AxiWeld Exothermic welding

Axiweld Exothermic Welding

AxiWeld Exothermic welding is a simple, cost-effective, self-contained, and portable process of forming a high quality and permanent metal-to-metal connections.

The AxiWeld line of products is manufactured and tested in accordance with IEEE 837.

Through this process, connections are made by a reaction of a powdered copper compound and aluminium which allows the superheated molten copper alloy to form on and around the conductors to be joined. The final connections are electrically conductive due to their high copper content and have strong corrosion-resistant properties. 

The exothermic welding process can be used to weld materials for electrical purposes including but not limited to:

Stainless Steel, Brass, Copper, Bronze, Galvanized Steel, Steel Rail, Cast Iron, and Copper Clad Steel.


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Procedure for Exothermic welding:

Tools and Accessories required :

1) Mould

2) Handle Clamp

3) Welding Powder

4) Retaining Disc

5) Brushes (Cable cleaning brush, Busbar cleaning brush, Mould cleaning brush)

6) Mould scrapper

7) Mould sealing compound

8) Flint Gun

9) Gloves

10) Safety Glasses

11) Hammer

12) Screw Driver

13) Flat file

14) Combination Plier

Safety equipment such as gloves and safety glasses must be worn for this procedure.

1) Identify the correct mould for which the joint has to be made.

2) Identify the correct weight of welding powder from the datasheet of the mould.

3) Identify the correct brush to clean the conductors or strips.

4) Clean the mould using brush and scrapper if required.

5) Preheat the mould.

6) Fix the mould onto the Handle clamp.

7) Locate the conductors within the mould.

8) Close and lock the mould using the handle clamp.

9) Seal the conductor openings on the mould using the mould sealing compound. This restricts the outflow of molten metal during the welding process.

10) Place the steel retaining disc in the mould cup above the top hole.

11) Pour the required amount of weld powder into the mould cup.

12) Pour the starting powder such that it makes a path till the lip of the mould.

13) Close the mould. 

14) Make sure the technician has worn gloves and safety glasses before igniting the powder.

15) Ignite the starting powder from the side using the flint gun

16) Allow the mould and joint to cool down.

17) Open the mould.

18) Use appropriate tools to carefully remove the welded joint from the mould.

19) Clean the joint and remove any excess slag.

Congratulations! You have now successfully joined the two conductors!

For YouTube description:

The process uses aluminium particles as a reducing agent with copper oxide to produce the chemical composition. Exothermic welding is a bonding of high conductivity, high copper content alloy and possess high corrosion resistance properties.

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. Since the reaction is quick, the total amount of heat applied to the conductors or surfaces is considerably less than that of brazing or soldering. 


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