http://www.mahoodsculpture.com/wire-sculpture-for-children/
What types of metal wire can be soldered and what types of flux and solder do you need for each of them?
I am a metal artist and I am getting ready to teach a class to older children. My dilema is this: I weld most of my items and rarely have I soldered. It is inpractical for me to use or do welding while teaching this class; hence, I have decided to do wire sculpture with the students. We will of course explore this by primarily twisting, bending, and hammering the wire for desired effects and shapes, but, I would like to be able to connect certain structural areas in a more permanent way than twisting. I am familiar with soldering copper and brass wire, but the cost of these metals are currently very high; hence, I am attempting to explore other more affordable options. The hardware stores carry a variety of galvanized wire in several guages. I know that the zinc (galvy coating) is unsafe in terms welding, but is there a way to solder this wire, and is it safe?
Galvanized metal solders very easily, IF you flux with dilute muratic acid. Of course, you might not want to use this with kids. You could experiment with distilled vinegar and see if that’s strong enough to flux with. Soldering temps are too low to vaporize zinc, so at least that won’t be a problem.
I’ve used galv. wire (usually sold as electric fence wire) for these kind of projects before, and haven’t been happy with it. It’s very stiff, and hard to manipulate–and I was teaching college students. The wire I prefer is re-bar tie wire–about 18 g. It’s black, soft iron–a 5# roll costs about $4. I’m teaching a sculpture class in the fall and am having exactly the same questions as you–my plan is to have students braze the wire with propane or MAPP gas torches, but I’d prefer soldering. I still need to test the re-bar wire and see if there’s any way to solder it–if I come up with anything, I’ll add on to this answer, or add to comments if you’ve already picked a Best Answer.
Children’s Crafts: Clay Frogs : Clay Frogs: Using Wire to Attach Features