: http://www.molex.com/molex/products/group?key=direct_solder__boardin_crimp_terminals&channel=products

Soldering stranded cable which is then flexed is always a problem, because the strain at the end of the rigid soldered section is extremely high, which leads to failure.