WO2021011453A1 - Allumeur pour soudage exothermique - Google Patents

Allumeur pour soudage exothermique Download PDF

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Publication number
WO2021011453A1
WO2021011453A1 PCT/US2020/041775 US2020041775W WO2021011453A1 WO 2021011453 A1 WO2021011453 A1 WO 2021011453A1 US 2020041775 W US2020041775 W US 2020041775W WO 2021011453 A1 WO2021011453 A1 WO 2021011453A1
Authority
WO
WIPO (PCT)
Prior art keywords
ignition
cartridge
ignitor
welding
plug
Prior art date
Application number
PCT/US2020/041775
Other languages
English (en)
Inventor
Nicholas Turner
Greg MARTINJAK
Steven ROIS
Christian Paul BARCEY
Original Assignee
Erico International Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Erico International Corporation filed Critical Erico International Corporation
Publication of WO2021011453A1 publication Critical patent/WO2021011453A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K23/00—Alumino-thermic welding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F42—AMMUNITION; BLASTING
    • F42B—EXPLOSIVE CHARGES, e.g. FOR BLASTING, FIREWORKS, AMMUNITION
    • F42B3/00—Blasting cartridges, i.e. case and explosive
    • F42B3/10—Initiators therefor
    • F42B3/12—Bridge initiators

