Exothermic Weld

FEATURES

The MOLECULAR BOND that eliminates connections by forming an electrically perfect bond unaffected by corrosion.

Connections are the weak point of all electrical circuits and especially earthing circuits subjected to ageing and corrosion. The capacity of an earthing circuit to protect the safety of personnel depends on the quality of the connections made.

APPLICATIONS

Onshore and Marine. Used on Cathodic Protection applications including pipelines, tanks and buried structures, bracelet anodes etch.

MAJOR USERS

Specified by leading oil, gas and water companies and consulting engineers.

THE EXOTHERMIC PROCESS

Makes it possible to produce copper/copper, copper/aluminium, copper/steel and aluminium/aluminium electrical molecular bonds with no external energy or heat source. The principle consists of bringing together a welding filler material and ignition agent in a suitable graphite mold. The weld metal composition depends upon the metals to be welded (copper oxide and aluminum for a copper/copper weld).

The reduction of copper oxide by aluminum produces molten copper and aluminum oxide slag at extremely high temperatures.

The shape of the mold, its dimensions, and the size of the weld metal, are all dependent on the items to be welded and their size.

THE BASIC PRINCIPLE

The welding material and starting powder are poured into the mold crucible. They are contained during the reaction, by means of a metal disc seat. When the reaction is complete, the molten metal is released and flows down the tap hole onto the items to be welded in the weld cavity.

STEP 1. Prepare conductor ends with a wire brush for welding. Place cable ends into open mold.

STEP 2. Close handles to lock mould halves together. Drop metal disk into crucible ensuring it is correctly seated, covering tap hole.

STEP 3. Deposit weld metal into crucible. Tap bottom of container to release starting material. Spread a little starting material on top of mold.

STEP 4. Close the cover and ignite with flint gun. Open the mold after 10 seconds, when metal has solidified.

WELDING MOULDS

A semi-permanent graphite mold is used for making most EXOTHERMIC connections.

The mold controls the direction and speed of the molten EXOTHEMIC weld metal flow and its final shape. The graphite used in a EXOTHERMIC mold is a high temperature type that lasts for an average of 50 or more EXOTHERMIC connections under normal usage.

Weld material

Exothermic Weld Metal is a mixture of copper oxide and aluminum, packaged by size in individual plastic bags.

• Starting metal and weld metal backed in separate bags.
• Starting metal and weld metal bags packed in carton boxes with the corresponding metal disks.
• Each weld uses one disk.

These materials are not explosive and not subject to spontaneous ignition.

TOOLS & ACCESSoRIES

A plastic tool box with flint Igniter, spare flints, Mold clean soft brush and scraper tools are available with each order.

CS1 HORIZONTAL STEEL SURFACE

• Horizontal concentric copper conductor to flat steel surface or top of horizontal pipe
• A test weld should be made to check the possibility of burn-through on thin sections or thin wall pipe.
• Concentric stranded copper cable listed.