KW Weld Metal Powder
For Grounding & Lightning Protection Systems
Kumwell weld metal powder KW type is exothermic welding connection process for grounding and lightning
protection system must maintain a low contact resistance often under adverse conditions for the expected
lifetime. Connections in grounding and lightning protection system network are subjected to serve corrosion,
high mechanical stress due to electromagnetic force, and rapid thermal heating due to high current magnitude
during fault conditions.
Applications
Suitable for typical installation in grounding and lightning protection’s connections their fore copper to
copper, copper to steel, steel to steel, copper to stainless steel, and stainless steel to stainless steel.
Standards
• UL 467 – Standard for Grounding & Bonding Equipment.
• IEEE 837 – Standard for Qualifying Permanent Connections used in Substation Grounding.
• IEC 62561-1 – Lightning Protection Systems Component (LPSC) for connection components.
Criteria of Test Kumwell Exothermic welding connections have been successfully tested in accordance with:
• IEEE Std. 837 Standard for Qualifying Permanent Connection (For type test product)
1. Mechanical pullout test
2. Electromagnetic force
3. Sequential test group has 3 main procedures to test each if it passes the set standard of each procedure;
a. Current Temperature Cycling
b. Freeze Thaw Cycling
c. Corrosion Sequence Run: Salt Spray Test, Acid Test
• UL 467 Standard for Grounding & Bonding Equipment/UL Inspection Witness
1. Weld metal powder quality: Percentage of material, Particle size, Density of each composition, Starting powder and ignition
2. Reaction: Steady burn, No pop, No drastic colour change, No porosity in the resulting copper, Consistency of colour
3. Shot Time Current Test
4. Mechanical Sequence from UL 486
• American Railway Engineering and Maintenance-of-way Association (AREMA)
Test methods for tensile testing of metallic material evaluate the consistency chemistry and overall quality
of KW, KB and KR Welding material resulting to the average of 43,000 psi tensile strength.
• IEC 62561-1 Lightning Protection Systems Component (LPSC) for connection component
1. Environmental Test: Salt Spray Test, Humid Sulphurous atmosphere test.
2. Electrical Test: Lightning Impulse Current Test, Contact Resistance Measurement
3. Static Mechanical Test: Tensile Test
Quality Assurance
Kumwell also is internationally recognized for high standard of its graphite mould and the exothermic welding powder from successfully passed the control test in accordance with the UL467 Standard for Grounding and Bonding Equipment/UL Inspection Witness.
Process
Kumwell Exothermic Welding process is a molecular chemical reaction between copper oxide and aluminium, generating a tremendous superheat with molten metals reaching approximately temperatures of 2,537 °C (4,598 °F). The process can be completed itself automatically without external source of power or heat.
Safety starting and weld metal powder
• Nontoxic and heavy metal
• Non self-ignite
• Ignition temperature at least 400°C
• Smooth reaction • High conductivity
• Steady burn without pop and fire out
• No slag and porosity
• Consistency of colour
Technical Comparison
Exothermic welding withstands about 5 times higher than clamp’s connection in mechanical force. Unlike compression and bolt clamp, exothermic welded joint become homogeneous metal.
Packaging
Kumwell weld metal powder is contained a moisture-resistant plastic cartridge, packed in a paper box. Integral weld metal package is identified as to the weld metal powder’s amount, type of metal powder to be connected, Lot No., the number of tubes to manufacturing date (MFD).
| Code | KW15 | KW25 | KW32 | KW45 | KW65 | KW90 | KW115 | KW150 | KW200 | KW250 |
| Weight/Tube | 15g | 25g | 32g | 45g | 65g | 90g | 115g | 150g | 200g | 250g |
| Tubes/Box | 40 | 20 | 20 | 20 | 20 | 20 | 10 | 10 | 10 | 10 |
Storage
It should be stored at ambient temperature and kept away from moisture.
Resources and Downloads
| – Kumwell Grounding & Lightning 2024 | Download |
| – Kumwell Exothermic Welding 2024 | Download |
