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Flux Corrosion?

Flux Corrosion?

Flux Corrosion?

(OP)
I'm currently a Co-op looking for some good advice.  I've been researching this problem we have with flux corrosion.  And I need to find a good resolution to this.  The Products are light bulbs and the variables are the flux, lead wire, base and solder.  Currently the base eyelet is made of brass, the lead wires are (a section of copper and a section of nickel plated copper) with a flux made of hydrobromic acid, hydrochloric acid and Ethylamine, the specifics are available here:

http://www.frytechnology.com/pdf_uploads/radsolp.PDF

I believe the solder is lead free, silver and tin combination.  

This combination of materials in high wattage light bulbs can lead to corrosion of the lead wires.  This corrosion increases the resistance of the wires, leading to increased heat, snowballing and creating many potential problems.  

I'm trying to find if changing the base material to something that has a few different characteristics would solve this problem
.
1)    It must not cause galvanic corrosion with the lead wires.   
2)    The oxide layer of the material should be removed from it with a flux that does not cause corrosion in the lead wires.
3)    And the lead wires should get a good solder with the base eyelet.  

Oh yes, I almost forgot, as well as our current method cannot be changed.  They're extremely limiting my options to strictly materials.  

Sorry for the long description.   If anyone has any kind of input at all it would be greatly appreciated.   Thank you in advance

Shane

RE: Flux Corrosion?

In any corrosion cell remove the electrolyte and you will take away the corrosion. Suggest you look at a less corrosive less acidic flux such as one of the rosin fluxes.  Talk to your solder metal supplier.

Good Luck

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