Exothermic Welding System and Method

Abstract

The system comprises a mold (6) which in turn comprises: a weld cavity (4), housings (5) for the components (1) to be welded, a crucible-funnel (7) communicated with the weld cavity (4) for housing filling material (3), at least one additional cavity (10) for housing an exothermic mixture (2); and an inner shell (11) that separates the crucible-funnel (7) and the at least one additional cavity (10) to transmit heat produced in the exothermic reaction from the additional cavity (10) to the crucible-funnel (7). It allows the exothermic mixture to be isolated to avoid contact with the filling material (3) and to prevent it from reaching the weld cavity (4). The system can further include a first filler (13) and a second filler (16), arranged to be mounted over the mold (6) for introducing the filling material (3) and the exothermic mixture (2), respectively.

Claims

1. An exothermic welding system comprising a mold (6) to produce an exothermic weld, the mold (6) comprising: at least two housings (5) for housing components (1) to be welded; and at least one weld cavity (4) into which the housings (5) open; the system being characterized in that the mold (6) further comprises: a crucible-funnel (7) which comprises: a lower opening (9), communicated with an upper part of the weld cavity (4); and an upper opening (8), for receiving a solid filling material (3) in the crucible-funnel (7) and in the weld cavity (4); at least one additional cavity (10) that surrounds the outside of at least the weld cavity or cavities (4), and which is intended to house an exothermic mixture (2); and an inner shell (11) which separates the at least one additional cavity (10) from the crucible-funnel (7) and from the weld cavity (4), to allow for the transmission of heat from the additional cavity or cavities (10) to the crucible-funnel (7) and the weld cavity (4).

2. The exothermic welding system according to claim 1, characterized in that the mold (6) additionally comprises an outer body (12) which surrounds the outside of the additional cavity or cavities (10).

3. The exothermic welding system according to claim 2, characterized in that the outer body (12) is made of a poor heat-conductive material, in order to favor a transmission of heat from the additional cavities (10) towards the crucible-funnel (7) and the weld cavity (4) through the inner shell (11).

4. The exothermic welding system according to any one of claims 2-3, characterized in that the outer body (12) has a substantially greater thickness than the inner shell (11).

5. The exothermic welding system according to any one of claims 2-4, characterized in that outer body (12) comprises sand and/or ceramic material.

6. The exothermic welding system according to any one of claims 1-5, characterized in that the lower opening (9) of the crucible-funnel (7) opens directly into the upper part of the weld cavity (4).

7. The exothermic welding system according to any one of claims 1-6, characterized in that the mold (6) comprises a plurality of pieces (20, 21, 22, 23), which in turn comprise: a first group (22, 23), which form the housings (5), the weld cavity (4), the crucible-funnel (7), and the inner shell (11), and a second group (20, 21), which forms the outer body (12) and the additional cavities (10).

8. The exothermic welding system according to claim 7, characterized in that the first group (22, 23) comprises two pieces separated by the median plane of the housings (5) to facilitate the introduction of the components (1) to be welded in the housings (5), and to leave the welded joint in sight once it is made.

9. The exothermic welding system according to any one of claims 1-8, characterized in that the additional cavity or cavities (10) additionally surround at least one lower part of the crucible-funnel (7).

10. The exothermic welding system according to any one of claims 1-9, characterized in that it additionally comprises a first filler (13), intended to be mounted on top of the mold (6), and which comprises a first body (14) in which a first hollow (15) in the form of a funnel is defined which communicates with the crucible-funnel (7) for pouring the filling material (3) into the crucible-funnel (7) and into the weld cavity (4).

11. The exothermic welding system according to any one of claims 1-10, characterized in that it additionally comprises a second filler (16) intended to be mounted on top of the mold (6), and which comprises a second body (17) in which a second hollow (18) is defined in the form of a funnel with bifurcations (19) that communicate with the corresponding additional cavity or cavities (10), for pouring the exothermic mixture (2) into said additional cavity or cavities (10).

12. The exothermic welding system according to any one of claims 1-11, characterized in that the inner body (12) comprises graphite or graphene.

13. An exothermic welding method with the addition of a filling metal and with exothermic mixture as heat source, which uses the system described in one of claims 1-12, characterized in that it comprises the following steps: arranging the mold (6) mounted with the components (1) to be welded arranged in the respective housings (5) thereof and with the ends of the components (1) inside the weld cavity (4); pouring the filling material (3) through the upper opening (8) of the crucible-funnel (7) such that the filling material (3) is housed in the weld cavity (4) and in the crucible-funnel (7); placing the exothermic mixture (2) inside the additional cavities (10); producing an exothermic reaction in order to generate heat which is transmitted from the at least one additional cavity (10) to the crucible-funnel (7) through the inner shell (11) to melt the filling material (3), which pours, and is housed, in the weld cavity (4), generating a welded joint.

