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What Is a Cold Solder Joint and How Do You Prevent It?
Thursday, May 29th, 2025

When a cold solder joint appears on a PCB, it might not fail immediately. But over time, it can cause real trouble—intermittent signals, unstable connections, or even complete circuit failure. These defects are often hidden, and if not caught early, they can waste time and money in rework.

In this blog, you’ll learn:

  • What a cold solder joint looks like
  • What causes it
  • How to avoid and fix it
  • Why a trusted PCB assembly partner like Best Technology matters

What is a Cold Solder Joint?

A cold solder joint or cold joint solder, is a defective connection between a component lead or terminal and a PCB pad during PCB assembly process. Unlike a properly formed solder joint, which provides a strong, reliable electrical and mechanical connection, a cold solder joint fails to fully bond the two elements together.​

When soldering is done correctly, the solder melts completely and wets both the component lead and the PCB pad, creating a smooth, shiny, and concave surface. In the case of a cold solder joint, however, the solder doesn’t reach its optimal melting point or doesn’t flow properly. This results in a rough, dull, and often uneven surface. The joint may look like it’s attached, but in reality, the connection is weak and prone to failure. It might conduct electricity intermittently or not at all, leading to erratic behavior in the electronic device, from occasional glitches to complete breakdowns.​

What Is a Cold Solder Joint and How Do You Prevent It?

Cold Solder Joint Causes

Several factors can contribute to the formation of cold solder joints. Understanding these causes is the first step in preventing them.​

What Is a Cold Solder Joint and How Do You Prevent It?
  • Inadequate Soldering Temperature

One of the primary culprits is insufficient soldering temperature. Each type of solder has a specific melting range, and if the soldering iron or reflow oven doesn’t reach and maintain the appropriate temperature, the solder won’t melt fully. For example, if the temperature is too low, the solder may only partially liquefy, leaving solid particles that prevent a proper bond.

  • Incorrect Soldering Time

If the soldering iron is applied for too short a time, the solder won’t have enough time to melt and flow properly. On the flip side, overheating the joint by leaving the soldering iron on for too long can also cause problems. It can damage the component leads, PCB pads, or even change the properties of the solder itself, potentially leading to a cold solder joint.​

  • Poor Surface Preparation

The cleanliness and condition of the surfaces to be soldered are vital. If the component leads or PCB pads are dirty, oxidized, or contaminated with oils, residues, or other substances, the solder won’t adhere properly. Oxidation, in particular, forms a thin layer on the metal surfaces that acts as a barrier to soldering.

  • Inappropriate Flux Usage

Flux is a key component in the soldering process. It helps clean the surfaces, remove oxidation, and promote the flow of solder. However, using the wrong type of flux, too little flux, or applying it incorrectly can lead to cold solder joints. Some fluxes may not be compatible with certain solders or components, while insufficient flux won’t provide enough cleaning and wetting action.

  • Component Movement During Soldering

When components move while the solder is still molten, it can disrupt the formation of a proper joint. This can happen due to vibrations during the soldering process, improper handling of the PCB, or insufficient securing of the components. Even a small movement can break the developing bond, resulting in a cold solder joint or a weak connection.​

Cold Solder Joint Pictures

Visual aids can be extremely helpful in identifying cold solder joints. Here are common visual signs:

  • Dull, Grainy Appearance: A good joint is shiny and smooth. Cold ones look frosty or matte.
  • Cracks or Gaps: Visible separations or voids between the component and pad.
  • Ball-Like Shape: If the solder beads up instead of flowing smoothly, it likely didn’t bond.
  • Lifting Leads: Components that seem slightly off the pad may signal a cold joint underneath.

Below are some typical colder solder joint pictures examples:​

How to Identify Good Solder Joint​?

Identifying a good solder joint is just as important as recognizing a cold one. A high-quality solder joint has several distinct characteristics:​

1. Appearance​

    A good solder joint should have a smooth, shiny, and concave surface. The solder should flow evenly around the component lead and onto the PCB pad, forming a natural fillet.

