Extruded Bar vs. Cast Bar Processes

Wave and selective solder “make-up bar” is available in several shapes: cast, extruded, anode, ingot, etc. Regardless of format, the purpose is the same—to replenish material removed from the solder pot during use. The alloy itself is identical across all bar types.

Is there any difference in alloy performance?

No. Both extruded and cast bars are made from the same alloy, from the same master pot, and meet the same technical specifications.

Is the shape different?

Yes. Extruded bars are more dimensionally consistent because they are formed through a die, whereas cast bars may show minor shape variations. This difference matters mainly for equipment that uses auto-feeders requiring precise bar dimensions.

Potential Limitation for Lead-Free Cast bar:

• Some Electrovert wave soldering machines have a lead-free bar solder option that requires the use of a triangular shaped bar. Our triangular shaped extruded bar fits this equipment. This design is to prevent tin-lead solder from being added into a wave solder machine running lead-free.

• This option is only on some Electrovert machines, and we have no knowledge of any other manufacturers with this requirement.

• If you plan to convert a customer from extruded bar to cast bar it is advised to inquire if the equipment they use has any limitations on the dimensions of the solder bar.