HOW TO DO EXOTHERMIC WELDING - AMIABLE VIDEO


Exothermic Welding ?

Exothermic Welding is a simple, cost-effective and permanent Welding 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 Powder and Graphite Mould is also known as with different brand names such as AMIABLEWELD, CAD WELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, CADWELD, TECTOWELD, BURNDY WELD etc.



Exothermic Welding

Our AmiableWeld Exothermic Welding is ISO Certified company - ISO 9001:2008, ISO 14001, ISO 18001. Our Products is also compliance with CE and ROHS and meet all the standard of IEEE.

ACCESSORIES REQUIRE FOR EXOTHERMIC WELDING ?

Graphite Mould for having Exothermic Welding

At the point when making a copper wire connection of Ground bar or other metal connection, put the Welding Powder into the Graphite Mould. Simply ignite to begin the Welding procedure. The outcome will be spotless and smooth connection surface. It is likewise pertinent for other metal, for example, Iron, Galvanized Steel, Railway track, Cast Iron, Bronze, and Brass. It can be utilized as a part of different applications to have the absolutely great connections in work. For example, Lightning and Surge Protection, Grounding in Electrical Work, Railway Construction, Cathodic Protection.

The connection mold is intended to keep going for a normal average of 60 to 100 connections. This will vary as indicated by the consideration given the mold during use. Graphite mold is made of brilliant graphite appropriate for top notch Welding work and can be utilized for a few times.

Exothermic Weld Mould

Features:

  • Dimensional accuracy as per the customers demand.
  • High quality Graphite which ensures Longer Life.

Mould Handle Clamp (Universal)

Connections which includes lugs, cable or rectangular bus, Exothermic Handle Clamps are utilized. These will fit 90% of all standard Exothermic Moulds. Typically we prescribe One Handle for each two molds. These are produced by the experts utilizing fantastic raw material. These Mould Handle Clamp confirm their adherence with the business standards.


Mould Handle

Features:
  • Light in weight (Nearly 1.5 to 2.0 Kg)
  • Handy in nature
  • Rust-proof
  • Tare used for two part molds
Steel Metal Disk

Steel disc are vital. The disc demonstrations timing gadget to permit the Welding powder to warmth to appropriate temperature. Steel Disk is intended to contain the exothermic reaction to the upper crucible of a mold until the reaction is finished and prepared to Welding. One Metal is must for each shot.


Steel Metal Disc

Features:
  • Depressed center
  • Medium hard bond
  • High speed rotation
Exothermic Welding Powder

Exothermic Welding Powder is the most solid and reliably performing Welding metal accessible with us. Quality acceptance steps are taken for each lot we deliver. Upon conclusive acknowledgment, our Welding metal is exceptionally bundled in dampness safe plastic cartridges with unique closure caps. At that point the cartridges and required metal plates are bundled in dampness safe boxes.
Our Standard Packing for Welding powder is the following : -
Firstly Welding powder is in the tube and beginning powder/Ignite Powder is in tube at the base of Welding Powder as appeared in chart .

Moisture Free Packing in Foil All sizes of Welding metal are accessible.
Principles Size Packing accessible are – 50 Grams, 100 Grams, 125 Grams, 150 Grams, 200 Grams, 250 Grams, 1 Kilogram


Exothermic Weld Powder

Features:
  • High quality products at Affordable prices
  • High performance

Ignite Powder (Starting Powder)

Ignite Powder is otherwise called Starting Powder and is required and is must. Sprinkle lettle Starting Powder on the Mould followed by the Exothermic Welding Powder and again sprinkle it little on the Top Side of Mould. Than Ignite beginning powder with a sparkle weapon.

This outcomes in exothermic reaction and the Welding powder melts to liquid copper alloy. The liquid copper alloy liquefies the retaining disc and streams into the Welding cavity where it is in part liquifies the conductors. Ignite Powder of 2-4 grams is adequate for this Process.


Ignite Starting Powder

Features:
  • High quality Ignite Powder with Fast Ignition ability.

Gloves

Gloves are required for safety purpose as the Exothermic Welding Powder melts at more than 1400 degree Celcius.
We recommend a Pair of Gloves for Every 150 Joints

Welding Hand Gloves

Features:
  • High quality Gloves that can easily bear heat upto 400 degree Celcius which is more than enough to Hold the Mould.
Flint Gun

It is planned with the benefits of wellbeing, safety and comfort. It is utilized to ignite Starting Powder so as to result in Exothermic Reaction. We suggest one Flint Gun for each 100 Shots


Flint Gun

Brush (Soft and Hard)
Two Brush Required:Exothermic Welding Brush

  • Soft Brush – Its used to Clean Mould Welding Cavity because its shape is very sensitive and there should not be any damage while using Brush, so we recommend to use Soft
  • Hard Brush – Its used to clean other section of Mould
    We recommend a Pair of Brush for 50 Connection
Brush

Slag Removal Tool

It is utilized to expel the Metal Scrap from Mould after the Welding Process is finished.
We suggest One Slag Tool for Every 200 Joints.

