Before Performing Exothermic Welding Operation, the following Accessories should be kept ready:

TOOLS REQUIRED FOR EXOTHERMIC WELDING PROCESS / EXOTHERMIC WELD ACCESSORIES


1) Graphite Mold

Graphite mold is made of high quality graphite suitable for high quality welding work and can be used for several times. The exothermic welding reaction takes place in a specially designed, semi‐permanent graphite mold. The mold is designed and manufactured with a specific weld cavity and it is in this cavity that the molten metal is allowed to flow to all sections of the required connection creating the permanent connection. The connection mold is designed to last for an average of 30 to 100 connections depending upon the amount of Powder used per Joint (More the Powder Consumption per Joint, less will be the Connection & vice versa) . This will also vary according to the care given the mold during use. We recommend not using Mold for more than 60 to 70 Connection because the Weld cavity Size increases after every joint, eventually making the Weld Cavity shape improper resulting in improper shape Joint.



2) Mold Handle Clamp (Universal)

These will fit 90% of all standard exothermic Molds especially for the Graphite Mold which consumes less than 250 grams Powder 
Normally we recommend one Handle for every three molds

 

3) Steel Metal Disk

Steel discs are very important. The disc acts timing device to allow the welding powder to heat to proper temperature, the disc away allowing the molten copper to a point where it would weld metal to enter the weld gravity before ignition. One Metal Disc is must for every shot.



4) Exothermic Welding Powder - Amiable-Weld Powder


Exothermic Weld Powder is the most reliable and consistently-performing weld metal available with us. Quality validation steps are taken for every lot we produce. Upon final acceptance, our weld metal is specially packaged in moisture-resistant plastic tubes with special closure caps. Then the cartridges and required metal discs are packaged in moisture-resistant boxes. All sizes of weld metal are available.
Standards Size Packing available are – 15 Grams, 25 Grams, 45 Grams, 65 Grams, 90 Grams, 115 Grams, 150 Grams, 200 Grams, 250 Grams
Our standard packing for welding powder is the following - Firstly welding powder is in the tube and starting powder / Ignite Powder is in tube at the bottom of welding powder as shown in diagram 1.2.

 

5) Ignite Powder (Starting Powder)

Ignite Powder also known as Starting Powder is required and is must. 
Pour little Starting Powder on the Mold followed by the Exothermic Weld powder and again pour little on the Top Side of Mold. Then, Ignite starting powder with a spark gun. This resulting exothermic reaction reduces the weld powder to molten copper alloy. The molten copper alloy melts the retaining disc and flows into the weld cavity. Ignite Powder of 5 grams is sufficient for this Process.

 

6) Hand Gloves


Gloves is required for safety purpose as the Exothermic Weld Powder melts at more than 1400 degree Celcius. 
One Hand Gloves Good for 250 Joints

 

7) Flint Gun


It is designed with the advantages of safety and convenience. It is used to ignite starting Powder in order to result in exothermic reaction
We recommend one Flint Gun for every 80 Shots

 

8) Brush (Soft and Hard)


We offer two type of Brushes:
1) Soft Brush – Its used to Clean Mold Weld Cavity because its shape is very sensitive and cavity should not be any damage while using Brush, so we recommend to use Soft Brush to Clean Mold Weld Cavity
2) Hard Brush – Its used to clean other section of Mold
We recommend a Pair of Brush for 50 Connection

 

9) Slag Removal Tool

It is used to remove the metal Metal Scrap and Dust from the Mold.
We recommend one Slag Tool for 250 Connection

 

10) File Card Brush

It is used to clean the objects to be welded to remove rust and dirt
We recommend one Slag Tool for 100 Connection

 

11) Sealing Compound

Sealing Compound is used to fill the gap on the mold where the conductor is passing.
We recommend one Packet of Sealing Compound for 100 Connection

 

12) Flame Torch

Sealing Compound is used to fill the gap on the mold where the conductor is passing.

We recommend one Flame Torch for 250 Joints

 

13) Safety Eye Glasses

Safety Eye Glass should be wear to protect eyes. 
We recommend one Glasses for 500 Joints


Exothermic Welding Operation / Exothermic Welding Process

The Exothermic Weld process is a method of making electrical connections of copper-to-copper or copper-to-steel in which no outside source of heat or power is required. In this process, conductors are prepared, placed in a purpose designed graphite mould, and exothermically welded to produce a permanent molecularly bonded electrical connection. The steps outlined below are a general demonstration of a typical welded connection. These basic steps are used for all electrical connections. Be sure to read and follow the instructions included with every Mould before making a connection.

 

STEP - 1:  

Always wear protective safety glasses and gloves while working with exothermic welding products.

 
STEP - 2:

Gather all the proper material and equipment/accessories for the type of connection you are making. The typical Weld system requires all the Accessories as listed on Exothermic Weld Accessories page. Check to ensure the graphite Mould is not worn or broken, which could cause leakage of molten weld metal.

 
STEP - 3:

Slide the handle clamp into the pre-drilled holes with the proper orientation for the thumbscrews.

 

STEP - 4:

Tighten the clamp thumbscrews onto the mould.

 

STEP - 5:

Close the grips to tightly lock the Mould. Make adjustments to tighten/loosen the handle clamp.


STEP - 6: 

The material to be welded (cable, rod, tape etc.) must be clean using the wire Brush and dry using the Flame Torch included in the set of accessories. Thus the oxide layer and superficial impurity is eliminated.  Given that the graphite mould also absorbs moisture, this should be removed by preheating with a gas welding torch again to avoid a porous welding. 
P.N - After the first welding is done, it is not necessary to re-heat the mould if the next welding is done within 15 minutes as it conserves the previously generated heat.

 


STEP - 7: 

Place the conductors in the mould and close the handle clamps to avoid material leakages during the reaction.


Please Note – Always apply Sealing Compound at the places where the conductors is passing from the mould else at the time of Welding, the Exothermic Liquid will spread out as a flame resulting in improper joint
 

STEP - 8:

Place the metallic disk inside the mould and ensure that Powder should not enter into Weld Cavity.

 
STEP - 9:

Pour Exothermic Weld Powder into Graphite Mould. (Pour the Powder recommended and supplied by us)
 

STEP - 10:  

Empty 50% of the starting powder above Exothermic Weld Powder (Don’t Mix, just scatter) and then Close the Mould Mouth and then the rest 50% Starting Powder, sprinkle it on the Mould Mouth nearby the small hole given on the top of the Mould Mouth.

 
STEP - 11:  

Ignite the starting powder extended on the top/side of the mould using the flint igniters.

STEP - 12:  

Once started, the reaction will take 8-20 seconds during which it is recommended to stand clear of the mould.

 
STEP - 13:  

After at least 3 minutes of the Mould cooling down, open the mold by undoing the handle grip. Remove the mould from the joint and clean the joint by removing slag with help of Slag Removal Tool and hard brush. Then clean the weld cavity with soft brush gently. The mould will be ready now to use again without having to reheat it as it is already warm.

 

 

Note:
In Normal case minimum two mold should be used on site to keep the process continue while one mold is cooled and cleaned after firing, the other should be used. The task should be undertaken very peacefully and one should not hurry.

 

OUR SUMMARY:
Reviewer Amiable Impex
Review Date 26-08-2016
Reviewed Item Exothermic Welding
Author Rating ★★★★★

  

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