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Exothermic Weld Accessories Required for Exothermic Weld Process: 

1) Graphite Mould for having Exothermic Weld

Exothermic Weld Moulds


 We Manufactured Graphite Mould which ensure optimum results. Each Graphite Weld Mould is designed to give precise and reliable results. Amiable Impex used the finest quality of Weld Mould that can withstand continuous heat-cooling cycles. The connection mould is designed to last for an average of 60 to 100 connections. This will vary according to the care given the mould during use. 

 Features:
Dimensional accuracy as per the customers demand.
- High quality Graphite which ensures Longer Life.

Terms for use:
1. Graphite Mould is Designed to withstand high temperatures produced from the exothermic welding.
2. Graphite Mould requires preheating torch flame in order to ensure that the mould is totally dry before every first joint regardless new or used mould. If its not Heated than, the mould may crack or break or a bad joint produced or cuts down the life span of Graphite mould.
3. Always ensure that the conductors fits Tights and sections of moulds are clamped tightly with the handle clamp to avoid leakage of weld metal. Leakage will produced a bad joint and cuts down the life span of the mould. Use of Sealing Compound ensures no leakage of weld metal
4. After every joint produced, always remove the slag with a recommended mould scrapper, then brush off the smaller particles with a proper mould cleaning brush.
5. Caution : Do not use any other hard object and brush that would damage the mould.
6. Always keep the mould away from water or damn areas while it is hot. Otherwise, the mould may crack or break.
7. Do not over-heat the mould the throughout too many joints. Always either allow to rest or use a spare mould. Otherwise, the mould may crack or break or a bad joint produced or cuts down the life span of the mould


2) Mould Handle Clamp (Universal)

Exothermic Mould Handle ClmapHandle clamps provide a means of both handling the mold, and also of clamping the mold halves together. For most connections involving lugs, cable or rectangular bus, Exothermic handle clamps are used. These will fit 90% of all standard exothermic molds. Normally we recommend One Handle for every two moulds
These are manufactured by the professionals using high quality raw material. These Mold Handle Clamp conform their
adherence with the industry standards.
Features:
Light in weight (Nearly 1.5 to 2.5 Kg)     - Handy in nature     - Rust-proof

 

3) Steel Metal Disk 
Exothermic Metal Disc
Steel discs acts timing device to allow the welding powder to heat to proper temperature. Steel Disk is designed to contain the exothermic reaction to the upper crucible of a mold until the reaction is complete and ready to weld. One Metal is must for every shot 
Features:
- Depressed center      - Medium hard bond    - High speed rotation



4) Exothermic Weld Powder

Exothermic Weld Powder

We offer Exothermic Weld Powder that is the most reliable and consistently-performing weld metal. 
Quality validation steps are taken for every lot we produce. Upon final acceptance, our weld metal is specially packaged  in moisture-resistant plastic cartridges with special closure caps. Then the cartridges and required metal discs are packaged in moisture-resistant boxes.
Standards Size Packing available are – 15 Grams, 25 Grams, 45 Grams65 Grams, 90 Grams, 115 Grams, 150 Grams, 200 Grams, 250 Grams

Moisture Free Packing in Foil


Features:
High quality products at Affordable prices 
- High performance

 

5) Ignite Powder (Starting Powder)
 Exothermic Welding Ignite Powder or Starting PowderIgnite Powder
is  also known as Starting Powder. Sprinkle little Starting Powder on the Mold followed by the Exothermic Weld powder and again sprinkle it little on the Top Side of Mould. Than Ignite starting powder with a spark gun.This results in exothermic reaction and the weld powder melts to molten copper alloy. The molten copper alloy melts the retaining disc and flows into the weld cavity where it partially melts the conductors. 
Ignite Powder of 2-4 grams is sufficient for this Process.

Features:High quality Ignite Powder with Fast Ignition ability.

6) Hand Gloves

Gloves is required for safety purpose as the Exothermic Weld Powder melts at more than 1400 degree Celsius.

We recommend a Pair of Gloves for Every 150 to 200 Joints
Features:
High quality Gloves that can easily bear heat up to 400 degree Celsius which is more than enough to Hold the Mould.


