What is Ball Soldering?

Ball soldering is a soldering technique frequently used in the high voltage industry. Large spherical balls of solder are used to make solder connections that are typically "at high voltage".  The large diameter, smooth spherical shape of the solder connection helps to control the local E-Field, suppressing the generation of corona.

The solder connection must be a solid mechanical joint as well as an effective corona suppression device. If it fails at either of these requirements it is not acceptable ball soldering. Making a good ball solder joint requires experience with the materials, solder time, temperature and technique. Typically trying to touch up a ball solder joint rarely improves a connection so this must be looked upon as a "do it right the first time" type of solder connection.