Definitions

  • Exothermic welding can be used in different settings to form high quality, high ampacity, and low resistance electrical connections between different conductors.
  • an exothermic welding process can fuse together separate conductors to provide a bond with a current carrying capacity substantially equal to that of the conductors themselves.
  • exothermic welds can be relatively durable and long-lasting, and can avoid problems of loosening and corrosion that can occur for mechanical and compression joints.
  • exothermic weld connections are widely used in grounding systems and other settings to enable connected sets of conductors to operate, effectively, as a continuous conductor with relatively low resistivity.
  • Some embodiments of the invention provide an ignitor for exothermic welding material that includes a cartridge with an open end, an ignition charge of welding material disposed within the cartridge, an ignition element configured to ignite the ignition charge, and a plug.
  • the plug can be formed from a hardened slurry of graphite material that seals the open end to retain the ignition charge and the ignition element within the cartridge.
  • a cartridge can be closed except at an open end, such that an ignition charge is fully enclosed by the cartridge and a plug that seals the open end.
  • no air gap may be provided between a plug and an ignition charge.
  • welding material of an ignition charge may not be classified as a division 4.1 flammable solid.
  • a slurry that forms a plug can be formed from materials including one or more of: graphite fines or sodium silicate.
  • a plug can retain an ignition element in contact with an ignition charge.
  • an ignition element can include a conductive filament that is electrically connected to electrical leads extending outside of the cartridge.
  • electrical leads can extend through a plug.
  • a cartridge can be a metal-walled cartridge.
  • an ignitor can be configured to be installed for ignition of a main charge of welding material with a plug opposite an ignition charge from the main charge.
  • Some embodiments of the invention provide an ignitor for exothermic welding material that includes a metal cartridge with a closed end and side walls that collectively define an internal cartridge area.
  • An ignition charge of welding material can be disposed within the internal cartridge area and an ignition element can be configured to ignite the ignition charge.
  • a plug of graphite material can be formed between the side walls, opposite the closed end, to close the internal cartridge area.
  • an ignition element can extend through a plug to contact an ignition charge.
  • an ignition element can include a conductive filament embedded within an ignition charge and electrical leads that can extend through a plug.
  • a plug can be formed from a slurry that includes graphite particles and a binder.
  • a welding material of an ignition charge can be powdered welding material.
  • Some embodiments of the invention provide a method of manufacturing an ignitor for exothermic welding material. The method can include providing a cartridge that includes side walls and an open end, at least partly filling the cartridge with an ignition charge of welding material, and disposing an ignition element for ignition of the ignition charge. A slurry of graphite material can be directed into the open end of the cartridge, and cured to form a hardened plug at the open end of the cartridge, to retain the ignition charge within the cartridge.
  • a slurry can be cured to form a hardened plug so that no air gap is provided between the plug and an ignition charge.
  • a cartridge can include a closed end opposite an open end, so that a plug at the open end, side walls, and the closed end fully enclose an ignition charge within the cartridge.
  • a welding mold can include a crucible to receive a main welding charge of welding material, and a welding chamber that is configured to receive one or more conductors to be welded.
  • An ignitor can be provided to ignite the main welding charge, and can include a cartridge for an ignition charge of welding material and a plug of graphite material to seal the cartridge.
  • a welding mold can include a lid for a crucible.
  • a lid can include an ignition port that is configured to receive an ignitor to hold the ignitor above a main welding charge.
  • a plug of an ignitor can substantially block an ignition port in a welding mold when the ignitor is received in the ignition port.
  • FIG. 1 is an isometric ignitor for exothermic welding material, including a cartridge and a plug, according to an example of this disclosure
  • FIG. 2 is an isometric view of the ignitor of FIG. 1, with the cartridge not shown to illustrate aspects of a plug and an internal ignition charge of welding material;
  • FIG. 3 is an isometric view of the insert ignitor of FIG. 1, with the cartridge rendered transparently and the ignition charge not shown;
  • FIG. 4 is a cross-sectional view of a welding apparatus that includes the ignitor of FIG. 1, according to an example of this disclosure
  • FIG. 5A is a side elevation view of another ignitor for exothermic welding material, including a cartridge, according to an example of this disclosure
  • FIG. 5B is a side elevation view of the ignitor of FIG. 5A, with the cartridge not shown;
  • FIG. 5C is a side elevation view of the ignitor of FIG. 5A with the cartridge and an ignition charge of welding material not shown.
  • the terms“mounted,”“connected,”“supported,” and“coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and“coupled” are not restricted to physical or mechanical connections or couplings.
  • exothermic welding can be used to connect together metal structures, such as copper conductors of an electrical system.
  • exothermic mixtures can include a combination of a reductant metal and a transition metal oxide, which react exothermically upon ignition to initiate and then sustain a continuing reaction of the mixture.
  • the resulting molten metal can be used to create a useful weld, such as may be controlled using a non-fusible (e.g., graphite) mold.
  • the resulting heat can be used directly.
  • some conventional mixtures of exothermic welding material can include aluminum and copper oxide.
  • the resulting exothermic reaction can provide a mixture of molten copper and aluminum oxide, or slag.
  • the molten copper which has a higher density than the slag, can accordingly be directed by a mold to weld together metal conductors (e.g., copper to copper or steel to steel).
  • the less dense aluminum oxide slag is generally removed from the weld connection and discarded.
  • other conventional mixtures can include iron oxide and aluminum, which can react with similar effect.
  • powdered starting material can be configured as a special fine-grained formulation of welding material that is highly combustible (i.e., relatively easily ignitable).
  • Such starting material can, for example, be sprinkled onto a main charge of standard welding material and can then be ignited using electrical or mechanical devices (e.g., a flint gun or an arc ignitor). The heat of the resulting reaction can then ignite the main charge of welding material so that a weld can be formed.
