Exothermic Weld

There are many advantages of using Exothermic Weld. The most important one being that the process produces a molecular joint and not just a mechanical one in between the conductors. It is produced through a starting reactant which provides enough energy to activate the welding reaction. This takes place quickly and safely inside a graphite mould.

Exothemic Mould Design

The mould is designed specifically for a certain union depending on the elements to be welded and the joint type required. We guarantees all types of joints, not only copper cable unions but also to weld tapes, brass metallic pieces, stainless steel, steel ground rods covered with copper, etc. It is especially useful for joining dissimilar metals.

Exothermic weld is a simple, cost-effective and permanent welded connection that uses a high-temperature exothermic reaction to create a molecular bond. It does not require an external heat or power source.

Exothermic weld is the universally preferred method for making permanent copper-to-copper and copper-to-steel electrical connections. Its performance is superior to all existing surface-to-surface mechanical connectors. Exothermic weld works when others won’t!

How it Exothermic Weld Works?

The Exothermic weld Exothermic Welding System is a welding process that utilizes an exothermic reaction (a chemical reaction that releases energy in the form of very high temperatures and light) to permanently joins metal connections.

Exothermic weld uses a light-weight, clamp-on graphite mold to safely position and contains any weld required. The exothermic reaction creates an intense miniature furnace with temperatures exceeding 2,500 °F, instantly producing molten metal which flows into the weld cavity, filling any available space. After waiting adequate time after the initial process, the mold can be released and the finished connection removed.

Exothermic Weld Powder

Exothermic Weld Powder Copper consists of copper oxide and aluminum which is measure into specific weight in grams for the connections should be made approximately 97 % of the contents of this cartridge is the weld metal, the remaining part is a starting powder which is tamped into the bottom of the each cartridge.


Electrical Connector Requirements

Improper connections between conductors are often the reason for electrical malfunctions. A proper connection should have the following characteristics: Capacity to withstand overload conditions without melting, burning or failing. Sustain electrical continuity and contact reliability. Connector temperature should remain lower than that of the conductor when conducting electrical current. Extensive service life. Will not deteriorate, corrode or decay over time, above or below-grade. Only exothermic weld connections meet or exceed all of the above criteria.

Exothermic Weld Recommendation 

Exothermic weld is recommended by IEEE and IEC. It has been shown to be the best choice where safety, reliability, longevity and current carrying capacity are critical. Exothermic weld specifically supersedes its competition with its hermetically sealed metallized pouch which provides the product with an extensive shelf life and easy portability.

Exothermic weld is CPRI Tested and is the preferred method for making copper-to-copper and copper-to-steel electrical connections.

The exothermic weld process is a simple, self- contained method of forming high quality electrical connections. The compact process requires no external power or heat source, making it completely portable. Connections are made inside a semi-permanent graphite mould using the high temperature reaction of powdered copper oxide and aluminium.

An exothermic connection is actually a molecular bond formed between two metals such as copper/copper, copper/steel and steel/steel. Copper oxide and aluminium are combined and ignited.

The result is an Exothermic Reaction that produces molten super-heated copper and aluminium oxide slag. The melting or fusing temperature rating of the finished joint is 2000°C plus. The molten super-heated copper melts the objects being connected together, forming the molecular bond. This bond will not loosen over time or deteriorate with age.

The connection’s current carrying capability is to that which it is being connected. In other words there is no increase in resistance in an exothermic weld connection as there is in most pressure connections. The majority of exothermic weld connections have at least twice the cross sectional area of the conductors being joined, and an equivalent or greater current carrying capacity. Because the connection is a fusion of high conductivity, high copper content alloy, it will withstand repeated fault currents, and will not loosen in the way that mechanical connections can.

Exothermic weld is a simple, economical method of making permanent, very high quality electrical connections – the process uses the high temperature reaction of copper oxide and aluminium, within a semi-permanent graphite mould, to form electrical connections mainly between copper to copper or copper to steel. Exothermic weld requires no outside source of power or heat – the system is also light and portable ideal for field use. Making an exothermic weld joint is a simple procedure which requires a mould, weld powder, handle clamp and exothermic weld tools.

