®
LPI Exoweld
Commercial in Confidence
Documents: 36 TD Exoweld.pub
Version 2.00
01/02/2008
Copyright 2008 LPI
1
®
LPI EXOWELD
Features
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Simple and proven method for exothermically bonding copper to copper or copper to steel
Most economical method for superior connections
Maintenance free connections
Product Description
LPI®’s EXOWELD is the brand name of the exothermic welding range of
products which are marketed and sold by Lightning Protection International
Pty Ltd, Australia.
LPI®’s EXOWELD welding process is a cost effective method of
completing a high quality electrical connection. The process is simple to
follow and through the use of a high temperature reaction a long lasting,
quality electrical bond is created between conductors.
Exothermic Welding Process
The exothermic welding process is a method of making electrical connections of copper to copper or
copper to steel where no outside source of heat or power is required. In this process, granular metals
(granular copper oxide and aluminium) are placed from a container into a graphite crucible and ignited.
The reduction of copper oxide by the aluminium (exothermic reaction) produces molten copper and
aluminium oxide slag. The slag floats to the surface and the disk melts, allowing molten copper to flow into
the weld cavity and complete the weld. The weld is allowed to solidify.
The mold is removed and made ready for the next weld. The process takes seconds to complete.
Advantages
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Does not deteriorate with age as the connections are permanent.
Does not loosen as the LPI® EXOWELD connections create a permanent molecular bond.
Excellent corrosion resistance.
Electrical characteristic are higher than typical mechanical connections.
Does not increase resistance above that of the conductor.
No External power or heat is required to make connections.
Quality can be assessed visually.
Easy and simple to install.
Commercial in Confidence
Documents: 36 TD Exoweld.pub
Version 2.00
01/02/2008
Copyright 2008 LPI
2
Making An Exoweld Connection
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Fit a handle clamp with a pre-determined carbon mold as per your specifications.
Remove all moisture from mold through use of a blow torch.
Fit a dry and clean conductor into the mold and close the handles to lock the carbon mold.
Drop the metal disk into the mold so as to hold the weld metal powder in place.
Place the weld metal into the mold and sprinkle the starting material over the weld metal and
onto the lip of the mold.
Close the cover and ignite starting material with the Ignitor gun.
Open the mold after the metal solidifies, and remove slag from mold.
Clean the mold for the next connection.
Commercial in Confidence
Documents: 36 TD Exoweld.pub
Version 2.00
01/02/2008
Copyright 2008 LPI
3
Product Application
EXOWELD connections come in 60 different configurations to allow the exact match of mold to the copper
to copper or copper to steel components to be bonded. Below is a partial selection of connections available
using LPI® Exoweld Products.
Cable to Cable
Cable to Busbar or Terminal Lug
Cable to Rebar
Cable to Earth Rod
Busbar to Busbar
Cable to Earth Plate
Cable to Steel Structure
Busbar to Earth Rod or
Steel Surface
Cable to Railway
A catalogue is available to assist in selecting the correct weld
metal size and mold type for your application. Please contact
LPI® or a local authorised distributor for a copy of the LPI®
Exoweld catalogue.
Cathodic Connection
Commercial in Confidence
Documents: 36 TD Exoweld.pub
Version 2.00
01/02/2008
Copyright 2008 LPI
4
EXOWELD Accessories
Weld Metals
Exoweld Weld Metal is a mixture of copper oxide and aluminium, packaged by size in individual plastic
tubes. Depending on the required connection type and conductor specifications, varying weld metal sizes
will be required.
Weld Metals
Weld Metal Ordering Code:
#15
#25
#32
#45
#65
#90
#115
#150
#200
#250
Weight per tube:
15g
25g
32g
45g
65g
90g
115g
150g
200g
250g
Number of tubes per box:
50
50
50
20
20
10
10
10
10
10
0.75kg
1.25kg
1.60kg
0.90kg
1.30kg
0.90kg
1.15kg
1.50kg
2.00kg
2.50kg
Weight per box:
Exoweld Cathodic Weld Metal is specifically designed for the welding of
cathodic protection leads to steel and cast iron pipes, tanks and other
structures.
