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Exothermic Welding


An exothermic welded connection may be tested by any of the non-destructive technique applicable to other welding processes. These include x-ray, ultrasonic, dye penetrate. None of these techniques can be used in a compression or crimped connection, since the joint will show up as a crack, which is actually what it is.

The exothermic welded connections can also be inspected visually since one can see immediately if welding has taken place. On the other hand one cannot see if a compression joint has been made correctly.

Mechanical connections can result in the following: Increase in time causes corrosion. Increases in corrosion cause increase in resistance. Increase in resistance causes heat, which in turn accelerates the corrosion. The ultimate result is premature failure. Exothermic connections avoid these problems.

The Tokai Weld moulds are designed to complete ±100 connections depending on the care given to the mould during usage, transport and storage.

Regular checks will determine if moulds are fit for use.

  1. Moulds must be dry and have lids.
  2. Mould face must be smooth, so when closed it seals properly.
  3. Mould disc seat must show no sign of chips, cracks, gauges or wear.
  4. Steel retaining disc must seal properly. No powder must fail into weld cavity prior to weld.
  5. Tap home must be well defined.
  6. Weld cavity must have no chips or signs of wear.
  7. Conductors must fit snugly and not be loose in mould.
  8. The correct mould cleaning told must be used.



Download our Tokai Exothermic Welding Catalogue here