Exothermic weld connections

Exothermic weld connections are tolerant to repeated fault currents, highly conductive, permanent and demonstrate excellent corrosion resistance – most exothermic weld connections have at least twice the cross-sectional area of the conductors being jointed. Exothermic weld is a very efficient and cost efficient method of making large or small numbers of high quality electrical connections. Exothermic weld is a simple self-contained system that uses the high temperature reaction of powdered copper oxide and aluminium, within a mould, to form permanent electrical connections.

Exothermic weld system

The Exothermic weld system requires no external power or heat source, creates high quality electrical connections, is completely portable, can be used safely with minimum training, is cost-effective and can be used for over 45 standard connection configurations. Exothermic weld  connections have several advantages in that they are tolerant to repeated faults, are highly conductive, do not loosen and have excellent corrosion resistance because of the very high copper content (>90%) of the alloy.

An Exothermic weld connection produces a joint superior in performance to any known mechanical or pressure type surface-to-surface contact connector. By virtue of its molecular bond, an Exothermic Weld connection will not loosen or increase in resistance over the lifetime of the installation. Connections are often the weak point in ground circuits, especially if they are subjected to high currents and corrosion. The capacity of a grounding circuit to protect property and personnel depends on the quality of its connections. Only an exothermic weld connection can provide the permanent, low-resistance connection needed to create a long-lasting, reliable grounding network.

Exothermic Weld Procedure

Exothermic weld is a process that achieves the molecular binding among two or more metallic conductors by a chemical reaction. This molecular binding improves mechanical, electrical and anti-corrosion properties compared with any mechanical connection. Exothermic weld is the best way to make permanent, reliable and high conductivity connections for any installation requiring an earthing system.

Exothermic weld is often used to join copper conductors. The welding process joins two electrical conductors by use of superheated copper alloy. An exothermic reaction requires no external heat or current source. The reaction occurs between a copper thermite compositions that heat the copper. The chemical reaction is aluminothermic, occurring between aluminum powder and copper oxides. The reaction reaches very high temperatures. Reactant powders and a spark is all that is needed for a high energy reaction.

Exothermic Weld System

Earth electrode and protective conductors are joined by exothermic weld process that employs superheated copper alloy to make permanent & maintenance free joint, avoiding unreliable screwed joints. The welding system is CPRI approved. Molding kits for all types of Grounding connections are available.

When Exothermic Weld is Used?

Exothermic weld is most commonly used for permanently joining copper conductors. It is the only acceptable means of bonding copper to galvanized cable. It can also be used on stainless steel, cast iron, steel, brass, bronze, and more. If joining two dissimilar metals, exothermic weld is a good option. You’ll find Exothermic weld under the names of exothermic weld. The exothermic weld Process is a simple, efficient method or welding Copper to Copper of Copper to Steel. One advantage is that No outside power is required when using the Exothermic Process.

The exothermic weld process uses high temperature reaction of powdered copper oxide and aluminium. The reaction takes place in a semi-permanent graphite mold. These molds should last approximately forty or more welds if proper care is given. The reaction takes place very rapidly; therefore the total amount of heat applied to the conductors or surfaces is considerably less than that of brazing or soldering. This is important to remember when welding to insulated cable thin wall pipe. This system is very field friendly, since its is light and portable and requires no outside power source. It requires very little time or skill to obtain an efficient, maintenance free connection when using this

Process Exothermic Weld

Exothermic-WeldExothermic weld process is for joining two electrical conductors that employs super heated copper alloy to permanently join the conductors.

The process employs an exothermic reaction of a copper thermite composition to heat the copper, and requires no external source of heat or current. The chemical reaction that produces the heat is an aluminothermic reaction between aluminum powder and a metal oxide. The reaction reaches very high temperatures, depending on the metal oxide used.

The reactants are usually supplied in the form of powders, with the reaction triggered using a spark from a flint lighter. The activation energy for this reaction is very high however, and initiation requires either the use of a “booster” material such as powdered magnesium metal or a very hot flame source. The aluminum oxide slag that it produces is discarded.

When welding copper conductors, the process employs a semi-permanent graphite crucible mould, in which the molten copper, produced by the reaction, flows through the mould and over and around the conductors to be welded, forming an electrically conductive weld between them.  When the copper cools, the mould is either broken off or left in place. Alternatively, hand-held graphite crucibles can be used.

