TM
AXI-WELD
EXOTHERMIC
WELDING
CONTENTS
1.
2.
3.
4.
5.
INTRODUCTION
BASIC INSTALLATION
EXOTHERMIC PROCESS
POWDER AVAILABLE
SPECIALIZATION
2
3-4
5-6
7
8
6. WELDING JOINTS
CABLE TO CABLE
CABLE TO ROD
CABLE TO STEEL
BUSBAR TO TAP
TAP TO CABLE
9-14
15-20
21-26
27-31
32-36
7. SELECT CHART
8. GRAPHITE MOULD
9. ACCESSORIES
10. TROUBLE SHOOTING TIPS
37-40
41
42-43
44
AXI-WELD / EXOTHERMIC WELDING
INTRODUCTION
Axi-weld / Exothermic welding is simple, cost efficient, self contained
process of forming high quality connections. This process requires no
external power or heat source making it completely portable. It uses high
temperature reaction of powdered copper oxide and aluminium, within a
mould, to form permanent connections.
In this process connections are made by pouring superheated molten
copper alloy on and around the conductors to be joined.The reaction takes
place very rapidly, therefore 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 or
thin wall pipe.
The process use aluminium particles as reducing agent with copper oxide to
produce the chemical composition. Exothermic welding is a bonding of high
conductivity high copper content alloy and high corrosion resistance.
BASIC INSTALLTION
The majority of connections have at least twice the cross sectional area of
the conductors being joined and equivalent or greater current carrying
capacity because the connection is a fusion of high conductivity high copper
content alloy it will withstand repeated fault current and will not loosen in
the way that mechanical connectors can corrosion resistance too, is
exceptional, due to the alloy very high copper content.
The moulds are designed to complete +/- 30 connections depending on the
care given to the mould during usage, transport and storage.
The exothermic welding process has been used to weld materials other than
copper for electrical purposes.Materials welded include:
Stainless Steel, Columbium, Brass, Copper, Plain Steel, Bronze, NichromeV, Everdur, Niobium, Galvanized Steel, Kama, Chromax, Silicon Bronze,
Steel Rail, Cast Iron, Copper Clad Steel, Cor-Ten, Monel
When welding to galvanized steel it is recommended to resurface exposed
bare steel.
Exothermic Process
1. Conductors must be clean & dry when placed in the mould.
2. Close & lock the mould handle clamp.
3. Place the steel retaining disc in the mould cup over the tap
hole.
4. Pour weld metal powder into the mould cup.
5. Pour some starting powder on mould lip.
6. Close the lid of mould & from the side ignite the starting
powder with the flint gun.
Use Recommended Powder for
Recommended Joint.
Powders Are Available In Different Gramage For
Different Joint.
1
2
3
4
5
6
7
8
Avail.
Gram.
15 gram
25 gram
32 gram
45 gram
65 gram
90 gram
115 gram
150 gram
Given
Code
AWP15
AWP25
AWP32
AWP45
AWP65
AWP90
AWP115
AWP150
9
200 gram
AWP200
How we are Specialised.
Specialization :
Manufacturing of the Exothermic welding copper powder can be distributed to the user
all around the world and satisfied the quality of our products and service.
Our factory has been grown up with the best quality on the complete cycle of the
Grounding & Lightning protection system including the survey, designs, material
supplies, installation, trial maintenance, consultation and problem solving.
All this leads to our high quality products at reasonable prices, which answers
our slogan " We will give the best to our customers" which we will cherish
forever.
Cable To Cable
Horizontal End To End
A
mm2
10
16
25
35
50
70
95
120
150
185
240
300
500
Powder
(g)
25
32
32
32
45
65
90
115
115
150
200
250
200 x 2
Mould
Type
ACC1-C-10
ACC1-C-16
ACC1-C-25
ACC1-C-35
ACC1-C-50
ACC1-C-70
ACC1-C-95
ACC1-C-120
ACC1-C-150
ACC1-C-185
ACC1-D-240
ACC1-D-300
ACC1-E-500
Clamp
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
AHCD
Cable To Cable
Horizontal To Horizontal Cable Cross
A
B
mm2
mm2
Powder
(g)
10
10
32
16
16
45
25
25
35
35
35
50
Mould
Clamp
