How to Avoid Common Mistakes in Exothermic Welding

Practical Guide for Electrical Installations

In the electrical installations sector, ensuring a high-quality exothermic welding is essential for the durability and safety of connections. However, common mistakes in exothermic welding during the process can compromise the integrity of the installation. In this guide, we show you the most common errors to avoid, along with practical solutions to make your welds flawless.

A small mistake in welding can compromise your entire project. Learn how to avoid them.

KLK Electro Materials Engineering Department
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Common Errors in Exothermic Welding

1. Moisture in Materials

Moisture is one of the main enemies of exothermic welding. It can create bubbles in the joint, weakening the structure and affecting its conductivity. Before starting, ensure all components are dry. This step can prevent many long-term issues.

2. Not Preheating the Mold

A cold mold can prevent the metal from settling properly. Heating the mold for 5 minutes helps the weld flow smoothly, ensuring a solid and reliable connection. This step is crucial to ensure that the exothermic weld is uniform.

3. Dirty Surfaces

Impurities and dirt on the materials can interfere with the quality of the weld. It is recommended to clean all surfaces with a wire brush before proceeding with welding. Cleanliness is key to ensuring good electrical conductivity and durability.

4. Improperly Positioned Cables or Incorrect Sections

The positioning and section of the cables are essential for a proper weld. Make sure that the cables are correctly positioned and that the section matches the project specifications. This will avoid long-term performance issues.

5. Not Using Sealing Paste When Needed

Sealing paste is crucial to protect the weld from corrosion in certain applications. If the project requires the use of this paste and it is not used, the lifespan of the weld may be compromised, affecting the system’s safety.

6. Incorrect or Inadequate Cartridges

Each type of weld requires a specific cartridge. Using an inadequate cartridge can affect both the safety and efficiency of the weld. Always check that the cartridge is the correct one for the application and weld size.

7. Misaligned Separation Discs

If the separation discs are not properly aligned or if stuck discs are used, the metal flow may be compromised, affecting the weld quality. Ensure that the discs are separated and well-positioned before starting the process.

Specialized Solutions for Each Type of Exothermic Welding

At KLK, we understand that not all electrical connections are the same. From the railway industry to renewable energy systems, each project presents specific needs that require tailored solutions. Our expertise in exothermic welding enables us to offer custom molds and systems that ensure a reliable and long-lasting connection in any environment.

“Every connection is unique, each solution must be as well”

Railway connections need to withstand the high stresses and vibrations generated by heavy traffic. These solutions are specially adapted to ensure maximum durability in the railway environment.

Aluminum, known for its high conductivity and lightness, presents challenges due to its tendency to oxidize. Our solutions for aluminum connections ensure that corrosion issues are avoided and that the efficiency of the electrical system is maintained.

Unions between different metals, such as aluminum and copper, require molds that minimize the effects of galvanic corrosion. At KLK, we design specific molds for these connections, ensuring that the union is safe and durable.

For industries such as gas and oil, where high-pressure pipes are subjected to extreme conditions, we design custom molds that ensure the integrity of the connections. These solutions are prepared to withstand high pressures and temperature changes in the environment.

In lightning protection and grounding systems, welds must be able to withstand significant surges. Our solutions ensure that these connections remain safe and operational in critical situations.

With the growth of renewable energies, such as wind and solar farms, connections must be resistant to harsh weather conditions while maintaining optimal performance. At KLK, we design tailored molds to ensure that connections maintain their performance in adverse outdoor conditions.

We design robust molds made from high-quality granite, ensuring connections capable of withstanding any type of impact. Our solutions are specially adapted to guarantee maximum durability in any environment.

Can’t find the connection you need? Ask us about our Custom Solutions for any type of connection with KLK WELD.

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