The advantages of these crucibles include portability, lower cost and flexibility, especially in field applications. The weld formed has higher mechanical strength than other forms of weld, and excellent corrosion resistance. It is also highly stable when subject to repeated short-circuit pulses, and does not suffer from increased electrical resistance over the lifetime of the installation. However, the process is costly relative to other welding processes, requires a supply of replaceable  moulds, suffers from a lack of repeatability, and can be impeded by wet conditions or bad weather.

Exothermic weld Joint Technique

Exothermic weld is a joining technique used to create a permanent connection between two metallic components. It involves a chemical reaction that generates heat, known as an exothermic reaction.

This process is particularly noted for the durability of the bond produced and for preserving good electrical conductivity between the joined components. Creating a bond by exothermic weld typically involves heat created by a chemical reaction between some type of heavy metal oxide and a reducing agent.

For example, iron oxide is a commonly used metal oxide and aluminum is a common reducing agent. These reactants produce heat extremely rapidly when ignited, thereby achieving the high temperatures needed for welding. Such heating is generally initiated once the parts to be joined are fitted together in a mold which contains the materials and the reaction as it takes place.

Filler metal in liquid form is produced by this reaction and mixes with melted metal from the parts being joined to form a bond shaped by the mold. Molds used in exothermic weld may be made of graphite, ceramic, or other appropriate materials.

Exothermic weld connects cables, ground rods, terminals and structures; the resulting molecular bond produces a permanent connection that won’t loosen or corrode over the lifetime of the installation.

You should use exothermically welded connections when: you require long life/permanent connections; you expect high current faults; or corrosive conditions exist. The equipment required to make exothermic connections is lightweight, portable and does not require outside power.

The resulting bond is a permanent joining of metallic parts that form an electrically conductive path. This will ensure electrical continuity and the capacity to conduct any potential current safely.

These permanent connections will carry as much, or more, current as the conductor. These connections eliminate bimetallic corrosion at the point of the weld. All strands of the conductor will equally share the current load.

Exothermic weld system from Altec provides precision engineered molds for optimal results. Permanent molecular bonding is the preferred method for making copper to copper and copper to steel electrical connections.

It is a connection using a high-temperature exothermic reaction that does not require an external heat or power source. Its performance is superior to all existing surface to surface connectors. Features include simplicity, corrosion resistance, extended shelf life, high conductivity, portability, ease of use, and it requires no external heat or power source.

Why Use Exothermic Weld?

The Exothermic Connecting created a permanent, homogeneous, and molecular bond that cannot loosen or corrode, and will carry more current that the conductor. The Exothermic Weld Connection are solid molecular bonds, they do not loosen or corrode over the lifetime of connection. The ame cannot be said about other methods; such as brazing, crimp, split bolt, or compreion type connections.

Advantages and Disadvantages of Exothermic Weld:

Compared for some other forms of welding, exothermic bonds employ a greater mechanical toughness. The weld can be proof against corrosion. You simply won’t notice an increase in electrical excess weight despite repeated small signal pulses; your weld is highly firm.

The procedure is more costly, however. The task requires replaceable moulds, is not easily repeatable, which enable it to be impeded by means of poor weather conditions if the work is done out of doors.

Exothermic weld may also be done far from others. That reduces dangers to employees. A igniter is used with widespread graphite molds or a palatable made drop within weld metal ink cartridge, semi-permanent graphite crucible pattern, and an ignition company that connects your container with a cord.

Exothermic weld is usually used for welding copper conductors but is suitable for welding a wide range of metals, including stainless steel, cast iron, common steel, brass, bronze, and Monel. It is especially useful for joining dissimilar metals.

Because of the good electrical conductivity and high stability in the face of short-circuit pulses, exothermic welds are one of the options specified by the grounding conductors and bonding jumpers. It is the preferred method of bonding, and indeed it is the only acceptable means of bonding copper to galvanized cable.

The NEC does not require such exothermically welded connections to be listed or labelled, but some engineering specifications require that completed exothermic welds be examined using X-ray equipment.

Strength of Exothermic Weld 

An exothermic weld has higher mechanical strength than other forms of weld, and excellent corrosion resistance It is also highly stable when subject to repeated short-circuit pulses, and does not suffer from increased electrical resistance over the lifetime of the installation.

However, the process is costly relative to other welding processes, requires a supply of replaceable moulds, suffers from a lack of repeatability, and can be impeded by wet conditions or bad weather.