14. The exothermic welding method according to claim 13, characterized in that, for pouring the filling material (3), a first filler (13) is used which is mounted on top of the mold (6), and which comprises a first body (14) in which a first hollow (15) is defined in the form of a funnel which communicates with the crucible-funnel (7).

15. The exothermic welding method according to claim 14, characterized in that the first filler (13) is configured to cover the additional cavities (10) when it is mounted on the mold (6).

16. The exothermic welding method according to claim 13, characterized in that for pouring the exothermic mixture (2), a second filler (16) is used, which is able to be mounted on top of the mold (6), and which comprises a second body (17) in which a second hollow (18) is defined in the form of a funnel with bifurcations (19) that communicate with the corresponding additional cavities (10).

17. The exothermic welding method according to claim 16, characterized in that the second filler (16) is configured to cover the upper opening (8) of the crucible-funnel (7) when it is mounted on the mold (6).

18. The exothermic welding method according to any one of claims 13 to 17, characterized in that the heat produced in the exothermic reaction is additionally transmitted to the housings (5) and the weld cavity (4).

Description

DESCRIPTION OF THE DRAWINGS

[0023] As a complement to the description provided herein and for the purpose of helping to make the characteristics of the invention more readily understandable, in accordance with a preferred practical embodiment thereof, said description is accompanied by a set of drawings constituting an integral part of the same, which by way of illustration and not limitation represent the following:

[0024] FIG. 1 shows an elevation view of the mold of the invention.

[0025] FIG. 2 shows a plan view of the mold of FIG. 1.

[0026] FIG. 3 shows a cross-sectional view through plane III-III of FIG. 2.

[0027] FIG. 4 shows a cross-sectional view through plane IV-IV of FIG. 2.

[0028] FIG. 5 shows the use of a first filler for pouring the filling material.

[0029] FIG. 6 shows the use of a second filler for pouring the exothermic mixture.

[0030] FIG. 7 shows a plan view of a mold formed by several pieces according to a preferred embodiment.

[0031] FIG. 8 shows a cross-sectional view through plane VIII-VIII of FIG. 7.

[0032] FIG. 9 shows a cross-sectional view through plane IX-IX of FIG. 7.

PREFERRED EMBODIMENT OF THE INVENTION

[0033] What is offered below, with the help of the aforementioned FIGS. 1-9, is a detailed description of a preferred exemplary embodiment of an exothermic welding system, in accordance with the present invention.

[0034] The system of the invention allows exothermic welding to be carried out, in particular alumunothermic welding, in which components (1) are welded, wherein some of the components (1) can comprise aluminum or an aluminum alloy, using an exothermic mixture (2) and solid filling material (3), together with a flux product (not shown) if needed, without the drawbacks that exist in the state of the art.

[0035] The system comprises a mold (6), which in turn comprises a weld cavity (4) for receiving the melted filling material (3), which is produced by melting the solid filling material (3), as a result of the heat generated in an exothermic reaction.

[0036] The mold (6) additionally incorporates corresponding housings (5) for inserting the components (1) to be welded, wherein the housings (5) converge in the weld cavity (4). There are generally two housings (5), but there could be more, if a greater number of components (1) need to be joined by means of welding.

[0037] In the upper part of the mold (6) there is a crucible-funnel (7), which comprises an upper opening (8), communicated with the outside of the mold (6) and a lower opening (9), communicated with the upper part of the weld cavity (4). Preferably, the lower opening (9) of the crucible-funnel (7) superiorly opens into the weld cavity (4). The crucible-funnel (7) is intended to receive a solid, preferably granular mixture through the upper opening (8), comprising solid filling material (3), along with, if applicable, the flux product.

[0038] The invention is characterized in that it further includes at least one additional cavity (10), preferably several additional cavities (10), in particular two additional cavities (10). The additional cavities (10) surround the outside of the weld cavity (4), and at least one part further below the crucible-funnel (7), as well as they are intended to house the exothermic mixture (2).

[0039] The additional cavity or cavities (10) are separated from the crucible-funnel (7) and, if applicable, from the weld cavity (4) by means of at least one inner shell (11) of a reduced thickness and highly heat-conductive material, such as graphite, to allow for a quick transmission of heat from the additional cavities (10) towards the crucible-funnel (7), and if applicable, the weld cavity (4) and the housings (5).

[0040] Lastly, an outer body (12) surrounds the outside of the additional cavity or cavities (10). The outer body (12) is made of a poor heat-conductive material, and preferably of a thickness that is substantially greater than the inner shell (11) in order to favor a transmission of heat towards the inside, in other words, from the additional cavities (10) towards the crucible-funnel (7), and, if applicable, to the weld cavity (4) and the housings (5).

