How to use Exothermic Welding Kit ?

1 – Graphite Mould for Exothermic Weld

1.) 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. Graphite Mould is made of high quality graphite suitable for high quality Weld work and can be used for several times.
2.) Designed to withstand high temperatures produced from the exothermic weld.
3.) Requires pre-heating with a butane torch to ensure the Graphite mould is totally dry before every first joint regardless new or used Graphite mould. Otherwise, the mould may crack or break or a bad joint Produced or cuts down the life span of the mould.
4.) Always ensure that the conductors fits snugly and sections of Graphite mould 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 Graphite mould.
5.) After every joint produced, always remove the slag with a recommended Graphite mould scrapper, then brush off the smaller particles with a proper mould cleaning brush.
6.) Caution : Do not use any other hard object and brush that would damage the Graphite mould
7.) Always keep the mould away from water or damn areas while it is hot. Otherwise, the Graphite mould may crack or break.
8.) 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 Graphite mould.

2 – Mould Handle Clamp (Universal)

Handle 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.

3) Steel Metal Disk

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

4) 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 Grams, 65 Grams, 90 Grams, 115 Grams, 150 Grams, 200 Grams, 250 Grams

5) Ignite Powder (Starting Powder)

Ignite Powder is also known as Starting Powder. Sprinkle little Starting Powder on the Mold followed by the Exothermic Weld powderand 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.

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.

7) Flint Gun

Flint Gun is designed with the advantages of safety and convenience. It is used to ignite Starting Powder in orderto result in exothermic reaction.
We recommend one Flint Gun for every 80 to 100 Shots.

8) Brush (Soft and Hard)

Two Brush is Required: – 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
– Hard Brush – Its used to clean other section of Mould

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

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

11) 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.

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.