A
B
Powder
Type
Type
mm2
mm2
Mould
Clamp
(g)
Type
Type
ACC4-C-1010
AHCC
150
95
200
ACC4-D-15095
AHCD
ACC4-C-1616
AHCC
150
70
150
ACC4-C-15070
AHCC
45
ACC4-C-2525
AHCC
150
50
150
ACC4-C-15050
AHCC
65
ACC4-C-3535
AHCC
150
35
115
ACC4-C-15035
AHCC
25
65
ACC4-C-3525
AHCC
150
25
115
ACC4-C-15025
AHCC
50
90
ACC4-C-5050
AHCC
185
185
150 x 2
ACC4-E-185185
AHCD
50
35
90
ACC4-C-5035
AHCC
185
150
250
ACC4-D-185150
AHCD
50
25
90
ACC4-C-5025
AHCC
185
120
250
ACC4-D-185120
AHCD
70
70
115
ACC4-C-7070
AHCC
185
95
200
ACC4-D-18595
AHCD
70
50
115
ACC4-C-7050
AHCC
185
70
200
ACC4-D-18570
AHCD
70
35
115
ACC4-C-7035
AHCC
185
50
200
ACC4-C-18550
AHCC
70
25
115
ACC4-C-7025
AHCC
185
35
150
ACC4-C-18535
AHCC
95
95
150
ACC4-C-9595
AHCC
185
25
150
ACC4-C-18525
AHCC
95
70
150
ACC4-C-9570
AHCC
240
240
250x2
ACC4-D-240240
AHCD
95
50
115
ACC4-C-9550
AHCC
240
185
200x2
ACC4-D-240185
AHCD
95
35
115
ACC4-C-9535
AHCC
240
150
200x2
ACC4-D-240150
AHCD
95
25
115
ACC4-C-9525
AHCC
240
120
150X2
ACC4-D-240120
AHCD
120
120
200
ACC4-D-120120
AHCD
240
95
150X2
ACC4-D-24095
AHCD
120
95
200
ACC4-D-12095
AHCD
240
70
250
ACC4-C-24070
AHCC
120
70
150
ACC4-C-12070
AHCC
240
50
250
ACC4-C-24050
AHCC
120
50
150
ACC4-C-12050
AHCC
300
300
200x3
ACC4-D-300300
AHCD
120
35
115
ACC4-C-12035
AHCC
300
240
200x3
ACC4-D-300240
AHCD
120
25
115
ACC4-C-12025
AHCC
300
185
250x2
ACC4-D-300185
AHCD
150
150
250
ACC4-D-150150
AHCC
300
150
250x2
ACC4-D-300150
AHCD
150
120
250
ACC4-D-150120
AHCD
300
120
200x2
ACC4-D-300120
AHCD
300
95
200x2
ACC4-D-30095
AHCD
Cable To Cable
Horizontal Parallel Cable Cross
A
B
Powder
Mould
Clamp
mm2
10
16
25
35
50
50
50
70
70
70
70
95
95
95
95
120
120
120
120
mm2
10
16
25
35
50
35
25
70
50
35
25
95
70
50
35
120
95
70
50
(g)
45
45
45
65
90
65
65
115
115
90
90
150
115
115
115
200
200
150
115
Type
ACC6-C-1010
ACC6-C-1616
ACC6-C-2525
ACC6-C-3535
ACC6-C-5050
ACC6-C-5035
ACC6-C-5025
ACC6-C-7070
ACC6-C-7050
ACC6-C-7035
ACC6-C-7025
ACC6-C-9595
ACC6-C-9570
ACC6-C-9550
ACC6-C-9535
ACC6-C-120120
ACC6-C-12095
ACC6-C-12070
ACC6-C-12050
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
Cable To Cable
Horizontal Cable Tap To Horizontal Cable Run
A
B
mm2
mm2
Powder
Mould
(g)
Type
10
10
25
ACC2-C-1010
16
16
32
Clamp
A
B
Powder
mm2
mm2
Mould
Clamp
(g)
Type
AHCC
150
25
90
ACC2-C-15025
AHCC
ACC2-C-1616
AHCC
185
185
200
ACC2-D-185185
AHCD
25
25
45
ACC2-C-2525
AHCC
185
150
200
ACC2-D-185150
AHCD
35
35
45
ACC2-C-3535
AHCC
185
120
200
ACC2-D-185120
AHCD
35
25
45
ACC2-C-3525
AHCC
185
95
150
ACC2-C-18595
AHCC
50
50
90
ACC2-C-5050
AHCC
185
70
90
ACC2-C-18570
AHCC
50
35
45
ACC2-C-5035
AHCC
185
50
90
ACC2-C-18550
AHCC
50
25
45
ACC2-C-5025
AHCC
185
35
90
ACC2-C-18535
AHCC
70
70
90
ACC2-C-7070
AHCC
185
25
90
ACC2-C-18525
AHCC
70
50
90
ACC2-C-7050
AHCC
240
240
150 x 2
ACC2-E-240240
AHCD
70
35
45
ACC2-C-7035
AHCC
240
185
200
ACC2-D-240185
AHCD
70
25
45
ACC2-C-7025
AHCC
240
150
200
ACC2-D-240150
AHCD
95
95
115
ACC2-C-9595
AHCC
240
120
200
ACC2-D-240120
AHCD
95
70
90
ACC2-C-9570
AHCC
240
95
150
ACC2-C-24095
AHCC
95
50
90
ACC2-C-9550
AHCC
240
70
90
ACC2-C-24070
AHCC
95
35
90
ACC2-C-9535
AHCC
240
50
90
ACC2-C-24050
AHCC
95
25
90
ACC2-C-9525
AHCC
240
35
90
ACC2-C-24035
AHCC
120
120
150
ACC2-C-120120
AHCC
240
25
90
ACC2-C-24025
AHCC
120
95
150
ACC2-C-12095
AHCC
300
300
200 x 2
ACC2-E-300300
AHCD
120
70
90
ACC2-C-12070
AHCC
300
240
200 x 2
ACC2-E-300240
AHCD
120
50
90
ACC2-C-12050
AHCC
300
185
250
ACC2-D-300185
AHCD
120
35
90
ACC2-C-12035
AHCC
300
150
200
ACC2-D-300150
AHCD
120
25
90
ACC2-C-12025
AHCC
300
120
150
ACC2-D-300120
AHCD
150
150
200
ACC2-D-150150
AHCD
300
95
150
ACC2-C-30095
AHCC
150
120
150
ACC2-C-150120
AHCC
300
70
150
ACC2-C-30070
AHCC
150
95
150
ACC2-C-15095
AHCC
300
50
150
ACC2-C-30050
AHCC
150
70
90
ACC2-C-15070
AHCC
300
50
150
ACC2-C-30050
AHCC
150
50
90
ACC2-C-15050
AHCC
300
35
150
ACC2-C-30035
AHCC
150
35
90
ACC2-C-15035
AHCC
300
25
150
ACC2-C-30025
AHCC
Cable To Cable
Horizontal Parallel Through Cables.