  • an ignition device can be used to directly supply activation energy to a main charge of welding material (e.g., as may include a mixture of starting and non-starting welding material).
  • conventional approaches to igniting welding material can introduce complexity, cost, or other issues to welding processes.
  • management and use of starting powder can be generally difficult for operators, including due to the tendency of the fine grained material to disperse from optimal locations (e.g., during transport). Such dispersal, in particular, can sometimes render the starting powder useless for igniting a main welding charge.
  • ignitors that use starting powder may require enhanced safety precautions during manufacture, transport, and storage, even when fully enclosed in packaging.
  • implementing arc ignition may require substantial electronic circuitry, including relatively expensive capacitors or other devices.
  • Embodiments of the invention can address these and other issues.
  • some examples can be configured as self-contained ignitors, with a cartridge that contains an ignition charge of welding material, an ignition element, and a plug.
  • the plug can be formed from a non flammable and non-fusible composition and can be disposed both to maintain the ignition charge within the cartridge and to maintain the ignition element in appropriate alignment with the ignition charge (e.g., in contact with the welding material within the cartridge).
  • the plug can ensure that the welding material of the ignition charge remains in the cartridge until ignited and that the ignition element is appropriately disposed to ignite the ignition charge.
  • a self-contained ignitor can be formed with a cup-shaped cartridge that includes a closed end, closed side walls, and a single open end and is at least partly filled with an ignition charge of welding material.
  • the cartridge can be formed to include fusible material, such as a jacket of copper or other metal, so that molten material from reaction of the ignition charge can melt through the cartridge to reach and ignite a main welding charge.
  • a plug can be formed from graphite material (e.g., a composition of graphite and other substances) to close an open end of a cartridge and thereby seal an ignition charge within the cartridge.
  • Some plugs can also help to direct flow of the molten products of the eventual reaction of the ignition charge towards a main charge of welding material.
  • graphite is generally non-fusible and very difficult to combust, particularly in the transient-heating and limited-oxygen environment of exothermic welding conditions.
  • a graphite plug can help to ensure that the molten welding material from the ignition charge is directed primarily to melting or otherwise consuming material of the cartridge opposite the plug.
  • a generally non-combustible (in the intended environment) and non-fusible plug can help to reduce (e.g., eliminate) expulsion of molten material from the ignition charge in the direction of (and past) the plug.
  • a plug can be formed from a hardened slurry of graphite material, such as a slurry of graphite particles and a binder (e.g., sodium silicate).
  • graphite fines i.e., particles with median diameter of less than 150 pm
  • a non flammable, non-fusible plug can be relatively easily formed while making use of otherwise- wasted material that may independently have little saleable value.
  • slurry to form a plug can also provide other benefits.
  • the slurry when slurry is initially poured into a cartridge, the slurry can naturally settle onto and (as applicable) around an ignition charge within the cartridge. Accordingly, when the slurry has hardened into a solid plug, there may be no air gap between the plug and the ignition charge, which may provide various benefits. For example, with no air gap between the plug and the ignition charge, there may be negligible gases present that might otherwise pressurize the cartridge as the ignition charge reacts. Additionally, with the elimination of empty space within a cartridge, it may be possible to ensure continuous engagement (e.g., contact) between an ignition element and an ignition charge regardless of the current orientation of the cartridge. Accordingly, some embodiments can be reliably used for ignition even after relatively rough transport or other physical disturbances.
  • a plug may continue to secure part or all of an ignition element, such as an initially closed-circuit filament of tungsten or other material, even after ignition of an ignition charge of welding material within a cartridge.
  • an ignition element such as an initially closed-circuit filament of tungsten or other material
  • a non-fusible and generally non combustible plug such as may be formed from hardened graphite slurry, can remain largely intact after reaction of the associate ignition charge and can, correspondingly, continue to secure any non-consumed parts of an ignition element along with attached parts of the cartridge. This may, for example, help to ensure that parts of the ignition element do not fall into the weld being formed, or otherwise interfere with welding operations.
  • a non-fusible and generally non-combustible plug such as a plug formed from graphite slurry
  • some examples can include a graphite welding mold with a crucible to hold a main welding charge, a lid to cover the crucible, and an ignition port within the lid to receive an ignitor for ignition of the main welding charge.
  • the graphite (or other) material of a plug of the ignitor can effectively fill a cross-section of the ignition port and thereby reduce (e.g., eliminate) expulsion of welding material from the crucible through the ignition port during welding operations.
  • a self-contained ignitor can be configured as a self-contained ignitor and main welding charge.
  • an ignitor such as generally described above may sometimes include a welding charge that is large enough to provide sufficient material to form a desired weld.
  • the ignition element can be arranged to ignite an ignition charge that is also a main welding charge, with the reaction of an ignition/welding charge directly providing molten material to form a weld.
  • FIGS. 1-3 illustrate aspects of a self-contained ignitor 20 for initiating exothermic reactions in main welding charges for exothermic welding.
  • the ignitor 20 includes a cartridge 22 that is formed (e.g., die drawn) as a copper cup with cylindrical side walls 24, a closed end 26, and an open end 28 with a flared mouth. As shown in FIG. 2 in particular, an ignition charge 30 substantially fills the cartridge 22.
  • an ignition charge can be formed from welding material with similar constituents as a main welding charge (not shown in FIGS. 1-3), such as a conventional mixture of exothermic welding material.
  • a composition of an ignition charge can be a somewhat adjusted formulation as compared to a main welding charge, such as may result in comparatively large heat generation.
  • an ignition charge can be formed differently than conventional starting material for exothermic welding, such that the ignition charge may not be classified as a flammable solid.
