INSTRUCTION

Galmarweld System exothermic welding

I

General safety instruction

1.
2.
3.
4
5.
6.
7.
8.

Always wear protective clothing, glasses and gloves.

Every form is designed to one (dedicated) type of connection.
Never use worn out or broken form, which can cause leak of melted weld metal.
Make sure that welded objects fits to the mould and if mould fits tight.
Avoid breathing the smoke, because it can be harmful to health.
Avoid contacts with hot conductors after preheating, or with mould after welding.
Avoid moisture inside mould and welded objects. Contact between molten powder with moisture or other dirt can cause spillage.
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.

2.

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).
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 protection of surfaces).

4.

In some situations (especially bigger

sizes of conductors) there is danger
that heated conductor can open mould, the best way to avoid that problem
is to construct the clamp that will
hold the connection.

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

8.

9.

Put the small amount of starting

powder located in the bottom of
cartridge into designated place.

starting
powder

Ignite the starting powder using the

flint gun. Use protective gloves.

INSTRUCTION

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
Problem

Possible cause

Solution

Cannot ignite

Insufficient starting powder in ignition place

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

the powder
Mold does not close

the designated place

Flint igniter not creating big enough spark

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

Handle clamp is not properly adjusted

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

tightly causing weld

tension should be clamped strong, but without excessive force

Conductor bends during welding,

Prepare the clamp holding the conductors, which will immobilize

and open mold

them during welding

Bent conductor

Straighten or cut out bad section of conductor

Weld connection is not

Havent used steel disc or disk did not seat

Make sure disc is seated at bottom of crucible before pouring

made after firing

properly at bottom of crucible

the powder into crucible

metal to leak out

starting powder
Bubbly or gassy

Oil, grease, moisture or foreign material

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

appearance, poor weld

on conductors or mold

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

Weld powder has gotten wet

Replace with another, dry weld powder

Insufficient metal

Used out mold resulting in leaking weld metal

Use new mold or if old one is worn around conductor

to make weld

Wrong size of cartridge

Compare the cartridge size and mold metal plate

Wrong mold type for desired connection

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

Improper way to clean mold

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

Mold wearing out

to fast

Weld will not stick

between welding. Do not use wire brush or metal objects inside molds
Bent or deformed conductor causes chipping

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

and faster wear of the graphite mold

the mold as clamp prepare external clamp to hold the conductors

Improperly cleaned area on steel

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

to metal surface

metal, then preheated

Moisture or dirt on cable

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

or conductor surface

on conductors to remove any foreign materials left on conductors

Galmar Marciniak s.j.

ul. Kobyliska 5
61-424 Pozna, Poland
tel. +48/61/835 80 00
fax +48/61/830 10 20
e-mail: office@galmar.pl
www.galmar.pl