Glass Sleeves for Butt Welding Stranded Cable Cross-Sections : 0.16 mm² - 35 mm²
Video 1- Electroweld Stranded Cable Butt Welding on Micro Wire Butt Welder using Glass Sleeves-Operational Video
Video 2- Electroweld Micro Wire Butt Welder-Operational Video
Video 2- Electroweld Micro Wire Butt Welder-Operational Video
Product Details
Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.
Applications: Electroweld Glass Sleeves are designed for butt welding of stranded conductors. Example: For enabling continuous wire drawing manufacturing operations, the two ends of the stranded conductor to be welded are inserted into the Glass Sleeve openings on each end, such that they meet in the middle of the tube. This assembly of the stranded cables and glass sleeve is then clamped into the jaws of the matching Electroweld Butt Welding machine. When the butt welding process is initiated, the glass sleeves act as crucibles during the butt welding process and the ends of the stranded conductors inside the sleeve fuse to form a burr free and pore free weld. The glass sleeve is then broken with a hammer or mallet revealing the butt welded stranded cable which can then be processed upstream, ensuring continuous operations of the wire drawing manufacturing process.
Note: The Welding Jaw Clamping mechanism on Electroweld Butt Welding Machines is either Hand Operated, Foot Operated or Pneumatic Cylinder Operated, depending on the stranded conductor being welded and the corresponding matching machine rating. Regarding Upset Pressure mechanism in Electroweld Butt Welding Machines- For smaller cross-section stranded conductors, the butt welding upset pressure is applied via spring tension and for larger cross-section stranded conductors, the butt welding upset pressure is applied via pneumatic cylinders. Additionally the clamping pressure should be approximately twice the upset butt welding pressure to avoid slippage and turning of the stranded conductors inside the sleeve during butt welding.
Glass Sleeves for Butt Welding Stranded Cable Cross-Sections : 0.16 mm² - 35 mm²
Ordering and Lead Times for Delivery :
Note: MINIMUM ORDER QUANTITY (MOQ) FOR GLASS SLEEVES IN ANY PARTICULAR DIMENSION- 100 Qty.
Minimum 4-5 Weeks Lead time for Delivery of MOQ. Samples could be made available earlier on request.
Please contact sales@electroweld.com for sample requests, price quotes or purchase orders for your required applications and quantities
Specifications Table for Various Types of Conductor Outer Diameter and Guide for Matching Various Glass Sleeve Sizes :
Advantages of Glass Sleeves :
Note 1: Sleeve Inner Diameter Size Selection - Clearance between the sleeve and the conductor :
The conductor must slip in the sleeve but with a little friction to be well driven. If the clearance is too large, the axial rigidity of the strand is reduced and the wires begin to fold in the sleeve. The sleeve size must be considered as one would consider the size of a welding die. It must not stop the conductor from being introduced, but some friction needs to exist.
Additionally, the choice of a good cutter is an important step towards a successful weld. If we advise our users to do not over-strand the conductor after cutting, it is also for this reason. As the manual over-stranding is never regular, it changes not only the quality of sliding in the sleeve, but also the clearance and all the other parameters. Furthermore, another negative consequence of a larger diameter weld is the risk of being broken or drawn when it later goes through the insulation head.
Note 2: Using Right Tool for Cutting Stranded Conductor before introduction into the Glass Sleeve for Butt Welding :
The users often cut the conductors with scissors. Even if it is difficult to see, this increases the conductors length and let a flat burr outside the strand. Furthermore, the conductor un-strands easily and the user tries to over-strand it to keep it again rigid. As a result, he must then use a sleeve larger than necessary and this increases the clearance between the sleeve and the conductor. Another negative consequence of this over-stranding is the lay-length decrease which decreases the flowing of the melted metal between the wires. The operator must then increase the upset to compensate for the larger clearance but cannot increase the pressure because the conductor is less well driven in the sleeve during the fusion. As the welding is not satisfactory, the operator then requires longer sleeves, hoping to correct the problem. The weld then becomes longer and breaks easily after several folding in the accumulator further down the line.In fact, a good driving in the sleeve requires as little as possible clearance between the sleeve and the conductor.
