Exothermic Weld System is a very effective and cost efficient method of making electrical connections in high quality which includes Large Connection or Small Connection. It is a simple self-contained system that uses the high temperature reaction of powdered copper oxide, aluminium and other required chemical and materials, within a mould to form permanent electrical connections.
The process of exothermic Weld is a method of making electrical connections from Copper to Copper or Copper to Steel and it can join any Metals to Metals like Bronze, Galvanized metals and Stainless steel etc , in which no outside source of heat or power is required.
In Exothermic Weld Process, the following are the steps -
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Step 1 - The two conductors that is to be joined are placed in the Weld cavity and than the steel disc is located in the base of the crucible in the Graphite Mould.
Step 2 - After the disc is placed in the Mould, Exothermic Weld Powder Material is poured down into Graphite Mould followed by Starting Powder
Step 3 - Some Ignite Powder should also be sparkled on the Mouth of Mould and than ignited by Flint Gun.
The process of igniting the particles creates extremely high heat i.e upto 1400 degree Celcius and produces Exothermic Reaction which also melts the Steel Disc and then the Exothermic Weld Powder flows into the Weld cavity thus filling any available space and completes the Weld. In Weld cavity the molten copper alloy partially melts the conductors. The molten copper alloy gets cooled and forms a fusion Weld which solidify before it is removed from the mould.
This entire process takes only upto 10 to 15 seconds to complete. Then the mould is ready for the next Weld after a brief cleaning with a brush. Exothermic Welded connections produce a permanent connection, superior in performance to any known mechanical or pressure type surface-to-surface contact connector. Due to the fact that the connection produced is a molecular bond so an exothermic Welded connection will not loosen and there will be increase in resistance over the lifetime of the installation.
The Process is very Simple and hence a Laymen can do the Job Work by just seeing the process once. Hence one need to ensure that the process should be undertaken carefully and proper instruction should be maintained by the Laymen.
exothermic weld is a process that achieves the molecular binding among two or more metallic conductors by a chemical reaction. This molecular binding improves mechanical, electrical and anti-corrosion properties compared with any mechanical connection. exothermic weld is the best way to make permanent, reliable and high conductivity connections for any installation requiring an earthing system.
here are many advantages of using Exothermic Weld. The most important one being 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 mould. The mould is designed specifically for a certain union depending on the elements to be welded and the joint type required. We guarantees all types of joints, not only copper cable unions but also to weld tapes, brass metallic pieces, stainless steel, steel ground rods covered with copper, etc. It is especially useful for joining dissimilar metals.
The Exothermic weld Connecting created a permanent, homogeneous, and molecular bond that cannot loosen or corrode, and will carry more current that the conductor.
The Exothermic Weld Connection are solid molecular bonds, they do not loosen or corrode over the lifetime of connection. The ame cannot be said about other methods; such as brazing, crimp, split bolt, or compreion type connections.
Compared for some other forms of welding, exothermic 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.
Exothermic weld 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.
Exothermic weld is usually used for welding copper conductors but is suitable for 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.
Because of the good electrical conductivity and high stability in the face of short-circuit pulses, exothermic welds are one of the options specified by the grounding conductors and bonding jumpers. It is the preferred method of bonding, and indeed it is the only acceptable means of bonding copper to galvanized cable. The NEC does not require such exothermically welded connections to be listed or labelled, but some engineering specifications require that completed exothermic welds be examined using X-ray equipment.
An exothermic weld has higher mechanical strength than other forms of weld, 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 otherwelding processes, requires a supply of replaceable moulds, suffers from a lack of repeatability, and can be impeded by wet conditions or bad weather.
Amiable Impex was founded with the goal of being at the forefront in the Electrical Metal Industry in both India and overseas. Since our foundation, the company has grown through continuous development.
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