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THE FURSEWELD
PROCESS
The Furseweld exothermic welding process is a simple,
self contained method of forming high quality electrical connections.
The compact process requires no external power or
heat source making it completely portable.
Connections are made inside a semi-permanent graphite
mould using the high temperature reaction of powdered copper oxide and
aluminium.
This is how it works:
The Mould (1) features a Crucible (2), a Tap Hole
(3) and a Weld Cavity (4). The conductors (5) and (6) to be joined,
are located in the weld cavity as shown, and the mould is closed. A
steel Retaining Disc (7) is located in the bottom of the crucible to
retain the Weld Powder (8) and Starting Powder (9) which are poured
in on top.
Ignited with a spark gun, the starting powder sets
off an exothermic reaction in the weld powder, reducing it to molten
copper alloy. This instantaneously melts the retaining disc, and flows
down the tap hole, to the weld cavity, where it partially melts the
conductors, before cooling to leave a fusion weld of great mechanical
strength and electrical integrity.
THE FURSEWELD CONNECTION
The majority of Furseweld connections have at least
twice the cross sectional area of the conductors being joined, and an
equivalent or greater current carrying capacity.
Because the connection is a fusion of high conductivity
, high copper content alloy, it will withstand repeated fault currents,
and will not loosen in the way that mechanical connectors can.
Corrosion resistance too, is exceptional, due to the
alloy's very high copper content (in excess of 90%).
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FURSEWELD EQUIPMENT AND ACCESSORIES
Furseweld weld powders are contained in plastic cartridges,
and are packed in plastic boxes of 10 or 20, depending on their size.
Different joints require different powder sizes, and
relates to the powders nominal weight in grams.
The weld powder packaging also contains the retaining
discs and starting powder. The retaining discs are contained in a separate
bag within the box. The starting powder is compacted into the bottom
of the cartridge, underneath the weld powder, and is released by tapping
the cartridge base firmly.
Furseweld powders are suitable for making connections
from copper to copper and from copper to steel.
MOULDS
Furseweld graphite moulds are dedicated to producing
one type of connection. With care, they should be capable of producing
up to 75 connections each.
Each mould carries a tag which gives the mould part
number, the weld powder size for use with the mould and the conductor
sizes for which it is intended.
HANDLE CLAMPS
Handle clamps provide a means of both handling the
mould, and also of clamping the mould halves together (or of clamping
the mould to the surface to which a connection is to be made).
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
- Handle Clamp
- Powder Boxes and Cartridges
- Mould
- Mould Brush
- Flint Gun
- Mould Scraper
- Retaining Discs
- Cable Brush
- File Card Brush
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