A
B
Powder
mm2
mm2
Mould
Clamp
(g)
Type
Type
10
10
32
ACC7-C-1010
AHCC
16
16
32
ACC7-C-1616
AHCC
25
25
45
ACC7-C-2525
AHCC
35
35
65
ACC7-C-3535
AHCC
35
25
65
ACC7-C-3525
AHCC
50
50
90
ACC7-C-5050
AHCC
50
35
90
ACC7-C-5035
AHCC
50
25
65
ACC7-C-5025
AHCC
70
70
115
ACC7-C-7070
AHCC
70
50
115
ACC7-C-7050
AHCC
70
35
90
ACC7-C-7035
AHCC
70
25
90
ACC7-C-7025
AHCC
95
95
150
ACC7-C-9595
AHCC
95
70
150
ACC7-C-9570
AHCC
95
50
115
ACC7-C-9550
AHCC
95
35
115
ACC7-C-9535
AHCC
120
120
200
ACC7-C-120120
AHCC
120
95
200
ACC7-C-12095
AHCC
120
70
150
ACC7-C-12070
AHCC
120
50
150
ACC7-C-12050
AHCC
150
150
150x2
ACC7-D-150150
AHCD
150
120
250
ACC7-C-150120
AHCC
150
95
200
ACC7-C-15095
AHCC
150
70
150
ACC7-C-15070
AHCC
185
185
150x2
ACC7-D-185185
AHCD
185
150
150x2
ACC7-D-185150
AHCD
185
120
250
ACC7-C-185120
AHCC
185
95
200
ACC7-C-18595
AHCC
240
240
200x2
ACC7-D-240240
AHCD
240
185
150x2
ACC7-D-240185
AHCD
240
150
150x2
ACC7-D-240150
AHCD
240
120
250
ACC7-C-240120
AHCC
300
300
250x2
ACC7-D-300300
AHCD
300
240
250x2
ACC7-D-300240
AHCD
300
185
200x2
ACC7-D-300185
AHCD
300
150
150x2
ACC7-D-300150
AHCD
Cable To Cable
Horizontal Parallel Through Cables.
A
B
Powder
Mould
Clamp
mm2
mm2
(g)
Type
Type
25
25
65
ACC11-M-2525
AHCD
35
35
90
ACC11-M-3535
AHCD
50
50
150
ACC11-M-5050
AHCD
70
70
200
CC11-M-7070
AHCD
70
50
200
ACC11-M-7050
AHCD
70
35
150
ACC11-M-7035
AHCD
95
95
250
ACC11-M-9595
AHCD
95
70
250
ACC11-M-9570
AHCD
95
50
200
ACC11-M-9550
AHCD
95
35
200
ACC11-M-9535
AHCD
120
120
150x2
ACC11-M-120120
AHCD
120
95
150x2
ACC11-M-12095
AHCD
120
70
250
ACC11-M-12070
AHCD
120
50
250
ACC11-M-12050
AHCD
120
35
200
ACC11-M-12035
AHCD
150
150
200x2
ACC11-V-150150
AHCD
150
120
200x2
ACC11-V-150120
AHCD
150
95
150x2
ACC11-M-15095
AHCD
150
70
150x2
ACC11-M-15070
AHCD
150
50
250
ACC11-M-15050
AHCD
150
35
250
ACC11-M-15035
AHCD
185
185
250x2
ACC11-V-185185
AHCD
185
150
250x2
ACC11-V-185150
AHCD
185
120
250x2
ACC11-V-185120
AHCD
185
95
200x2
ACC11-V-18595
AHCD
185
70
150x2
ACC11-M-18570
AHCD
185
50
150x2
ACC11-M-18550
AHCD
185
35
150x2
ACC11-M-18535
AHCD
240
240
200x3
ACC11-V-240240
AHCD
240
185
200x3
ACC11-V-240185
AHCD
240
150
200x3
ACC11-V-240150
AHCD
240
120
200x3
ACC11-V-240120
AHCD
240
95
250x2
ACC11-V-24095
AHCD
240
70
250x2
ACC11-V-24070
AHCD
240
50
200x2
ACC11-V-24050
AHCD
Cable To Ground Rod
Horizontal Cable Terminal To Ground Rod
A
B
Powder
Mould
Clamp
mm
mm2
10
16
25
35
50
70
95
120
10
16
25
35
50
70
95
120
150
185
240
10
16
25
35
50
70
95
120
(g)
65
65
65
65
65
90
90
90
65
65
65
90
90
90
90
90
115
150
150
65
65
65
65
90
90
90
90
Type
ACR1-C-12710
ACR1-C-12716
ACR1-C-12725
ACR1-C-12735
ACR1-C-12750
ACR1-C-12770
ACR1-C-12795
ACR1-C-127120
ACR1-C-14210
ACR1-C-14216
ACR1-C-14225
ACR1-C-14235
ACR1-C-14250
ACR1-C-14270
ACR1-C-14295
ACR1-C-142120
ACR1-C-142150
ACR1-C-142185
ACR1-C-142240
ACR1-C-17210
ACR1-C-17216
ACR1-C-17225
ACR1-C-17235
ACR1-C-17250
ACR1-C-17270
ACR1-C-17295
ACR1-C-172120
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
12.7
14.2
17.2
Cable To Ground Rod
Horizontal Cable Terminal To Ground Rod Continued….
