Vertical Bus Bar End to Web Rail – BX4

The AI Weld Process:

Six basics steps in the AI Weld Process lead to a successful exothermic weld:

1. Six basics steps in the AIWeld Process lead to a successful exothermic weld:
2. Insert the conductors into the mould cleaned while ensuring that the mould is dry with minimal moisture. This can be ensured either by the process of preheating or possibly a test connection.
3. Fit the provided metal disc at the bottom of the mould crucible.
4. Pour in the weld metal completely, which you find under its green lid.
5. Add on top of the weld metal, the starting powder found under its red cap. Only a small quantity shall be applied on the lip of the mould for easy ignition, then close the lid.
6. Draw a charge from the flint gun to ignite the starting powder, pull the chargeback immediately after firing in order not to foul the gun.
7. Caution: Have no part of your body over the top or in front of the aperture
8. When 20 seconds have elapsed open the mould by crank handle. Use the cleaning brush to remove slag and clean the mould and crucible and lid liberally.

Select from various sizes, weld metals, and handle clamp options to customize your exothermic welding solution.

Available Variations (3 options)

Features

• High-quality graphite that provides ease of machining and resilience to thermal and mechanical shocks during welding, with heat over 2000ºC.
• Designed for 50-60 weld connections per mould; under proper care, the lifetime can be significantly extended.
• Due to graphite’s brittleness and rather soft nature, handling requires much care.
• Moulds come with nameplates specifying connection type, part code, and required weld metal size.
• In the event no particular connections or configurations of the conductors are present, the sales team is here to provide customized support.

Mould Care Guide

• For maximum lifetime and proper working of AIWeld moulds
• Clean after each weld using only AIWeld cleaning apparatus (soft brush).
• Keep dry and do not allow the mould to get moist
• Store in the packaging when out of use to avoid any damage
• Do not hit or drop the mould or bang its edges with the conductors.
• Never use a wire brush to clean.
• Always use the correct weld metal size, tools, and handle clamps.
• Mould

Inspection Checklist

• Careful handling. Mould must be dry and in good condition with the lid tight.
• Label must be fitted
• Faces of the mould must be smooth for closure
• Steel disc seat must have no wear, cracks or gouges to prevent weld metal from leaking out.
• The definition in the tap hole must be distinct.
• The weld cavity should have no signs of wear, and the conductors should be fitted to suit a 3mm gap in between.
• Routine checking with care ensures the AIWeld moulds are not damaged.