    2. Wetting​

    Proper wetting is a key indicator of a good solder joint. The solder should spread and adhere evenly to both the component lead and the PCB pad, covering the surfaces completely. When the wetting is correct, there will be no gaps, voids, or bare spots where the metal surfaces are exposed.

    3. Strength​

    A well-soldered joint should be strong enough to hold the component in place firmly. Gently tugging on the component (with appropriate care not to damage it) should reveal a solid connection.

    How to Avoid Cold Solder Joints​?

    Prevention is better than repair. Here’s how to keep cold solder joints from happening in the first place:

    1. Use the Right Temperature

    Always set your soldering iron between 350°C to 400°C for standard lead-based solder. Higher temperatures may be needed for lead-free types.

    2. Pre-Clean Pads and Leads

    Use isopropyl alcohol to clean surfaces before soldering. Dirt and oxidation are invisible enemies.

    3. Don’t Skip the Flux

    Flux removes oxidation and improves solder flow. Many solder wires include it, but extra flux helps in difficult spots.

    4. Keep Steady Hands

    Hold the component and iron steady until the solder cools. Use clamps or tools if needed.

    5. Pick Quality Tools

    Poor-quality irons with unstable tips lead to inconsistent heat. Invest in a reliable soldering station with temperature control.

    6. Work in a Clean, Static-Safe Area

    Humidity, static, and poor lighting all raise the chances of making mistakes.

    How to Fix Cold Solder Joints​?

    Despite our best efforts, cold solder joints may still occur. Fortunately, there are ways to fix them:​

    1. Soldering​

      The first step in fixing a cold solder joint is often desoldering. Use a desoldering pump or wick to remove the existing solder from the joint. Heat the joint with the soldering iron to remelt the solder, and then use the desoldering tool to suck up or absorb the molten solder. Make sure to remove all the old solder completely to start fresh.​

      2. Cleaning​

      After desoldering, clean the surfaces again to remove any flux residues, oxidation, or other contaminants that may have accumulated. This step is crucial for ensuring a proper repair. Use a suitable cleaning solution and a clean brush or cloth to wipe the surfaces clean.​

      3. Resoldering​

      Once the surfaces are clean, it’s time to resolder the joint. Apply a small amount of fresh flux to the cleaned surfaces, and then heat the joint with the soldering iron. When the flux starts to bubble and activate, feed a small amount of solder into the joint.

      4. Inspection and Testing​

      After resoldering, inspect the joint visually to make sure it looks good and meets the criteria for a proper solder joint. Then, use testing equipment to verify the electrical connection. Check for continuity and make sure the joint is conducting electricity properly. If any issues are found, repeat the desoldering, cleaning, and resoldering process until the joint is fixed.​

      Trust PCB Assembly Service Provider – Best Technology

      Avoiding cold solder joints isn’t just about skills—it’s also about choosing the right PCB assembly partner. At Best Technology, we follow strict quality processes to ensure every joint is clean, strong, and reliable. Here’s how we guarantee excellence:

      • Automated Soldering Equipment: Reflow ovens, selective soldering, and wave soldering eliminate manual errors.
      • X-ray and AOI Inspection: We detect hidden cold joints and ensure solid connections throughout.
      • Skilled Technicians: Our team is trained to international IPC standards, ensuring precision with every solder joint.
      • Fast Prototyping and Mass Production: Whether you’re scaling up or fine-tuning, we support your project at every stage.

      Need flawless assembly for your next project? Contact Best Technology today for a quote or consultation. Let’s build something reliable—together.

      FAQs

      1. What is a cold solder joint in simple terms?

      It’s a weak or poorly connected solder point that didn’t heat properly and can fail over time.

      2. Are cold solder joints dangerous?

      Yes, they can cause circuits to fail, especially in safety-critical systems like medical or automotive electronics.