17.2
150
185
240
300
115
150
150
200
ACR1-C-172150
ACR1-C-172185
ACR1-C-172240
ACR1-C-172300
AHCC
AHCC
AHCC
AHCC
Cable To Ground Rod
Horizontal Through To Ground Rod
A
B
Powder
Mould
Clamp
mm
mm2
10
16
25
35
50
70
95
120
10
16
25
35
50
70
95
120
150
185
240
10
16
25
35
50
70
95
120
150
185
240
300
(g)
90
90
90
90
90
90
115
150
65
65
90
90
90
115
115
150
200
200
250
65
65
90
90
115
115
115
150
200
200
250
150x2
Type
ACR2-C-12710
ACR2-C-12716
ACR2-C-12725
ACR2-C-12735
CR2-C-12750
ACR2-C-12770
ACR2-C-12795
ACR2-C-127120
ACR2-C-14210
ACR2-C-14216
ACR2-C-14225
ACR2-C-14235
ACR2-C-14250
ACR2-C-14270
ACR2-C-14295
ACR2-C-142120
ACR2-C-142150
ACR2-C-142185
ACR2-C-142240
ACR2-C-17210
ACR2-C-17216
ACR2-C-17225
ACR2-C-17235
ACR2-C-17250
ACR2-C-17270
ACR2-C-17295
ACR2-C-172120
ACR2-C-172150
ACR2-C-172185
ACR2-C-172240
ACR2-D-172300
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
12.7
14.2
17.2
Cable To Ground Rod
Horizontal Run & Tap Cable To Ground Rod
A
B
Powder
Mould
Clamp
mm
mm2
25
35
50
70
95
120
25
35
50
70
95
120
150
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
(g)
90
90
115
150
200
200
90
115
150
200
250
150x2
200x2
90
115
150
200
250
150x2
200x2
200x2
200x3
115
150
200
250
150x2
200x2
250x2
250x2
250x3
Type
ACR17-C-12725
ACR17-C-12735
ACR17-C-12750
ACR17-C-12770
ACR17-C-12795
ACR17-C-127120
ACR17-C-14225
ACR17-C-14235
ACR17-C-14250
ACR17-C-14270
ACR17-C-14295
ACR17-D-142120
ACR17-D-142150
ACR17-C-17225
ACR17-C-17235
ACR17-C-17250
ACR17-C-17270
ACR17-C-17295
ACR17-D-172120
ACR17-D-172150
ACR17-D-172185
ACR17-D-172240
ACR17-C-23125
ACR17-C-23135
ACR17-C-23150
ACR17-C-23170
ACR17-D-23195
ACR17-D-231120
ACR17-D-231150
ACR17-D-231185
ACR17-D-231240
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
AHCD
AHCD
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
AHCD
AHCD
AHCD
12.7
14.2
17.2
23.1
Cable To Ground Rod
Horizontal Parallel Run Cable To Ground Rod
A
B
Powder
Mould
Clamp
mm
mm2
25
35
50
70
95
120
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
(g)
115
115
150
200
250
150x2
115
150
200
250
150x2
200x2
250x2
250x2
250x3
115
150
200
250
150x2
200x2
250x2
250x2
250x3
150
200
250
150x2
200x2
250x2
200x3
200x3
Type
ACR24-C-12725
ACR24-C-12735
ACR24-C-12750
ACR24-C-12770
ACR24-C-12795
ACR24-D-127120
ACR24-C-14225
ACR24-C-14235
ACR24-C-14250
ACR24-C-14270
ACR24-D-14295
ACR24-D-142120
ACR24-D-142150
ACR24-D-142185
ACR24-D-142240
ACR24-C-17225
ACR24-C-17235
ACR24-C-17250
ACR24-C-17270
ACR24-D-17295
ACR24-D-172120
ACR24-D-172150
ACR24-D-172185
ACR24-D-172240
ACR24-C-23125
ACR24-C-23135
ACR24-C-23150
ACR24-D-23170
ACR24-D-23195
ACR24-D-231120
ACR24-D-231150
ACR24-D-231185
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
AHCD
AHCD
AHCD
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
AHCD
AHCD
AHCD
AHCC
AHCC
AHCC
AHCD
AHCD
AHCD
AHCD
AHCD
12.7
14.2
17.2
23.1
Cable To Ground Rod
Horizontal Through Cable to Side of Ground Rod
A
B
Powder
Mould
Clamp
mm
mm2
10
16
25
35
50
70
95
120
10
16
25
35
50
70
95
120
150
185
240
10
16
25
35
50
70
95
120
150
185
240
300
(g)
90
90
90
90
115
115
115
150
90
90
90
90
115
115
115
150
200
250
200x2
90
90
90
90
115
150
150
200
250
200x2
200x2
200x3
Type
ACR3-E-12710
ACR3-E-12716
ACR3-E-12725
ACR3-E-12735
ACR3-E-12750
ACR3-E-12770
ACR3-E-12795
ACR3-E-127120
ACR3-E-14210
ACR3-E-14216
ACR3-E-14225
ACR3-E-14235
ACR3-E-14250
ACR3-E-14270
ACR3-E-14295
ACR3-E-142120
ACR3-E-142150
ACR3-E-142185
ACR3-J-142240
ACR3-E-17210
ACR3-E-17216
ACR3-E-17225
ACR3-E-17235
ACR3-E-17250
ACR3-E-17270
ACR3-E-17295
ACR3-E-172120
ACR3-E-172150
ACR3-J-172185
ACR3-J-172240
ACR3-J-172300
Type
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
12.7
14.2
17.2
Cable To Steel Surface
Horizontal Cable to Horizontal Steel Surface
A
Powder
Mould
Clamp
mm2
10
16
25
35
50
70
95
120
150
185
240
300
(g)
45
45
45
45
90
90
115
115
150
200
200
250
Type
ACS1-A-10
ACS1-A-16
ACS1-A-25
ACS1-A-35
ACS1-C-50
ACS1-C-70
ACS1-C-95
ACS1-C-120
ACS1-C-150
ACS1-C-185
ACS1-C-240
ACS1-C-300
Type
AHCA
AHCA
AHCA
AHCA
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
Cable To Steel Surface
Horizontal Through Cable To Horizontal Steel Surface
A
Powder
Mould
Clamp
mm2
10
16
25
35
50
70
95
120
150
185
240
300
(g)
45
45
45
45
90
115
115
150
200
250
150x2
200x2
Type
ACS2-A-10
ACS2-A-16
ACS2-A-25
ACS2-A-35
ACS1-C-50
ACS1-C-70
ACS1-C-95
ACS1-C-120
ACS1-C-150
ACS1-C-185
ACS1-D-240
ACS1-D-300
Type
AHCA
AHCA
AHCA
AHCA
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
Cable To Steel Surface
Angular Cable to vertical Steel Surface
ACS–3 Type mold are used to join the end of a copper cable at a 45° angle
to a vertical steel surface
A
Powder
Mould
Clamp
mm2
10
16
25
35
50
70
95
120
150
185
240
300
(g)
45
45
45
45
90
90
115
115
150
200
200
250
Type
ACS3-A-10
ACS3-A-16
ACS3-A-25
ACS3-A-35
ACS3-C-50
ACS3-C-70
ACS3-C-95
ACS3-C-120
ACS3-C-150
ACS3-C-185
ACS3-C-240
ACS3-C-300
Type
AHCA
AHCA
AHCA
AHCA
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
Cable To Steel Surface
Vertical Through cable To Vertical Steel Surface
ACS-4 Type mould are used to join a vertical through copper cable
A
mm2
25
35
50
70
95
120
150
Powder
(g)
90
115
200
200
250
250
250
Mould
Type
ACS4-Y-25
ACS4-Y-35
ACS4-Y-50
ACS4-Y-70
ACS4-Y-95
ACS4-Y-120
ACS4-Y-150
Clamp
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
Cable To Steel Surface
ACS-7 Overhead Vertical Tap Cable to vertical Steel Surface
ACS-7 Type Mould are used to join an overhead vertical copper
conductor drop tap to a vertical steel surface.Note that the cable is surface.