  • the ignitor 20 also includes an ignition element 32. In some examples, it can be useful to form an ignition element from a conductive filament in a closed- circuit configuration with external electronics (not shown).
  • the ignition element 32 is formed as a partially looped (e.g., U-shaped) tungsten filament, with electrical leads 34 that separately extend through a plug 36.
  • This arrangement, and other closed-circuit arrangements can allow for ignition of the ignition charge with relatively low power, such as may allow the use of simple battery-powered ignitors without complex circuitry, large capacitors, or other expensive or bulky electronics.
  • a closed-circuit arrangement can help the ignitor element to retain a desired shape and orientation, such as may be helpful to ensure continuous contact between the ignitor element and an ignition charge, even without the use of biasing elements such as springs.
  • the ignitor 20 includes a plug 36.
  • the plug 36 is disposed to close the open end 28 of the cartridge 22, and thereby to seal the ignition charge 30 within the cartridge 22.
  • the plug 36 secures the ignition charge 30 within the cartridge 22, with the tungsten filament of the ignition element 32 embedded within the ignition charge 30 and with the electrical leads 34 extending through the plug 36 to the exterior of the cartridge.
  • the plug 36 can prevent the material of the ignition charge 30 from escaping the cartridge 22. Further, the embedding of the ignition element 32 in the plug 36 can ensure that the ignition element 32 remains fixed in the intended position until (and while) it is used to ignite the ignition charge 30, with easy connection points at the electrical leads 34 to receive power from external ignition electronics. Secure engagement of an ignition element by a plug can also help to secure the ignition element against loss (e.g., incorporation into a weld).
  • the plug 36 can be formed with no air gap between the ignition charge 30 and the plug 36 (or other features at the open end 28 (now closed by the plug 36) of the cartridge 22. Thus, there is no substantial amount of air to become super heated and thereby highly pressurized, during reaction of the ignition charge 30.
  • the plug 36 can effectively serve as a non-melting lid that remains intact during the reaction of the ignition charge 30 and the subsequent melting of the closed end 26 of the cartridge 22 (i.e., for the molten products of the ignition charge 30 to fall onto a main welding charge).
  • the plug 36 can provide a barrier that prevents the products of the potential highly volatile reaction of the ignition charge 30 from escaping the cartridge 22 at any point except through a melted opening at the (formerly) closed end 28.
  • a plug can be formed from graphite material, such as a composition of graphite and other components.
  • the plug 36 is formed from hardened graphite slurry that includes an approximate (i.e., within 15%) equal ratio of graphite fines and binder, such as a 40% aqueous solution of sodium silicate. Accordingly, during manufacture of the ignitor 20, the ignition charge 30 can be filled into the cartridge, the ignition element 32 oriented for use, and a slurry poured and hardened to form the plug 36.
  • slurry such as to form the plug 36
  • slurry can allow for relatively easy construction of an ignitor, including because the flowable nature of the slurry can help to automatically and substantially eliminate air gaps between an ignition charge and a plug, and to ensure reliable (e.g., surrounding) engagement of an ignitor element of any variety of configurations.
  • some cartridges can be formed in other shapes or from other materials.
  • different types of graphite (or other) materials can be used for a plug, including for plugs that are formed in different ways than the plug 36.
  • ignitors other than tungsten filaments can be used and, although closed-circuit ignitor elements may be useful in many cases, other approaches are possible.
  • FIG. 4 illustrates an example welding apparatus 40 that is configured for use with the ignitor 20.
  • the apparatus 40 includes a graphite mold 42 with a lid 44 that can hinge to open a crucible 46, and a welding chamber 48 with conductor openings 50 to receive conductors (not shown).
  • the lid 44 is generally solid, but includes an ignition port 52 that extends from the outside of the lid 44 to the top of the crucible 46.
  • an ignitor such as the ignitor 20 can be disposed in the ignition port 52.
  • the flared mouth of the cartridge 22 can help to secure the ignitor 20 against slipping through the ignition port 52, with the plug 36 substantially blocking the open top end of the ignition port 52 and the ignition charge 30 suspended within the ignition port 52 above the crucible 46.
  • a main welding charge such as a self-contained welding cup 54 filled with welding material
  • the ignition charge 30 can then be ignited using the ignition element 32 (see, e.g., FIG. 3), with the heat of the resulting reaction melting through the cartridge 22 opposite the plug 36 so that molten welding material falls from the cartridge 22 onto the welding cup 54.
  • the heat of this welding material can then ignite welding material within the welding cup 54 (e.g., after melting through a top of the cup 54), so that exothermic welding of conductors (not shown) within the welding chamber 48 can be completed.
  • the ignition charge 30 can remain within the ignition port 52, to help prevent expulsion of products via the ignition port 52.
  • the ignitor 20, with the cartridge 22 now partially melted and empty of welding material and the plug 36 retaining any non-consumed pieces of the cartridge and the ignition element 32, can then be removed from the lid 44 and discarded.
  • FIGS. 5A-5C illustrate aspects of another ignitor 60 according to an example of the disclosure.
  • the ignitor 60 includes a cup-shaped copper cartridge 62, which is configured to contain an ignition charge 64 of welding material (e.g., not conventional starting powder).
  • An ignition element 66 with strip-like electrical leads 68 extends into the cartridge 62 so that a closed-circuit filament 70 is embedded into the ignition charge 64.
  • a plug 72 such as may be formed from a slurry of graphite material, is formed at an open end of the cartridge 62 to fully seal the ignition charge 64 within the cartridge and to secure the ignition element 66 relative to the cartridge 62 and the ignition charge 64.
  • the ignitor 60 can be implemented similarly to the ignitor 20 (see FIGS. 1-3), or otherwise, with similar benefits.
  • the disclosed ignitors and apparatus for welding can provide improved functionality and handling, and more economical manufacturing and transport, as compared to conventional systems.
  • self-contained ignitors with plugs according to some embodiments can allow for easier and more reliable ignition of welding materials, including after jostling or other disturbances during transport and use.
  • some configurations can help to ensure that the energy of the reaction of an ignition charge of welding material is primarily and efficiently directed towards ignition of a main charge of welding material to execute exothermic welding operations.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Feeding, Discharge, Calcimining, Fusing, And Gas-Generation Devices (AREA)