7) Flint Gun

Flint Gun for Exothermic Welding

Flint Gun 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 to 100 Shots
 


8) Brush (Soft and Hard)

Cleaning Brush for Exothermic WeldingTwo Brush is Required:
1) Soft Brush – Clean Mould Weld Cavity because its shape is very sensitive and there should not be any damage while using Brush, so we recommend to use Soft Brush 

2) Hard Brush – Its used to clean other section of Mould
We recommend a Pair of Brush for 50 Connection
 

9) Slag Removal Tool


It is used to remove the metal Scrap from Mould after the Welding Process is done.
We recommend One Slag Tool for Every 200 Joints

 

10) File Card
File Card Brush for Exothermic Welding
It is used to clean the objects to be welded.
We recommend One Slag Tool for Every 100 Joints
 


11) Sealing Compound
Sealing Compound  for Exothermic WeldingSealing Compound
is used to fill the gap on the mould where the conductor is passing
We recommend 1 Kg Sealing Compound for Every 100 Joints


12) Flame Torch
Graphite absorbs moisture from weather. So there is a need for propane torch to dry out the inside of the mould thoroughly on both sides,
therefore heating the mold to approximately 250 degrees Fahrenheit

We recommend using one Flame torch for Every 200 Joint and than use the refiling

 

  

Product Features For Exothermic Weld : 

  • Safe operation, without professional technology knowledge or any other  special protection, easy to learn.
  • Without external energy, very simple tools and equipment, execution of high efficiency.
  • Connector in copper of high purity, strong corrosion resistance.
  • The connector to be formed in metal bonds, not loose.
  • Current carrying capacity of the connector  is greater than that of wire connector.
  • Widely applied , can be used for copper to copper, copper to steel, welding between copper and galvanized steel and other metal materials.
  • Connectors can withstand multiple large inrush current impact without degradation.

     

Download here for free catalogue

  Exothermic Weld Accessories - Amiable Impex

  Thermit Weld Accessories - Amiable Impex®

  Thermite Weld Accessories - AIWELD® 

 

EXOTHERMIC WELD PROCESS

Exothermic Welding Process

The process of Exothermic Weld 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, a special weld 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 1400 degree celsius, and produces a molten metal slag. This liquid copper metal flows into the weld cavity, filling any available space and completes the weld. The weld is then allowed to cool and solidify before it is removed from the mold. The mold is ready for the next weld after a brief cleaning with a brush. This entire process takes only seconds to complete.

Exothermic Welded connections produce a permanent connection, superior in performance to any known mechanical or pressure type surface-to-surface contact connector. Because the connection produced is a molecular bond, an exothermic welded connection will not loosen or increase in resistance over the lifetime of the installation.

 

The Exothermic Weld Process is a simple, efficient method or welding Copper to Copper of Copper to Steel. One advantage is that No outside power is required when using the Exothermic Weld Process. The exothermic process uses high temperature reaction of powdered copper oxide and aluminium. The reaction takes place in a semi-permanent graphite mold. These molds should last approximately forty or more welds if proper care is given. The reaction takes place very rapidly; threfore the total amount of heat applied to the conductors or surfaces is considerably less than that of brazing or soldering. This is important to remember when welding to insulated cable thin wall pipe.

 

This system is very field friendly, since its is light and portable and requires no outside power source. It requires very little time or skill to obtain an efficient, maintenance free connection when using this Exothermic Weld Process. 

FEATURES

  • It has a superior electrical conductivity than the conductors themselves.
  • It does not corrode oxide or degrade with time and is resistant to galvanic coupling.
  • It is able to withstand repeated electrical discharges.
  • It never increases its resistance.
  • It has higher mechanical and squeezing resistance than the conductors themselves.
  • It  offers  a  permanent  welding  and  a  low  resistance   connection,   essential  for  achieving longwearing and trustworthy  results in earthings
  • 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.

     

Process for Exothermic Weld is as follows:

STEP - 1:  
Always wear protective safety glasses and gloves while working with exothermic weld 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 thumbscrews.


STEP - 4:  
Tighten the clamp thumbscrews 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 preheating 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 igniters.


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


STEP - 13:  Exothermic WeldingAfter at least 2 minutes of the bonding, open the mould by undoing the handle grip. Remove the mould from the
joint and clean the joint for any slag. Once open, clean the slag sticking to the mould with the relevant tool and
clean the cavities. 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 moulds should be used on site to keep the process continue while one mould is cooled and cleaned after firing, the other should be used. The task should be undertaken very peacefully and one should not hurry.