on the Surface
A
Powder
Mould
Clamp
mm2
10
16
25
35
50
70
95
120
150
185
240
300
(g)
65
65
65
65
150
150
200
200
250
150x2
200x2
200x2
Type
ACS7-C-10
ACS7-C-16
ACS7-C-25
ACS7-C-35
ACS7-C-50
ACS7-C-70
ACS7-D-95
ACS7-D-120
ACS7-D-150
ACS7-D-185
ACS7-D-240
ACS7-D-300
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
Cable To Steel Surface
ACS-3 Type Mould used to join the end of a copper cable at a 45° angle to
a vertical steel surface
A
PIPE
Powder
Mould
Clamp
mm2
10
16
25
35
50
70
SIZE
(g)
45
45
90
90
115
115
Type
ACS3.1-C-10
ACS3.1-C-16
ACS3.1-C-25
ACS3.1-C-35
ACS3.1-C-50
ACS3.1-C-70
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
1 1/4" to 4"
4" to 6"
6" to 10"
12" 7 up
BusBar To Tape , Cable and other Steel Surface
ABS-1 Type Mould are used to connect a vertical copper bus bar tap to a
vertical steel surface. Bus flat side is parallel to surface.
A
mmxmm
Powder
(g)
Mould
Type
Clamp
Type
20x2
65
ABS1-C-202
AHCC
20x3
65
ABS1-C-202
AHCC
25x2
90
ABS1-C-252
AHCC
25x3
90
ABS1-C-253
AHCC
25x4
90
ABS1-C-254
AHCC
25x6
150
ABS1-C-256
AHCC
30x2
90
ABS1-C-302
AHCC
30x3
90
ABS1-C-303
AHCC
30x4
115
ABS1-C-304
AHCC
30x5
150
ABS1-C-305
AHCC
31x3
90
ABS1-C-313
AHCC
31x6
200
ABS1-C-316
AHCC
38x3
150
ABS1-C-383
AHCC
38x5
200
ABS1-C-385
AHCC
38x6
250
ABS1-C-386
AHCC
40x3
150
ABS1-C-403
AHCC
40x4
200
ABS1-C-404
AHCC
40x5
200
ABS1-C-405
AHCC
40x6
250
ABS1-C-406
AHCC
50x3
200
ABS1-C-503
AHCC
50x4
250
ABS1-C-504
AHCC
50x5
250
ABS1-C-505
AHCC
BusBar To Tape , Cable and other Steel Surface
ABS-1 Type Mould are used to connect a vertical copper bus bar tap to a
vertical steel surface. Bus flat side is parallel to surface.
Continued…
50x6
150x2
ABS1-D-506
AHCD
50x8
200x2
ABS1-D-508
AHCD
60x6
200x2
ABS1-D-606
AHCD
60x8
250x2
ABS1-D-608
AHCD
60x10
200x3
ABS1-D-6010
AHCD
80x6
250x2
ABS1-D-806
AHCD
80x8
200x3
ABS1-D-808
AHCD
80x10
250x3
ABS1-D-8010
AHCD
ABS-2 Horizontal Tap to Horizontal Steel Surface
ABS-2 Type Mould are used to connect a horizontal copper bus bar
tap to a horizontal steel surface. Bus flat side is parallel to surface.
A
Powder
Mould
Clamp
mmxmm
(g)
Type
Type
20x2
65
ABS2-C-202
AHCC
20x3
90
ABS2-C-203
AHCC
25x2
90
ABS2-C-252
AHCC
25x3
90
ABS2-C-253
AHCC
25x4
90
ABS2-C-254
AHCC
25x6
150
ABS2-C-256
AHCC
30x2
115
ABS2-C-302
AHCC
30x3
115
ABS2-C-303
AHCC
ABS-2 Horizontal Tap to Horizontal Steel Surface
ABS-2 Type Mould are used to connect a horizontal copper bus bar
tap to a horizontal steel surface. Bus flat side is parallel to surface.
Continued………
30x4
150
ABS2-C-304
AHCC
30x5
200
ABS2-C-305
AHCC
31x3
115
ABS2-C-313
AHCC
31x6
200
ABS2-C-316
AHCC
38x3
150
ABS2-C-383
AHCC
38x5
200
ABS2-C-385
AHCC
38x6
200
ABS2-C-386
AHCC
40x3
115
ABS2-C-403
AHCC
40x4
200
ABS2-C-404
AHCC
40x5
200
ABS2-C-405
AHCC
40x6
250
ABS2-C-406
AHCC
50x3
200
ABS2-C-503
AHCC
50x4
150x2
ABS2-D-504
AHCD
50x5
150
ABS2-D-505
AHCD
50x6
150x2
ABS2-D-506
AHCD
50x8
200x2
ABS2-D-508
AHCD
BusBar To Tape , Cable and other Steel Surface
ABB-2 Horizontal to Vertical at Right Angle
ABB-2 Type Mould are used to join horizontal copper bus bar at right
angles a vertical steel surface to the top of vertical bus bar. Flat sides of
both are vertical and parallel.
