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INSTRUCTION

Galmarweld System exothermic welding

I General safety instruction

1. Always wear protective clothing, glasses and gloves.

2. Every form is designed to one (dedicated) type of connection.

3. Never use worn out or broken form, which can cause leak of melted weld metal.

4 Make sure that welded objects fits to the mould and if mould fits tight.

5. Avoid breathing the smoke, because it can be harmful to health.

6. Avoid contacts with hot conductors after preheating, or with mould after welding.

7. Avoid moisture inside mould and welded objects. Contact between molten powder with moisture or other dirt can cause spillage.

8. When welding pipes special attention need to be kept:

welding process can have influence on construction elements, or thin walls of pipes or containers,

in case of welding pressurized containers, pipes or they contain (or contained) flammable, explosive or dangerous materials

special attention need to be kept,

error during procedure or welding can cause improper weld, damage of welded materials or cause dangerous situations

to personnel.

9. Single welding process should last around 1 minute, till the weld is stabilized.

10. Another welding process can be made after clearing the mould.

II Procedure of welding

1. Adjust handle clamp for the new mold by removing set screw between the handles of

the mold and adjust handle tension (should clamp strongly, if cannot clamp wrongly

set screw).

2. Before first use dry the mold to remove moisture.

3. Using steel brush and flame clean

the connected parts (flame removes

oil, which is used for corrosion pro-

tection of surfaces).

4. In some situations (especially bigger

sizes of conductors) there is danger

that heated conductor can open mo-

uld, the best way to avoid that problemis to construct the clamp that will

hold the connection.

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INSTRUCTION

5. Make sure the welded parts fit tightly

to mould, otherwise the leak can

appear but avoid to use mould as

clamp the graphite is soft material

and can be damaged when exposed

to high stress.

6. After preparing the connection put the steel disc to the mould (warning: the lack of

disk can cause damage of the mould).

7. Then pour the weld powder (number and size shown on mold plate) into

the crucible.

welding

powder

starting

powder

8. Put the small amount of starting

powder located in the bottom ofcartridge into designated place.

9. Ignite the starting powder using the

flint gun. Use protective gloves.

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INSTRUCTION

Galmar Marciniak s.j.

ul. Kobyliska 5

61-424 Pozna, Poland

tel. +48/61/835 80 00fax +48/61/830 10 20

e-mail: office@galmar.pl

www.galmar.pl

10. Wait about 1 minute till the weld

changes to solid, after that gently

open the mould. Beware of high

temperature.

11. Using soft brush clean the mould to prepare it for another welding (the steel brush

cannot be used to clean mould). The weld should look similar like on picture.

III. Troubleshooting

SolutionPossible cause

Insufficient starting powder in ignition place

Flint igniter not creating big enough spark

Handle clamp is not properly adjusted

Conductor bends during welding,

and open mold

Bent conductor

Havent used steel disc or disk did not seat

properly at bottom of crucible

Oil, grease, moisture or foreign material

on conductors or mold

Weld powder has gotten wet

Used out mold resulting in leaking weld metal

Wrong size of cartridge

Wrong mold type for desired connection

Improper way to clean mold

Bent or deformed conductor causes chipping

and faster wear of the graphite mold

Improperly cleaned area on steel

Moisture or dirt on cable

or conductor surface

Cannot ignite

the powder

Mold does not close

tightly causing weld

metal to leak out

Weld connection is not

made after firing

starting powder

Bubbly or gassy

appearance, poor weld

Insufficient metal

to make weld

Mold wearing out

to fast

Weld will not stick

to metal surface

Put the right amount (around 50% of starting powder) into

the designated place

Clean flint igniter by soaking it with house ammonia or replace flint igniter

Remove set screw between the handles of the mold and adjust handle

tension should be clamped strong, but without excessive force

Prepare the clamp holding the conductors, which will immobilize

them during welding

Straighten or cut out bad section of conductor

Make sure disc is seated at bottom of crucible before pouring

the powder into crucible

Pre-heat conductors and mold (standard procedure on 1stwelding) and mold

with torch then use wire brush on conductor to remove any dirt left on it

Replace with another, dry weld powder

Use new mold or if old one is worn around conductor

Compare the cartridge size and mold metal plate

Check the metal plate on the mold, change the mold if wrong

Use mold cleaner, soft bristle brush or clean rag to clean mold

between welding. Do not use wire brush or metal objects inside molds

Straighten conductor. Use caution when closing mold. Do not use

the mold as clamp prepare external clamp to hold the conductors

An area larger than the weld area should be cleaned down to clean

metal, then preheated

Pre-heat conductors with torch then use a clean wire brush

on conductors to remove any foreign materials left on conductors

Problem