Following are some examples:
| cross sections | clearance |
| 0.25 to 0.35 mm² | 0.03 to 0.05 mm |
| 1.5 to 4 mm² | 0.5 to 0.7 mm |
Note 3: Slipping the conductor in the sleeve :
We also suggest that the operator creates a small cone at the inlet of the sleeve to ease the strand introduction, and avoid any irregular over-stranding.
Note 4: Clamping of the conductor in the jaws :
When the conductor folds during the fusion, the reason is often a bad clamping in the jaws. When the pressure is applied, badly clamped conductors slice in the jaws and the weld turns around those ones which are correctly clamped. Theoretically, the best shape for the jaws is a circular groove but practically, we advice to use 'U' grooves because the setting and the clamping is more reliable.
Material Properties of Borosilicate used for making the Borosilicate Glass Sleeve :
Material Properties of Quartz used for making the Quartz Glass Sleeve :
Note: MINIMUM ORDER QUANTITY (MOQ) FOR GLASS SLEEVES IN ANY PARTICULAR DIMENSION- 100 Qty.
Please contact sales@electroweld.com for sample requests, price quotes or purchase orders for your required applications and quantities
Operatonal Video for Stranded Cable Butt Welding on Electroweld Micro Wire Butt Welder using Glass Sleeves
Electroweld Micro Wire Butt Welder - YouTube
Operatonal Video for the Electroweld Micro Wire Butt Welder
Electroweld Micro Wire Butt Welder - YouTube
What is Butt-Welding or Upset Welding?
Butt-welding is a technique where two metal ends are connected with no overlap, forming a near seamless merger. To do so, the two ends are heated by passing an electric current through the weld interface. The interface causes heating due to resistance to the current. Heating continues until the metal reaches a plastic-like state. The ends (or butts) are then pressed together, where they form a knot or upset. The knot or upset is then ground down to a smooth finish. This technique is great for welding wires, bandsaw and saw blades, creating closed-loop steel rings or welding rods. Butt-welding is sometimes used interchangeably with Upset Welding. As we can see both of them are the exact same process with just a difference in the name.
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- Cost, insurance, and freight (CIF) is an expense paid by a seller to cover the costs, insurance, and freight of a buyer's order while it is in transit. The goods are exported to a port named in the sales contract. Until the goods are fully loaded onto a transport ship, the seller bears the costs of any loss or damage to the product. Further, if the product requires additional customs duties, export paperwork, or inspections or rerouting, the seller must cover these expenses. Once the freight loads, the buyer becomes responsible for all other costs.
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- For International Orders the listed price includes supplier paid shipping via CIF – Cost, insurance, and freight (named port of destination). FOB or DAP quotes available on request
- Cost, insurance, and freight (CIF) is an expense paid by a seller to cover the costs, insurance, and freight of a buyer's order while it is in transit. The goods are exported to a port named in the sales contract. Until the goods are fully loaded onto a transport ship, the seller bears the costs of any loss or damage to the product. Further, if the product requires additional customs duties, export paperwork, or inspections or rerouting, the seller must cover these expenses. Once the freight loads, the buyer becomes responsible for all other costs.
- Any additional brokerage, customs, and duty fees associated with international shipments are the customer's responsibility and are not included.
Standard Incoterms Information on included shipping to destination port via CIF (Cost, insurance, and freight) is available HEREWARRANTY:
We take pride in the quality and reliability of our well engineered Welding Machines . Our machines come with a Standard ONE Year Parts and Labor Warranty.
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Electroweld Industries
5, Hira Compound, R.C Marg, Chembur, Mumbai, INDIA - 400074
Call (India Office): +91 222 522 6180, +91-9702579330
Mobile/Whatsapp: +91-9820160332
Call (USA/Mexico Sales): +1 (214)-636-3048
Email: sales@electroweld.com
Drop us a line and we’ll get back to you as soon as possible
Contact Details:
Drop us a line via email or using the Contact form below and we will help find the best solution for your Welding Applications.
Electroweld Industries
5, Hira Compound, R.C Marg
Chembur, Mumbai, INDIA - 400074
Call (India Office): +91 222 522 6180, +91-9702579330
Mobile/Whatsapp: +91-9820160332
Call (USA/Mexico Sales): +1 (214)-636-3048
Email: sales@electroweld.com
Drop us a line and we’ll get back to you as soon as possible
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