File Card

It is used to clean the objects to be Weldinged.
We recommend One Slag Tool for Every 100 Joints

Sealing Compound

Sealing 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

Sealing Compound

Flame Torch

Graphite absorbs moisture from climate. So there is a requirement for propane torch to dry out within the mold altogether on both sides, in this way warming the mold to roughly 250 degrees Fahrenheit
We suggest utilizing one Flame Torch for Every 200 Joint and than utilize the refiling


Flame Torch

Exothermic Weld is also sold in the market in different names such as AMIABLEWELD, CADWELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, CADWELDING, TECTOWELD, BURNDY WELD etc.

Exothermic Weld Process :

The Process of Exothermic Welding is a strategy for making electrical connections of copper to copper or copper to steel in which no outside wellspring of warmth or force is required. In this procedure, a unique weld material is put into a high temperature resistant mold and ignited. The way toward igniting the particles makes greatly high warmth and liquid metal (exothermic response) up to 1400 degree celsius, and produces a liquid metal slag. This fluid copper metal streams into the weld cavity, filling any accessible space and completes the weld. The weld is then permitted to cool and set & solidify before it is expelled from the mold. The mold is prepared for the following weld after a brief cleaning with a brush. This whole procedure takes just seconds to finish.

Exothermic Welding Process

Exothermic Welding connections create a changeless connections, better in execution than any known mechanical or weight sort surface-to-surface contact connector. Since the connections delivered is an atomic bond, an exothermic welded association won't release or increment in resistance over the lifetime of the establishment.

Exothermic welding is also exported worldwide with Brand names such as AMIABLEWELD, CAD WELDING, EXO WELDING, FURSE WELDING, THERMO WELDING, KUMWELLING, TECTO WELDING & BURNDY WELDING.

Features of Exothermic Welding:
  • 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.

Exothermic weld system from AmiableWeld provides precision engineered molds for optimal results which gives about 30 to 100 Joints from one Graphite Mould. Features include simplicity, corrosion resistance, extended shelf life, high conductivity, portability, ease of use, and it requires no external heat or power source.

Exothermic welding is also supplied worldwide with Brand names such as AMIABLEWELD, CADWELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD & BURNDYWELD.

Process for Exothermic Process

  • Step 1 :- Always wear protective safety glasses and gloves while working with exothermic welding products.Exothermic Welding Process
  • 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.Exothermic Welding Accesories
  • Step 3 :- Slide the handle clamp into the pre-drilled holes with the proper orientation for the thumbscrews.Exothermic Welding Process
  • Step 4 :- Tighten the clamp thumbscrews onto the mould.Exothermic Welding Process
  • Step 5 :- Close the grips to tightly lock the mold. Make adjustments to tighten/loosen the handle clamp.Exothermic Welding Process
  • 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.Exothermic Welding Process
  • 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 jointExothermic Welding Process
  • Step 8 :- Obstruct the tap hole with the metallic disk. Exothermic Welding Process
  • Step 9 :- Empty the contents of the welding mixture package.Exothermic Welding Process
  • 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.Exothermic Welding Process
  • Step 11 :- Ignite the starting powder extended on the top/side of the mould using the flint igniters.Exothermic Welding Process
  • Step 12 :- Once started, the reaction will take 3-4 seconds during which it is recommended to stand clear of the mould.Exothermic Welding Process
  • Step 13 :- After 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.Exothermic Welding Process