Cathodic Weld Metals
Weld Metal Ordering Code:
CA-15
CA-25
CA-32
CA-45
Weight per tube:
15g
25g
32g
45g
Number of tubes per box:
30
30
20
20
0.45kg
0.75kg
0.64kg
0.90kg
Weight per box:
Molds
A Graphite Mold is used for Exothermic welding connections. The mold controls
the direction and speed of the molten weld metal flow and the formation of the
weld. The graphite used is a high temperature type that lasts for an average of 50
or more welding connection under normal usage
Description:
Ordering Code:
Exoweld Mold
Consult LPI Exoweld Brochure for individual mold
codes
Application:
Mold for completion of exothermic connection
Material:
Carbon Graphite
Temperature Withstand:
Commercial in Confidence
Documents: 36 TD Exoweld.pub
2200 deg. Celcius
Version 2.00
01/02/2008
Copyright 2008 LPI
5
Handle Clamps
Handle Clamps such as the one shown below are required for most molds. Two types of clamp are offered,
as shown in table below. For some molds, specialized frames with handles are required.
Ordering Code
Description:
EC-M
EC-L
Handle Clamp (Medium)
Handle Clamp (Large)
Application:
Pack Dimension:
Weight:
To clamp the mold correctly for welding
270 x 120 x 85mm
280 x 115 x 100mm
1.10 kg
1.25kg
Flint Ignitors
Flint Ignitors are used to ignite the starting material.
Ordering Code
EF-R
Description:
Ignitor Gun (Flint)
Application:
To ignite the starting material
Pack Dimension:
190 x 80 x 10mm
Weight:
125g
Mold Brush
Mold brush is useful for removing the slag from the mold after the welding connection is completed.
Ordering Code
EB-R
Description:
Mold Cleaner (Brush)
Application:
To remove slag from mold
Pack Dimension:
250 x 40 x 25mm
Weight:
55g
Mold Sealer
Mold Sealer is for sealing molds to eliminate leakage of molten weld metal.
Ordering Code
ES-M
Description:
Mold Sealer
Application:
To seal mold to eliminate leakage
Pack Dimension:
122 x 122 x 73mm
Weight:
Commercial in Confidence
Documents: 36 TD Exoweld.pub
40g
Version 2.00
01/02/2008
Copyright 2008 LPI
6
Slag Removal Spade
Slag removal spade is useful for removing the slag from the mold after the welding connection is
completed. They are especially useful for horizontally split molds.
Ordering Code
Description:
ET-009-S
ET-009-L
Slag Remover (Medium)
Slag Remover (Large)
Application:
Pack Dimension:
To remove slag
105 x 100 x 8mm
157 x 125 x 8mm
80g
115g
Weight:
Disks
Disks are used to seal the tap hole in the mold, allowing weld metal to be poured into the mold
Ordering Code
ET-002
Description:
Disk Sets (5 Sets of Disks, 3 Types)
Application:
To seal the tap hole in the mold
Contents:
5 x Disks for #15 - #65, 5 x Disks for #90 - #115 and
Disks for #150 - larger
Weight:
Ordering Code
Description:
Diameter:
Weight:
18.75g
ET-002-1
ET-002-2
ET-002-3
Disk for #15 - #65
(100 per pack)
Disk for #90 - #115
(100 per pack)
Disk for #150 - larger
(100 per pack)
19mm
25mm
38mm
54g
103g
218g
Cable Brush
Cable brush is recommended for cleaning heavily oxidized conductors and surfaces prior to the welding
connection.
Ordering Code
ET-008
Description:
Cable Cleaning Brush
Application:
To clean oxidised conductors and surfaces
Pack Dimension:
245 x 38 x 38mm
Weight
Commercial in Confidence
Documents: 36 TD Exoweld.pub
80g
Version 2.00
01/02/2008
Copyright 2008 LPI
7
Cable Cleaning Brush
V-Shaped brush cleans any conductor and is especially useful for coarse or dirty conductors.
Ordering Code
ET-008-1
Description:
Cable Cleaning Brush, V-Shape
Application:
To clean conductors
Pack Dimension:
250 x 90 x 40 mm
Weight
280g
Note and Remarks
Commercial in Confidence
Documents: 36 TD Exoweld.pub
Version 2.00
01/02/2008
Copyright 2008 LPI
8