A
Powder
Mould
Clamp
mmxmm
25x3
25x5
25x6
25x8
25x12
31x6
38x3
38x6
38x8
50x3
50x4
50x5
50x6
50x8
(g)
65
90
115
150
250
150
115
200
250
90
115
200
250
150x2
Type
ABB2-C-253
ABB2-C-255
ABB2-C-256
ABB2-C-258
ABB2-C-2512
ABB2-C-316
ABB2-C-383
ABB2-C-386
ABB2-C-388
ABB2-C-503
ABB2-C-504
ABB2-C-505
ABB2-C-506
ABB2-D-508
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
BusBar To Tape , Cable and other Steel Surface
ABS-4 Horizontal or Vertical Thru Bar to Horizontal Steel Surface
ABS-4 Type Mould are used to join a horizontal through copper
bus bar to a vertical steel surface. Bus flat side is parallel to surface.
A
mmxmm
20x2
20x3
25x2
25x3
25x4
25x6
30x2
30x3
30x4
30x5
31x3
31x6
38x3
38x5
38x6
40x3
40x4
40x5
40x6
50x3
50x4
50x8
60x6
60x8
60x10
Powder
(g)
90
90
115
115
150
150
115
115
200
200
150
200
150
200
250
150
200
200
250
200
250
200x2
200x2
250x2
250x3
Mould
Type
ABS4-C-202
ABS4-C-203
ABS4-C-252
ABS4-C-253
ABS4-C-254
ABS4-C-256
ABS4-C-302
ABS4-C-303
ABS4-C-304
ABS4-C-305
ABS4-C-313
ABS4-C-316
ABS4-C-383
ABS4-C-385
ABS4-C-386
ABS4-C-403
ABS4-C-404
ABS4-C-405
ABS4-C-406
ABS4-C-503
ABS4-C-504
ABS4-D-508
ABS4-D-606
ABS4-D-608
ABS4-D-6010
Clamp
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
AHCD
AHCD
Tape To Cable
ACB-1 Horizontal Cable Tap to Horizontal Lug or Bus
ACB-1 Type Mould are used to connect a copper conductor
to a copper lug or bus bar.
A
Powder
Mould
Clamp
mm2
10
16
16
16
25
25
25
35
35
35
50
50
50
70
70
70
95
95
95
95
120
120
120
120
120
120
120
(g)
32
32
32
45
32
45
45
32
45
45
45
45
65
65
90
90
90
90
90
90
90
90
115
115
115
115
150
Type
ACB1-C-10202
ACB1-C-16202
ACB1-C-16203
ACB1-C-16253
ACB1-C-25202
AACB1-C-25203
ACB1-C-25253
ACB1-C-35202
ACB1-C-35203
ACB1-C-35253
ACB1-C-50202
ACB1-C-50203
ACB1-C-50253
ACB1-C-70253
ACB1-C-70254
ACB1-C-70256
ACB1-C-95253
ACB1-C-95254
ACB1-C-95255
ACB1-C-95256
ACB1-C-120253
ACB1-C-120254
ACB1-C-120255
ACB1-C-120256
ACB1-C-120305
ACB1-C-120503
ACB1-C-120506
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
HCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
Tape To Cable
ACB-1 Horizontal Cable Tap to Horizontal Lug or Bus
ACB-1 Type Mould are used to connect a copper conductor
to a copper lug or bus bar.
Continued…….
150
150
150
150
150
185
185
185
185
185
185
185
240
240
240
240
300
300
115
115
150
115
115
150
150
150
150
150
200
200
200
200
200
150x2
150x2
200x2
ACB1-C-150256
ACB1-C-150305
ACB1-C-150405
ACB1-C-150503
ACB1-C-150504
ACB1-C-185305
ACB1-C-185316
ACB1-C-185386
ACB1-C-185405
ACB1-D-185504
ACB1-D-185505
ACB1-D-185506
ACB1-D-240503
ACB1-D-240504
ACB1-D-240505
ACB1-D-240506
ACB1-D-300506
ACB1-D-300508
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
AHCD
Tape To Cable
ACB-4 Horizontal Cable Tap to Horizontal Bus
ACB-4 Type Mould are used to connect horizontal copper cable tap
to a horizontal copper bus bar with the flat side horizontal
A
B
Powder
Mould
Clamp
mm2
10
16
16
16
25
25
25
35
35
35
50
50
50
50
50
70
70
70
95
95
95
95
120
120
120
120
150
150
mmxmm
20x2
20x2
20x3
25x3
20x2
20x3
25x3
20x2
20x3
25x3
20x3
25x2
25x3
25x4
25x6
25x3
25x4
25x6
25x3
25x4
25x5
25x6
25x3
25x5
25x6
30x5
25x6
30x5
(g)
25
32
32
32
25
32
32
32
45
45
45
45
45
65
65
65
65
90
90
90
90
115
90
90
115
115
115
115
Type
ACB4-C-10202
ACB4-C-16202
ACB4-C-16203
ACB4-C-16253
ACB4-C-25202
ACB4-C-25203
ACB4-C-25253
ACB4-C-35202
ACB4-C-35203
ACB4-C-35253
ACB4-C-50203
ACB4-C-50252
ACB4-C-50523
ACB4-C-50254
ACB4-C-50256
ACB4-C-70253
ACB4-C-70254
ACB4-C-70256
ACB4-C-95253
ACB4-C-95254
ACB4-C-95255
ACB4-C-95256
ACB4-C-120253
ACB4-C-120254
ACB4-C-120255
ACB4-C-120256
ACB4-C-150256
ACB4-C-150305
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
Tape To Cable
ACB-4 Horizontal Cable Tap to Horizontal Bus
ACB-4 Type Mould are used to connect horizontal copper cable tap
to a horizontal copper bus bar with the flat side horizontal
Continued……..