GENERAL & SAFETY INSTRUCTIONS:

A. Only equipment and materials should be used to make connections.

B. Do not connect items except as detailed in instruction sheets. Failure to comply with these instructions may result in improper and unsafe connections, 
    damage to items being welded or even injury to body or property damage.

C. Do not use worn or broken equipment which could cause leakage. Sealing compound should be used in case of fine leakages.

D. When using Weld do not use welding material package if damaged or not fully intact.  

E. Make connections in conformance with instructions and all governing codes.

F.  Personnel should be properly trained and must wear safety glasses and  gloves.

G. Avoid contact with hot materials.

H. Advise nearby personnel to stand at least 7 to 10 Foot away of welding operations site.

I. Remove or protect the inflammable material from the operation site to safeguard against fire hazards.

J. Provide adequate ventilation to the work area.

K. Do not smoke when handling starting material.

L. Avoid direct eye contact with “flash” of light from ignition of starting material.

F. Welding material is an exothermic mixture and reacts to produce hot molten material with temperatures in excess of 1400°C (2500°F) and a localized release
   of smoke. Ignition temperatures are in excess of  900°C (1650°F) for welding material. These materials are not explosive.

G. Adhering to the welding procedures will minimize risk of burns and fire caused by hot molten material spillage. In case of fire, use of water or CO2 will aid in control of burning containers. Large quantities of water will aid in controlling a fire should the exothermic materials become involved. Water should be applied from a distance.

H. All governing codes and regulations and those required by the job site must be observed. Always use appropriate safety equipment such as eye protection, hard hat, and gloves as appropriate to the application.

 WARNING :

1.  Products shall be installed and used only as indicated in product instruction sheets.
2.  Products must never be used for a purpose other than the purpose for which they were designed or in a manner that exceeds specified load ratings.
3.  All instructions must be completely followed to ensure proper and safe installation and performance.
4.  Improper installation, misuse, misapplication or other failure to comply with instructions and warnings may cause bad weld joint, property damage or even serious badly injuries.

Advantages and Disadvantages of Exothermic Welding : 

Compared for some other forms of weldingexothermic bonds employ a greater mechanical toughness. The weld can be proof against corrosion. You simply won't notice an increase in electrical excess weight despite repeated small signal pulses; your weld is highly firm. The procedure is more costly, however. The task requires replaceable moulds, is not easily repeatable, which enable it to be impeded by means of poor weather conditions if the work is done out of doors.  

Exothermic welding may also be done far from others. That reduces dangers to employees. A igniter is used with widespread graphite molds or a palatable made drop within weld metal ink cartridge, semi-permanent graphite crucible pattern, and an ignition company that connects your container with a cord.  

MAINTENANCE & STORAGE INSTRUCTIONS:

1.  Mould is usually good for 50 - 60 connections in field conditions.
2.  The equipment is fragile and should be handled carefully while in use.
3.  Cleaning of moulds should be done using appropriate brush / tool after the mould is reasonably cool after a weld process. Avoid hot mould cleaning.
4.  Cavity cleaning should be carefully done to avoid damages / chipping.
5.  On completion of task, mould should be well cleaned from inside and from outside using soft cloth. It should be properly wrapped in Bubble Plastic Packing while storing it.
6.  The moulds and the weld powder should always be stored in cool & dry places.
7.  All tools and accessories must be cleaned before storing to safe reuse.

 Download here for free catalogue

  Exothermic Weld Process - Amiable Impex

  Thermit Weld Process - Amiable Impex®

  Thermite Weld Process - AIWELD® 

 Amiable Impex is the only Company that offer Quality of Exothermic Weld Powder and Exothermic Weld Accessories at reasonable rate and ensures delivery within 10 to 15 days in India. Get high quality of Our products at quickest lead time with fast response time. Our Products are tested and approved by CPRI Govt Body, Its also CE and ROHS Certified and we are also certified by ISO 9001:2008, Crisil verified Company.

We are one of the renowned companies specializes in Exothermic Weld Powder  & AccessoriesWe also undertakes Job Work Projects in India

For any questions or quote please feel free to contact us at  This email address is being protected from spambots. You need JavaScript enabled to view it.  or Call us at +91-22-28933996 / +91-9594899995

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

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Amiable Impex sells in India at Ahmedabad, Pune, Delhi, Mumbai, Bangalore, Chennai, Kolkata, Surat, Pune, Lucknow, Kanpur, Nagpur, Indore, Bhopal, Vadodara(Baroda).

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