Exothermic welding process

Exothermic welding is a simple self contained method of making high quality electrical connections for welding copper to copper, copper alloy such as brass, bronze or copper to steel.

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Exothermic welding is a simple self contained method of making high quality electrical connections for welding copper to copper, copper alloy such as brass, bronze or copper to steel.


The exothermic welding system uses the high temperature of reaction of powdered copper oxide and aluminium. The reaction takes place in a graphite mould, which is machined according to the conductor sizes to be welded and which can be used for approx. 60 welds or more welds if properly cared for. The reaction last a few seconds only and the process requires no external power or heat source, making it completely portable and ideal for field use.


Typical applications include earthing of sub-stations and power plant, cathodic protection, rail connections, lightning protection, telecommunications, etc…


An exothermic welding shows a lot of advantages in comparison to mechanical or crimping systems.

As it is a molecular weld it will not be affected by high current surge. It can be
shown by tests that the electrical conductor will melt before the exothermic weld when subject to high short circuit current.


The weld metal has the same melting point as copper and the cross section of the weld is higher than the cross section of the conductors to be welded so that the current carrying capacity is greater than that of the conductors.

In addition to copper material such as brass, bronze, stainless steel, steel rail, etc… may also be welded. The result will be a connection composed of an alloy without dielectric influence at the exothermic weld point and totally unaffected by corrosion.

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