[0041] As previously indicated, by means of the system described, an exothermic welding is enabled without contact being made between the exothermic mixture (2) and the filling material (3). This way, the filling material (3) can be selected from materials that are most ideal for the type of welding in question, based on the nature of the components (1) to be welded, and on the working conditions of the welded components (1), while the exothermic mixture (2) can be selected independently, avoiding the drawbacks of the products of the exothermic reaction coming into contact with the filling material (3).

[0042] This way it is possible, for example, to weld aluminum components (1) using aluminum as a filling material (3), thereby obtaining an ideal performance, with regard to corrosion, of the welded joint. Likewise, there is no drawback in the exothermic mixture (2) being the type that generates copper, given that since the mixture with the filling metal (3) for example, aluminum, does not exist, the problems of fragility are avoided. Additionally, it is no longer necessary to decant the products of the exothermic reaction, and thus the exothermic mixture (2) can be in contact with the inner shell (11) before the exothermic reaction is produced, thereby taking maximum advantage of the heat generated.

[0043] To carry out the exothermic welding using the system of the invention, we begin with an initial position in which the mold (6) is mounted and the components (1) to be welded are housed in the respective housings (5) thereof with the ends of the components (1) inside the weld cavity (4).

[0044] The filling material (3) and the exothermic mixture (2) are then provided. For example, firstly, the filling material (3) is poured through the upper opening (8) of the crucible-funnel (7) such that the filling material (3) is housed in the weld cavity (4) and in the crucible-funnel (7) itself. To pour the filling material (3) one can use a first filler (13) mounted on the upper part of the mold (6), which is mounted on top of the mold (6) and which comprises a first body (14) with a first hollow (15) in the form of a funnel which empties into the crucible-funnel (7). Preferably, the first body (14) is configured to cover the additional cavities (10) when it is mounted on the upper part of the mold (6).

[0045] The exothermic mixture (2) is then poured inside the additional cavities (10). To do so, a second filler (16) can be used, which comprises a second body (17) with a second hollow (18) in the form of a funnel and bifurcations (19) which communicate with the additional cavities (10). Preferably, the second body (17) is configured to cover the crucible-funnel (7) when it is mounted on the upper part of the mold (6).

[0046] The filling material (3) can be placed in the mold (6) either before or after the exothermic mixture (2).

[0047] Once the filling material (3) and the exothermic mixture (2) are placed, the exothermic mixture (2) is activated to produce the exothermic reaction, which generates heat which is transmitted to the crucible-funnel (7) through the inner shell (11) to melt the filling material (3), which is poured, and is housed in the weld cavity (4), generating a welded joint.

[0048] The exothermic reaction also results in products of the reaction (not shown), which remain in the additional cavities.

[0049] The heat emitted in the exothermic reaction is not only transmitted to the crucible-funnel (7) to cause the melting of the filling metal (3), but also to the housings (5) and the weld cavity (4). This way, on the one hand, the components (1) to be welded are heated to raise their temperature to the predetermined welding temperature, and on the other hand, the heat is concentrated in the weld cavity (4), wherein the filling material (3) must remain in a liquid state and with a high degree of fluidity to fill said weld cavity (4) and completely soak the components (1) to be welded.

[0050] Lastly, the mold is opened (6) and the welded components (1) are extracted, after, if applicable, a waiting period in order to allow them to cool. The welded joint may then be finished, either by eliminating extra material, polishing, etc.

[0051] The mold (6) can be made up of several pieces (20, 21, 22, 23), which when assembled form the different parts of the mold (6), in other words, the housings (5), the weld cavity (4), the crucible-funnel (7) and the additional cavities (10), such that the additional cavities (10) are perfectly separated from the crucible-funnel (7) and from the weld cavity (4), and thus there is no possibility of the filling material (3) coming into contact with either the exothermic mixture (2) or with the products of the exothermic reaction.

[0052] Thus, a first group (22, 23) of pieces (20, 21, 22, 23) which incorporates the mold (6) includes those which delimit the housings (5), the weld cavity (4) and the crucible-funnel (7), and which, therefore, include the inner shell (11), which has a small thickness and is made of a good heat conductive material, preferably graphite.

[0053] A second group (20, 21) of the pieces (20, 21, 22, 23) which incorporate the mold (6) include those which make up the outer part of the mold (6) and which, on the opposite part of the inner shell (11), delimit the additional cavities (10). The second group (20, 21), as previously stated, is made of a poor heat-conductive material, preferably silica sand.

[0054] The first group (22, 23) can be made up of two pieces separated by the median plane of the housings (5) such that the two pieces can be separated to facilitate the introduction of the components (1) to be welded in the housings (5), and to leave the welded joint in sight once it is made.