150
185
185
185
185
185
240
240
300
300
40x5
25x3
30x5
40x5
50x5
50x6
50x5
50x6
50x6
50x8
150
150
150
150
150
150
200
250
150x2
200x2
ACB4-C-150405
ACB4-C-185305
ACB4-C-185316
ACB4-C-185386
ACB4-C-185405
ACB4-C-185504
ACB4-C-240505
ACB4-C-240506
ACB4-D-300506
ACB4-D-300508
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCD
Tape To Cable
ACB-5 Type Mould are used to connect horizontal copper
bus bar, flat side horizontal, to a horizontal through run cable.
A
B
Powder
Mould
Clamp
mm2
10
16
16
16
25
25
25
35
35
35
50
50
50
70
70
70
95
95
95
120
120
120
150
150
150
185
185
185
240
240
300
300
mmxmm
20x2
20x2
20x3
25x3
20x2
20x3
25x3
20x2
20x3
25x3
20x3
25x2
25x3
25x3
25x4
25x6
25x4
25x5
25x6
25x5
25x6
30x5
25x6
30x5
40x5
30x5
40x5
50x5
30x5
50x6
50x6
50x8
(g)
45
45
45
65
45
45
65
45
45
65
65
65
65
90
115
115
150
150
150
150
150
200
200
200
250
250
250
150x2
250
200x2
250x2
250x2
Type
ACB5-C-10202
ACB5-C-16202
ACB5-C-16203
ACB5-C-16253
ACB5-C-25202
ACB5-C-25203
ACB5-C-25253
ACB5-C-35202
ACB5-C-35203
ACB5-C-35253
ACB5-C-50203
ACB5-C-50252
ACB5-C-50523
ACB5-C-70253
ACB5-C-70254
ACB5-C-70256
ACB5-C-95254
ACB5-C-95255
ACB5-C-95256
ACB5-C-120254
ACB5-C-120255
ACB5-C-120256
ACB5-C-150256
ACB5-C-150305
ACB5-C-150405
ACB5-C-185305
ACB5-C-185405
ACB5-D-185505
ACB5-C-240305
ACB5-D-240506
ACB5-D-300506
ACB5-D-300508
Type
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCC
AHCD
AHCC
AHCD
AHCD
AHCD
Select chart
ACC-1
ACC-2
ACC-3
ACC-4
ACC-5
ACC-6
ACC-7
ACC-11
ACC-13
ACC-14
ACC-21
ACC-23
ACC-24
ACC-25
ACC-26
ACC-27
ACC-28
ACC-29
ACC-30
ACC-31
ACC-33
ACC-34
ACC-35
ACC-36
ACR-1
ACR-2
ACR-4
ACR-3
ACR-5
ACR-6
ACR-7
AACR-9
ACR-12
ACR-13
ACR-14
ACR-15
ACR-16
ACR-18
ACR-17
ACR-19
ACR-20
ACR-22
ACR-25
ACR-24
ACR-27
ACR-30
ACR-31
ACR-32
ACR-35
ACR-36
ARR-1
ARR-2
ARS-1
(STL SURFACE)
ARS-2
(STL SURFACE)
ARS-3
(STL SURFACE)
ACS-1
(STL SURFACE)
ACS-2
(STL SURFACE)
ACS-3
(STL SURFACE)
ACS-4
(STL SURFACE)
ACS-5
(STL SURFACE)
ACS-6
(STL SURFACE)
ACS-7
(STL SURFACE)
ACS-8
(STL SURFACE)
ACS-9
(STL SURFACE)
ACS-11
(STL SURFACE)
ACS-12
(STL SURFACE)
ACS-13
(STL SURFACE)
ACS-14
(STL SURFACE)
ACS-15
(STL SURFACE)
ACS-18
(STL SURFACE)
ACS-22
(STL SURFACE)
ACS-23
(STL SURFACE)
ACS-27
(STL SURFACE)
ACS-28
(STL SURFACE)
ACS-43
(STL SURFACE)
ACS-46
(STL SURFACE)
ARS-3
(STL SURFACE)
ACRS-1
(STL SURFACE)
ACRS-2
(STL SURFACE)
ARE-1
ARE-2
ACB-1
ACB-2
ACB-3
ACB-9
ACB-5
ACB-6
ACB-7
ACB-8
ACB-4
ACB-11
ACB-12
ACB-15
ACB-16
ACB-17
ACB-16
ACB-17
ACB-19
ACB-20
ACB-21
ACB-22
ACB-25
ACB-26
ACB-27
ACB-29
ACB-38
ABB-1
ABB-2
ABB-3
ABB-4
ABB-5
ABB-6
ABB-7
ABB-12
ABB-14
ABB-17
ABB-20
ABB-21
ABB-22
ABB-27
ABB-41
ABS-1
(STL SURFACE)
ABS-2
(STL SURFACE)
ABS-3
(STL SURFACE)
ABS-4
(STL SURFACE)
ABS-5
(STL SURFACE)
ABS-6
(STL SURFACE)
ABS-7
(STL SURFACE)
ABS-8
(STL SURFACE)
ABS-13
(STL SURFACE)
ABS-14
ABS-15
(STL SURFACE)
ABS-16
(STL SURFACE)
ABS-17
(STL SURFACE)
ABS-18
(STL SURFACE)
ABS-19
(STL SURFACE)
ABS-20
(STL SURFACE)
ACRE-1
ACRE-2
ACRE-3
ACRE-4
ACRE-5
ACRE-6
ACRE-7
ACRE-8
ACRE-9
ACRE-11
ACRE-12
ACRE-13
ACRE-14
ACRE-15
ACRE-16
ACRE-17
ACRE-18
ACRE-19
ACRE-20
ACRE-21
AAC-1
AAC-2
AAR-1
GRAPHITE MOULD EXOTHERMIC WELDING PROCESS
A. Axi-weld Mould is made from graphite which makes it fragile and would crack or break
if not handled with care.