General & Safety Instructions

  • Just hardware and materials ought to be utilized to make connections.
  • Try not to connect things with the exception of as itemized in instruction sheets. Inability to agree to these directions may bring about dishonorable and hazardous connections, harm to things being welded or even harm to body or property harm.
  • Try not to utilize worn or broken gear which could bring about spillage. Fixing compound ought to be utilized as a part of instance of fine spillages.
  • At the point when utilizing Weld don't utilize welding material bundle if harmed or not completely in place.
  • Make connections in conformance with guidelines and every single administering code.
  • Work force ought to be legitimately prepared and should wear wellbeing glasses and gloves.
  • Maintain a strategic distance from contact with hot materials.
  • Encourage close-by faculty to remain no less than 7 to 10 Foot away of welding operations site.
  • Evacuate or shield the inflammable material from the operation site to defend against flame dangers.
  • Give sufficient ventilation to the work region.
  • Try not to smoke when taking care of beginning material.
  • Evade direct eye contact with "glimmer" of light from ignition of beginning material.
  • Welding material is an exothermic blend and responds to deliver hot liquid material with temperatures in abundance of 1400°C (2500°F) and a restricted arrival of smoke. Ignition temperatures are in abundance of 900°C (1650°F) for welding material. These materials are not unstable.
  • Holding fast to the welding strategies will minimize danger of smolders and fire brought on by hot liquid material spillage. If there should arise an occurrence of flame, utilization of water or CO2 will help in control of smoldering compartments. Vast amounts of water will help in controlling a flame ought to the exothermic materials get to be included. Water ought to be connected from a separation.
  • Every single overseeing code and controls and those required by the occupation site must be watched. Continuously utilize suitable security gear, for example, eye insurance, hard cap, and gloves as fitting to the application.

Advantages and Disadvantages of Exothermic Welding :

Thought about for some different types of welding, exothermic bonds utilize a more prominent mechanical durability. The weld can be confirmation against consumption. You essentially won't see an expansion in electrical abundance weight regardless of rehashed little flag beats; your weld is exceptionally firm. The system is all the more expensive, be that as it may. The assignment requires replaceable molds, is not effectively repeatable, which empower it to be obstructed by method for poor climate conditions if the work is done out of doors.

Exothermic Welding may likewise be done a long way from others. That decreases dangrs to workers. An igniter is utilized with boundless graphite molds or a satisfactory made drop inside weld metal ink cartridge, semi-permanent graphite cauldron design, and an ignition organization that connects your holder with a rope.

Warnings

  • Products might be introduced and utilized just as demonstrated as a part of Product guideline sheets.
  • Products should never be utilized for a reason other than the reason for which they were composed or in a way that surpasses determined burden appraisals.
  • All directions must be totally taken after to guarantee legitimate and safe establishment and execution.
  • Improper establishment, abuse, misapplication or other inability to consent to directions and notices may bring about awful weld joint, property harm or even genuine gravely wounds.

Exothermic Weld is welL known in overseas market with different names as AMIABLEWELD, CAD WELDING, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, CADWELD, TECTOWELD, BURNDY WELD etc.

Different Types of Joints :


These types of Joints are also offered in the market with Brand names such as AMIABLEWELD, CADWELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD & BURNDYWELD.

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

We also serves at: Andhra Pradesh - Hyderabad , Arunachal Pradesh - Itanagar, Assam - Dispur, Bihar - Patna , Chattisgadh - Raipur , Goa - Panaji ,Gujarat - Ahemdabad , Haryana - Chandigarh , Himachal Pradesh - Shimla , Srinagar, Jarkhand - Ranchi , Karnataka, Kerala - Thiruvanthapuram , Madhya Pradesh - Bhopal , Maharashtra - Mumbai , Manipur - Imphal , Meghalaya - Shillong , Mizoram - Aizwal , Nagaland - Kohima , Orissa - Bhubhaneshwar , Punjab - Chandigarh , Rajasthan - Jaipur , Sikkim - Gantok , Tamil Nadu - Chennai , Uttar Pradesh - Lucknow , Uttaranchal - Dehradun , West Bengal - Kolkata.

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Exothermic Welding
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Afghanistan, Algeria, Angola, Argentina, Australia, Austria, Azerbaijan, Bahrain, Bangladesh, Belarus, Belgium, Bolivia, Bosnia And Herzegovina, Brazil, Brunei, Bulgaria, Cambodia, Canada, Chile, Colombia, Costa Rica, Croatia, Cuba, Czech Republic, Denmark, Dominican Republic, Ecuador, Egypt, Ethiopia, Finland, France, Georgia, Germany, Ghana, Greece, Guatemala, Hong Kong, Hungary, India, Indonesia, Iran, Iraq, Ireland, Israel, Italy, Jordan, Kazakhstan, Kenya, Kuwait, Lebanon, Lithuania, Malaysia, Mexico, Morocco, Namibia, Nepal, Netherlands, New Zealand, Niger, Nigeria, Norway, Oman, Pakistan, Paraguay, Peru, Philippines, Poland, Portugal, Qatar, Russia, Republic Of The Congo, Romania, Saudi Arabia, Senegal, Singapore, Slovakia, South Africa, South Korea, Spain, Sri Lanka, Sudan, Sweden, Switzerland, Syria, Taiwan, Tanzania, Tunisia, Turkey, Uganda, Ukraine, United Arab Emirates, United Kingdom, United States, Uruguay, Uzbekistan, Venezuela, Vietnam, Yemen, Zambia & Zimbabwe.