Exothermic Welding

Exothermic welding is a simple, cost-effective and permanent welded connection that uses a high-temperature exothermic reaction to create a molecular bond. It does not require an external heat or power source. Exothermic welding is the universally preferred method for making permanent copper-to-copper and copper-to-steel electrical connections. Its performance is superior to all existing surface-to-surface mechanical connectors.

Exothermic Weld Process :

Exothermic welding, also known as exothermic bonding, thermite  welding (TW), and thermite welding, is a welding process that employs molten metal to permanently join the conductors. The process employs an exothermic reaction of a termite composition to heat the metal, and requires no external source of heat or current.

Exothermic welding, also known as exothermic bonding, thermite welding (TW), and thermit welding, is a welding process that employs molten metal to permanently join the conductors. The process employs an exothermic reaction of a thermite composition to heat the metal, and requires no external source of heat or current.

How Exothermic Welding Works ?

The Exothermic weld System is a welding process that utilizes an exothermic reaction (a chemical reaction that releases energy in the form of very high temperatures and light) to permanently joins metal connections.

Exothermic Weld Process:In this process, a special Welding material is placed into a high temperature resistant mold and ignited. The process of igniting the particles creates extremely high heat and molten metal (exothermic reaction) up to 2000 degree celcious, and produces a molten metal slag.

Exothermic Welding powder is also known as exothermic bonding, Termite Welding, and Termite Welding. There are many advantages of using Exothermic Welding powder. The most important one is that the process produces a molecular joint and not just a mechanical one in between the conductors. It is produced through a starting reactant which provides enough energy to activate the Welding reaction. This takes place quickly and safely inside a graphite mold.

An Exothermic welding has higher mechanical strength than other forms of welding and excellent corrosion resistance. It is also highly stable when subject to repeated short-circuit pulses, and does not suffer from increased electrical resistance over the lifetime of the installation. However, the process is costly relative to another welding process, requires a supply of replaceable Graphite molds, suffers from a lack of repeatability, and can be impeded by wet conditions or bad weather (when performed outdoors).

Exothermic welding is a simple, cost-effective and permanent welded connection that uses a high-temperature exothermic reaction to create a molecular bond. It does not require an external heat or power source. Exothermic welding is the universally preferred method for making permanent copper-to-copper and copper-to-steel electrical connections. Its performance is superior to all existing surface-to-surface mechanical connectors. Exothermic welding works when others won’t!.

Exothermic welding is usually used for Exothermic Welding copper conductors but is suitable for Exothermic welding a wide range of metals, including stainless steel, cast iron, common steel, brass, bronze, and Monel. It is especially useful for joining dissimilar metals. The process is marketed under a variety of names such as AmiableWeld®.

Learn how Exothermic Welding is done in below Video:

Animate Video: https://youtu.be/OstTLvjaJcs

Process of Exothermic Welding

Tools Required For Exothermic Weld Process

Exothermic Welding Process is as follows:

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 a graphite mold, handle clamp, welding material, natural bristle brush for mold cleaning, wire brush for cleaning/preparing conductors, flint igniter, and propane torch. Check to ensure the graphite mold 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 thumb screws.

STEP  4: Tighten the clamp thumbs crews onto the mould.

STEP  5: Close the grips to tightly lock the mold. Make adjustments to tighten/loosen the handle clamp.

STEP  6: The material to be welded (cable, rod, tape) must be clean and dry using the brush 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 pre-heating with a gas welding torch to avoid a porous welding. 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  If there is even a minor gap between the two Conductors, apply Sealing Compound at the places where the conductors is passing out else at the time of Welding, the Powder will spread out as a flame resulting in improper joint.

STEP 8: Obstruct the tap hole with the metallic disk.

STEP  9: Empty the contents of the welding mixture package.

STEP 10: Empty 50% of the starting powder above Exothermic Weld Powder (Don’t Mix, just scatter) and than Close the Mould Mouth and than 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 Igniter.

STEP 12: Once started, the reaction will take 3-4 seconds during which it is recommended to stand clear of the mould.

Exothermic Welding is used to Joint Copper to Copper or Copper to Steel where conductivity plays a very important role.Exothermic Welding ia also known as CADWELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD, BURNDYWELD.

Learn how Exothermic Welding is done in below Video

When Exothermic Cad Welding is require ?

When there is an improper connections between conductors which are often the reason for electrical malfunctions. A proper connection should have the following characteristics:

1.   Capacity to withstand overload conditions without melting, burning or failing.

2.   Sustain electrical continuity and contact reliability.

3.   Connector temperature should remain lower than that of the conductor when conducting electrical current.

4.   Extensive service life. Will not deteriorate, corrode or decay over time, above or below-grade.

Only exothermic Cad weld connections meet or exceed all of the above criteria. Exothermic weld is recommended by IEEE and IEC. It has been shown to be the best choice where safety, reliability, longevity and current carrying capacity are critical. 

Exothermic Cad  weld specifically supersedes its competition with its hermetically sealed metallized pouch which provides the product with an extensive shelf life and easy portability. 

An Exothermic Weld has higher mechanical strength than other forms of weld, and excellent corrosion resistance.

Lets Understand The Exothermic Welding Manufacturing Process

Exothermic welding manufacturing

Method for connection to electrical conductors that employ super heated copper alloy to permanent joint the conductors. The method employs associate degree reaction of a copper thermite composition to heat the copper and needs no external supply of warmth or current. The chemical process that produces the warmth is associate degree aluminothermic reaction between atomic number 13 powder and a metal chemical compound.

Exothermic Welding Process is as follows:

Follow the given Steps to do Exothermic Welding :

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 a graphite mold, handle clamp, welding material, natural bristle brush for mold cleaning, wire brush for cleaning/preparing conductors, flint igniter, and propane torch. Check to ensure the graphite mold 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 thumb screws.

STEP  4: Tighten the clamp thumbs crews onto the mould.

STEP 5: Close the grips to tightly lock the mold. Make adjustments to tighten/loosen the handle clamp.

STEP 6: The material to be welded (cable, rod, tape) must be clean and dry using the brush 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 pre-heating with a gas welding torch to avoid a porous welding. 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 ? If there is even a minor gap between the two Conductors, apply Sealing Compound at the places where the conductors is passing out else at the time of Welding, the Powder will spread out as a flame resulting in improper joint.

STEP 8: Obstruct the tap hole with the metallic disk.

STEP  9: Empty the contents of the welding mixture package.

STEP 10: Empty 50% of the starting powder above Exothermic Weld Powder (Don’t Mix, just scatter) and than Close the Mould Mouth and than 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 Igniter.

STEP 12: Once started, the reaction will take 3-4 seconds during which it is recommended to stand clear of the mould.

What is Exothermic Weld?

Exothermic Welding is used to Joint Copper to Copper or Copper to Steel where conductivity act a very essential role. Exothermic weld is a effortless, profitable and durable welding connection that adopt a high-temperature exothermic reaction to invent a molecular bond. It does not need an external heat or power source. 

Exothermic welding is the universally approved method for manufacturing enduring copper-to-copper and copper-to-steel electrical connections. 

Watch Video for more information:

Advantages of using Exothermic Welding:

It guarantees the most common connections not only between copper cables but also for Welding tapes and metallic pieces made of brass, stainless steel, and copper coated steel earth rods. Current carrying (fusing) capacity equal to or greater than the conductor.

It offers a permanent Welding and a low resistance connection, essential for achieving long wearing and trustworthy results in earthing.