Abstract

L'invention concerne un allumeur (20) pour matériau de soudage exothermique, qui peut comprendre une cartouche (22) avec une extrémité ouverte (28), une charge d'allumage (30) de matériau de soudage disposée à l'intérieur de la cartouche (22), et un élément d'allumage (32) conçu pour allumer la charge d'allumage (30). Une fiche (36), telle qu'elle peut être formée à partir d'une bouillie durcie de matériau de graphite, peut sceller l'extrémité ouverte (28) pour retenir la charge d'allumage (30) et l'élément d'allumage (32) à l'intérieur de la cartouche (22).
PCT/US2020/041775 2019-07-12 2020-07-13 Allumeur pour soudage exothermique WO2021011453A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201962873378P 2019-07-12 2019-07-12
US62/873,378 2019-07-12

Publications (1)

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WO2021011453A1 true WO2021011453A1 (fr) 2021-01-21

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2926072A1 (es) * 2021-04-12 2022-10-21 Klk Electro Mat S L U Sistema de iniciacion de la reaccion aluminotermica en soldadura exotermica y procedimiento asociado
WO2022266220A3 (fr) * 2021-06-15 2023-02-02 Erico International Corporation Système de soudage exothermique

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4014264A (en) * 1974-09-13 1977-03-29 Dynamit Nobel Aktiengesellschaft Combined igniter cap
US20040164438A1 (en) * 2003-02-26 2004-08-26 Delphi Technologies, Inc. Slurry composition and method for forming friction material therefrom
US20150041520A1 (en) * 2012-03-20 2015-02-12 Aplicaciones Tecnologicas, S.A. Ignition device for exothermic welding, mold for exothermic welding for the ignition device, and apparatus for exothermic welding comprising such a mold and such an ignition device

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4014264A (en) * 1974-09-13 1977-03-29 Dynamit Nobel Aktiengesellschaft Combined igniter cap
US20040164438A1 (en) * 2003-02-26 2004-08-26 Delphi Technologies, Inc. Slurry composition and method for forming friction material therefrom
US20150041520A1 (en) * 2012-03-20 2015-02-12 Aplicaciones Tecnologicas, S.A. Ignition device for exothermic welding, mold for exothermic welding for the ignition device, and apparatus for exothermic welding comprising such a mold and such an ignition device

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2926072A1 (es) * 2021-04-12 2022-10-21 Klk Electro Mat S L U Sistema de iniciacion de la reaccion aluminotermica en soldadura exotermica y procedimiento asociado
WO2022266220A3 (fr) * 2021-06-15 2023-02-02 Erico International Corporation Système de soudage exothermique

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