      3. Can cold solder joints be fixed easily?

      Yes, with the right tools, you can reheat and repair them quickly.

      4. What does a cold solder joint look like?

      It often appears dull, cracked, grainy, or uneven—unlike a shiny, smooth good joint.

      5. Can a PCB test miss a cold solder joint?

      Yes, especially if the fault is intermittent. That’s why visual inspection and X-ray are important.

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      How to fix a cold solder joint? Soldering problems
      Thursday, February 13th, 2025

      How to fix a cold solder joint? Cold solder joints refer to soldering that is not fully melted due to insufficient temperature or too short a time, resulting in a rough, dull solder joint surface and unreliable connection.

      The method to repair a cold solder joint is to reheat the solder joint with a soldering iron to melt and flow the solder, and add an appropriate amount of solder if necessary to ensure that the solder joint is smooth and the connection is firm.

      What is a cold solder joint?

      A cold solder joint occurs when a solder connection doesn’t properly melt and fuse the metal parts together. This results in a weak and unreliable electrical connection.

      How to fix a cold solder joint? Soldering problems

      Soldering is meant to create a strong bond between components and their pads or leads, but if the solder fails to properly flow and cool, you get a cold joint.

      A cold solder joint often happens when the joint doesn’t get hot enough to create the desired fusion between the metal parts, or when the solder doesn’t flow well due to contamination or poor technique.

      As a result, the solder might look dull or cracked, and the connection won’t be stable. A cold solder joint can occur in any soldering project, from simple DIY electronics to complex PCB assembly.

      What is the characteristic appearance of a cold solder joint?

      Some of the most common visual indicators of a cold joint solder include:

      • Dull or Grainy Appearance: A healthy solder joint should have a shiny, smooth finish. In contrast, cold joints usually look dull or rough. The dullness results from poor fusion between the solder and the metal parts.
      • Cracks or Gaps: Cold solder joints often have visible cracks or gaps between the solder and the components. These imperfections prevent a solid connection from forming.
      • Irregular Shape: Cold solder joints may appear lumpy or uneven, rather than smooth and symmetrical. A well-soldered joint should have a uniform shape, with the solder fully covering the lead and the pad.
      • No Flowing Solder: If the solder hasn’t flowed properly into the joint, you may see a lot of excess solder piled on one side, while the other side looks dry or incomplete.

      When you encounter a cold solder joint, it’s vital to address it promptly, as it can cause intermittent connections or total failure of the circuit.

      What are the effects of cold solder joints?

      A cold solder joint can lead to several issues that can disrupt the functionality of your electronics:

      • Intermittent Connections: A cold joint is unreliable and can cause intermittent electrical connections. The circuit might work only sporadically, making troubleshooting difficult.
      How to fix a cold solder joint? Soldering problems
      • Circuit Failures: If the solder joint fails completely, it may lead to a total breakdown of the circuit. This can result in device malfunction, loss of data, or even short circuits in extreme cases.
      • Signal Loss: In high-frequency circuits, even a small interruption in the signal path can lead to a noticeable degradation in performance, such as signal noise or data corruption.
      • Overheating: Cold joints can also contribute to overheating, as the weak connection might not handle the required current, leading to excess heat and further damage to components.

      In summary, cold solder joints are a significant issue that can affect the stability and reliability of your electronics. It’s important to identify and fix them before they cause more serious problems.

      How to prevent a cold solder joint?

      The best way to avoid cold solder joints is to ensure that you follow good soldering practices.

      • Proper Heating: Always heat both the pad and the lead properly before applying solder. The solder should flow smoothly once it touches the heated area.
      • Use Quality Solder: Ensure you’re using high-quality solder. The solder wire should have a proper flux core to promote good flow and prevent oxidation.
      • Clean Components: Clean the components and pads before soldering to remove any oil, dust, or oxidation. This can improve the connection and reduce the risk of a cold joint.
      • Right Soldering Technique: Don’t apply too much solder. The goal is to create a smooth, even connection, not a blob of excess solder. Avoid moving the component too much while the solder is cooling, as this can lead to a cold joint.
      • Good Soldering Iron Tip: Make sure your soldering iron tip is clean and tinned. A dirty or oxidized tip can result in uneven heating and poor solder flow.