B. Designed to withstand high temperatures produced from the exothermic welding.
C. Requires pre-heating with a butane torch to ensure the mould is totally dry before
every first joint regardless new or used mould. Otherwise, the mould may crack or
break or a bad joint produced or cuts down the life span of the mould.
D. Always ensure that the conductors fits snugly and sections of moulds are clamped
tightly with the handle clamp to avoid leakage of weldmetal. Leakage will produced a bad
joint and cuts down the life span of the mould.
E. 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.
F. Caution : Do not use any other hard object and brush that would damage the mould.
G. Always keep the mould away from water or damn areas while it is hot. Otherwise, the
mould may crack or break.
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.
(1)
(2)
(3)
(4)
Accessories
AXT-001 Cable Cleaning Brush
The Cable Cleaning Brush is recommended for cleaning heavily oxidized
cables. The V-shaped brushes permit their use orver a wide range of cable
sizes. Brush assembly consists of a handle with two stiff wire bristle brushes
that are Rotatable, for longer life and are replaceable.
AXT-002 Bus Bar Cleaning Brush
The Bus Bar cleaning brush is used to clean large conductors and bus bars. It
has short stiff bristles. These brushes should not be used to clean molds.
AXT-003 Mold Cleaning Brush
The Mold Cleaning brush is used to clean the molds without damaging the
molds.
AXT-004 Mold Cleaners
The Mold Cleaners are used to clean the slag from molds that are not split
through the crucible.
AXT-005 Flint Ignitor
This ignitor is used to ignite the strating powder for making the exothermic
welding joint. Each mold with a frame has a flint ignitor included.
Handle Clamp
AXHC-001 HANDLE CLAMPS
For most connections involving lugs, cable or rectangular bus, Handle
Clamps are used. These Handles Clamps make possible the use of many
different sizes and types of molds with only two different clamps. These
will fit 95% all standard molds.
AXHA-001 HANDLE ATTACHMENTS
Handle Attachment is used to hold a molds in position. It is easily
attached to the Handle Clamps.
Trouble Shooting Tips
PROBLEM
Insufficient metal to make
weld.
Mold does not close tightly
causing weld metal to leak
out.
PROBLEM CAUSE
CORREECTION TO MAKE
Worm mold resulting in leaking
weld metal.
Replace mold or if only worn around conductor
opening, use duct seal around conductor. Do not get
duct seal into mold cavity.
Wrong size cartridge for mold.
Check ID plate for mold and compare with number on
bottom of cartridge.
Too much spillage when
dumping powder.
Carefully open lid while holding over crucible and
dump.
Wrong mold for conductor being
used.
Replace with correct mold. In some applications, shim
stock or adapter sleeves can be used to enlarge cable
to fit mold.
Handle clamps not properly
adjusted.
Remove set screw between the handles or the mold
and adjust handle tension by backing out the eye
bolt.
Dirt or slag stuck in parting line
of mold.
Clean mold thoroughly between connections.
Bent or out-of-round cable.
Straighten or cut out bad section of cable.
Handle clamps will not lock Handle Clamps not properly
closed.
adjusted.
Remove set screw between the handles or the mold
and adjust handle tension by backing out the eye
bolt.
Excessively high weld,
bubbly or gassy
appearance, poor weld.
Weld metal blows out
top of mind.
PROBLEM
Cannot ignite powder.
Moisture in mold.
Pre -heat mold to above 220o F with a propane torch.
Oil, grease, moisture or
foreign material on
conductors.
Pre-heat conductors with propane torch then use a clean
wire brush on conductor to remove any residue left n
conductors. If welding to cast iron or steel surface, weld area
must be cleaned down to bright metal.
Duct seal in weld cavity.
Take special precautions to keep duct seal out or weld
cavity.
Weld powder has gotten
wet.
Replace with fresh, dry weld powder.
Mold worn or chipped
around disc seal allowing
powder to leak into mold
cavity.
Replace mold.
Forgot to use steel disc or
did not seat if properly at
bottom of crucible.
Make sure disc is seated at bottom of crucible before pouring
the powder into crucible.
PROBLEM CAUSE
Insufficient starting powder in
ignition pocket on mold lid.
CORREECTION TO MAKE
Place at least half of starting powder in ignition
pocket of mold lid.
Flint ignitor not shooting enough Clean flint ignitor according to directions on box or
spark.
replace flint ignitor.
Starting powder lumped
together.
Break up starting powder on lid with edge of powder
tube.
Mold wearing out ot fast.
Improper cleaning of mold.
Use mold cleaner, soft natural bristle brush or clean
rag to clean mold between shots. Do not use wire
brush or screwdriver on molds.
Poor weld to ground rod.
Weight of mold not supported
during reaction causing mold to
slip when cable melts.
Use locking pliers on ground rod under mold to
support the weight of the mold during the reaction.
Moisture or contaminant on
cable or ground rod.
Pre-heat conductors with propane torch then use a
clean wire brush on conductors to remove any residue
left on conductors.
Improperly cleaned area on
steel.
An area larger than the weld area should be cleaned
down to bright clean metal.
Moisture or contaminant on
cable or steel surface.
Pre-heat conductors with propane torch then use a
clean wire brush on conductors to remove any residue
left on conductors.
Weld will not stick to steel
surface.
Cable is improperly positioned in Position cable in mold in accordance with directions
mold, blocking the flow of weld
for mold. If directions are not available, position top
metal.
of cable in the center of where the liquid weld metal
hits the steel.
Weld will not stick to cast
iron surface.
All of the causes listed under
welding to steel surface also
apply to this section.
Not using CI (Cast Iron) powder. Specify "CI" behind cartridge when order powder.
Cable pulls out of mold
when it is fired.
Cables are either twisted or
under tension.
Use cable clamp or other method to remove tension.
Cut out severely twisted cable.