Cost-efficient, high-quality electrical connections are achieved with FurseWELD exothermic welding.
A simple, self-contained exothermic welding system using the high-temperature reaction of powdered copper oxide and aluminium within a mould to form permanent electrical connections.
How to make a FurseWELD joint
- Place the conductors in the weld cavity and close the mould. Make sure the conductors are clean and the mould is dry by pre-heating or making a test joint.
- Place the metal retaining disc in the bottom of the mould crucible, and pour in the weld powder spreading some starting powder onto the mould edge. Close the lid, and ignite with the flint gun from the side, firing the spark onto the starting powder.
- The exothermic reaction takes place safely inside the mould. Reducing the weld powder to molten copper alloy which melts the retaining disc and flows into the weld cavity where it partially melts the conductors.
- The molten copper alloy cools to leave a fusion weld of excellent mechanical and electrical integrity.
- Once the joint is finished, the mould should be cleaned using a mould scraper and brush, ready for the next joint.
Moulds
The FurseWELD system of exothermic welding uses moulds to contain the exothermic reaction that creates safe and robust connections. Different types of FurseWELD moulds are available, whose use depends on the project’s requirements.
- Full-size graphite moulds – Market-leading FurseWELD graphite moulds are robust and capable of creating over 75 connections each, if not more, when properly maintained.
- Mini-Moulds – FurseWELD mini-moulds are a cost-effective alternative to full-sized moulds, especially where fewer connections are required. They are smaller overall, less robust and therefore lower in price. Care is needed to achieve similar service lives to full-sized moulds.
Furseweld products
- A powder cartridge is required for each joint to be made
- Handle clamps enable the mould to be handled when hot and the two halves of the mould to be opened and clamped together
- Packing is required when welding to reinforcing bar
Conductors
The range of FurseWELD moulds is designed to work with all standard conductor formats.
- Flat tape conductor
- Stranded conductor
- Solid circular conductor
Sureshot
The FurseWELD Sureshot system is a single-use ceramic mould supplied complete with retaining disc and powders. It has been designed for use in applications where only a few exothermic welding connections are required.
Standard Tools
A flint gun is required to start the reaction. Cleaning tools for conductors, surfaces and moulds include:
- Cable Brush – for cleaning cables and other circular conductors such as rods
- Mould Scraper – for removing slag from the mould crucible after firing
- Mould Brush – for final mould cleaning
- File Card Brush – for cleaning conductors and surfaces
Typical applications include
- Earthing for power plants and high voltage substations
- Telecommunications
- Transmission and power distribution lines
- Cathodic protection
- Rail connections
FurseWELD System:
- Creates high-quality electrical connections
- Completely portable
- Can be used safely with minimum training
- Cost-effective exothermic welding
- Can be used for over 45 standard connection configurations
FurseWELD Earth Connection
- Tolerant to repeated fault currents
- Highly conductive
- Does not loosen
- Excellent corrosion resistance
Most FurseWELD connections have at least twice the cross-sectional area of the copper conductors being joined or welded and an equivalent or greater current carrying capacity. Corrosion resistance is exceptional due to the alloy’s very high copper content (> 90%).