      How to check for cold solder joints?

      Checking for cold solder joints is essential to ensure that your circuit works properly. You can inspect your joints visually and perform electrical tests to confirm their integrity.

      • Visual Inspection: The first step is to look closely at each solder joint. Check for dullness, cracks, irregularities, or excess solder. If the joint looks anything other than shiny and smooth, it may be a cold solder joint.
      • Use a Magnifying Glass: If the soldering is delicate or you’re working with tiny components, use a magnifying glass or a microscope to inspect the joints in more detail.
      • Electrical Testing: After performing a visual inspection, you can test the connection with a multimeter to check for continuity. If the multimeter shows no continuity or fluctuates, it indicates a poor connection due to a cold solder joint.
      • Functional Testing: Sometimes, simply testing the functionality of the circuit can help you detect cold solder joints. If certain components fail to work or intermittently cut out, cold solder joints are often the culprit.

      By regularly checking your solder joints, you can catch cold joints early and fix them before they cause problems.

      How to fix a cold solder joint?

      Fixing a cold solder joint involves reflowing the solder and ensuring that the connection is strong and reliable. Here’s a step-by-step guide on how to fix it:

      • Heat the Joint Again: Use your soldering iron to heat the cold solder joint. Allow the joint to heat up until the solder begins to melt. This will ensure the solder flows properly and fuses the components.
      How to fix a cold solder joint? Soldering problems
      • Add New Solder: If necessary, add a small amount of fresh solder to the joint. This will help create a stronger connection. The new solder should melt and flow smoothly around the pad and lead.
      • Remove Excess Solder: If there’s excess solder, use a desoldering pump or wick to remove it. Too much solder can create weak joints or cause shorts.
      • Let It Cool: Once the joint is properly soldered, let it cool naturally. Avoid disturbing the joint while it cools, as this can lead to a cold joint once again.
      • Check the Joint Again: After reflowing the solder, recheck the joint for a shiny appearance, good flow, and solid connection.

      What is the root cause of cold solder joint?

      The root causes of cold solder joints generally revolve around improper heating, poor soldering technique, or contaminated materials. Some common causes include:

      • Insufficient Heat: If the soldering iron is not hot enough or if the joint isn’t heated long enough, the solder will not properly fuse, resulting in a cold joint.
      • Dirty or Oxidized Components: If the components or pads are dirty or oxidized, the solder won’t adhere properly, leading to a weak bond.
      • Poor Soldering Technique: Applying solder too quickly, using too little solder, or moving the components while the solder is cooling can lead to cold solder joints.
      • Low-Quality Solder: Poor-quality solder may not melt properly or may have impurities, preventing the solder from flowing correctly.

      How do you change a cold solder joint to a correct one?

      To turn a cold solder joint into a correct, reliable one, you need to apply the correct amount of heat and solder while following proper soldering techniques. Here’s how to do it:

      • Remove the Cold Joint: If the joint is completely ineffective, use a soldering iron to reflow the solder, then remove it with a desoldering pump or wick.
      How to fix a cold solder joint? Soldering problems
      • Resolder the Joint: Heat the pad and lead again, then apply fresh solder and let it flow evenly.
      • Test the Joint: After resoldering, test the connection for continuity to ensure that the circuit works as intended.

      Conclusion:

      Always make sure to follow proper soldering practices, inspect your joints carefully, and reflow any faulty connections as needed. By taking care of cold solder joints early on, you ensure the longevity and functionality of your circuits.

      For professional soldering and PCB manufacturing services, Best Technology is here to help. Reach out to us at sales@bestpcbs.com for more information.

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