[0055] As was previously stated, the crucible-funnel (7) is envisaged to receive the filling material (3) in a solid state, optionally in a granular form, depending on the size of the upper opening (8) of the crucible-funnel (7), with the help of the first filler (13). Both the first filler (13) and the mold (6) can have first protrusions (24) to ensure a correct positioning. It is worth mentioning that once the first filler (13) is correctly positioned on the mold (6) it is not possible to pour the filling material (3) inside the additional cavities (10), the only possibility being to pour it into the inside of the crucible-funnel (7).

[0056] Furthermore, and as was previously stated, the additional cavities (10) comprised by the mold (6) are provided to receive the exothermic mixture (2), preferably in a granular form, for example, with the help of the second filler (16), the bottom of which branches into as many bifurcations (19) as there are differentiated additional cavities (10) incorporated by the mold (6), such that each channel ends in a hole small enough to receive the exothermic mixture (2) through the upper opening of corresponding additional cavity (10).

[0057] The second filler (16) with bifurcations (19) is provided to be placed on the mold (6) such that the final hole of each bifurcation (19) coincides with the upper opening of the corresponding additional cavity (10). Both the second filler (16) and the mold (6) can have second protrusions (25) to ensure that the first is correctly positioned with respect to the second. It is worth mentioning that once the second filler (16) is correctly placed on the mold (6) it is not possible to pour the exothermic mixture (2) into the inside of the crucible-funnel (7), the only possibility being to pour it into the inside of the additional cavities (10).

[0058] It is worth mentioning that if the filling metal (3) is in a granular form, the apparent density thereof will be much less than that of the filling metal (3) once it has been melted, and thus the volume of the crucible-funnel (7) will have to be much greater than the volume to be filled in the weld cavity (4) by said melted filling metal (3).

[0059] In the same way, if the exothermic mixture (19) is in a granular form, the apparent density thereof will be much less than that of the products of the reaction in liquid state, and thus the volume of the additional cavities (10) may not be sufficient to contain the total exothermic mixture (2), and therefore the same will tend to overflow at the top, occupying the bifurcations (19), and even the bottom of the second filler (16). It is in this higher part of the exothermic mixture (2) where the reaction can be easily initiated, which will propagate towards the entire mass of the exothermic mixture (2).

[0060] Given that the ignition of the exothermic mixture (2) is done at the bottom of the second filler (16), the same is preferably a refractory material, and furthermore can incorporate a lid (not shown), to prevent projections from coming out, or to house a fuse (not shown) to remotely carry out the activation.

[0061] In addition to the filling material (3), the object of the invention can make use of a flux. Both the filling metal (3) as well as the flux can be conventional and conveniently selected for carrying out the welding in question.

[0062] For example, if we are dealing with welding aluminum pieces or conductors, the filling material (3) can be an alloy with an eutectic composition made up of 88% aluminum and 12% silicon (AlSi12), and the flux can be potassium aluminum fluoride. Both can be in a granular form and made up of a mixture of, for example, 75% aluminum alloy and 25% fluoride. In this case, not only the filling material (3) is poured into the inside of the crucible-funnel (7), but also the mixture of filling metal (3) and the flux.

[0063] The exothermic mixture (2) of which the object of the invention makes use can consist of different types, including, for example, that which is formed by a mixture of copper oxide and aluminum oxide, or which is made up of a mixture of iron oxide and aluminum, or even a combination of different types.

[0064] Below are some considerations with regard to materials that can be used in manufacturing the inner shell (11) and the outer body (12).

[0065] For the case of the inner shell (11), a refractory material is required, since it must withstand extremely high temperatures reached in the aluminothermic reaction. Likewise, it should be an excellent heat conductor to enhance the heat flow by conduction through the same. Furthermore, it would be desirable if it did not adhere to the melted filling material (3). Lastly, it is desirable that the thickness be reduced, to reduce the temperature drop through the same as much as possible. As a result, a highly appropriate material for the inner shell (11) is graphite. Graphene is also a material that is notably suitable, since, besides having the aforementioned characteristics, even to a greater degree than graphite, it can be extended, forming a single layer of atoms (two-dimensional material). In the case of graphite, the inner shell (11) could be obtained by means of machining or molding, even by means of additive manufacturing using 3D printers. Likewise, and preferably, the inner shell, especially when manufactured in graphite, comprises a first part with a reduced thickness, to facilitate the exothermic welding process, and a second part in the form of a rigid frame surrounding the first part, to provide greater mechanical resistance and rigidity.

[0066] With regard to the outer body (12), a refractory material is desired, to be able to withstand extremely high temperatures reached in the aluminothermic reaction. Likewise, as was previously indicated, it is desirable that the same be a poor heat conductor so that the heat flow does not pass through the same, but rather in the opposite direction, towards the inner shell (11). Due to all of the aforementioned points, it is preferable that the outer body (12) be made of sand, or even ceramic materials. The outer body (12) is preferably obtained by molding.