The process of Exothermic Weld 

 A method of making electrical connections of copper to copper or copper to steel in which no outside source of heat or power is required. In this process, a special weld material is placed into a high temperature resistant mold and ignited. The process of igniting the particles creates extremely high heat and molten metal (exothermic reaction) up to 1400 degree celsius, and produces a molten metal slag. This liquid copper metal flows into the weld cavity, filling any available space and completes the weld. The weld is then allowed to cool and solidify before it is removed from the mold. The mold is ready for the next weld after a brief cleaning with a brush. This entire process takes only seconds to complete.

Exothermic Welded Connections produce a permanent connection, superior in performance to any known mechanical or pressure type surface-to-surface contact connector. Because the connection produced is a molecular bond, an exothermic welded connection will not loosen or increase in resistance over the lifetime of the installation.

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 Weld Process. Theexothermic 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; threfore 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.

The Exothermic Welding 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 Welding Connections 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.


Exothermic Welding Process

Exothermic Process

STEP - 1:  
Always wear protective safety glasses and gloves while working with exothermic welding Accessories.

STEP - 2:   
Gather all the proper material Exothermic Welding Accessories for the type of connection you are making. The typical Welding system requires a graphite mold, handle clamp, welding Powder, natural bristle brush for mold cleaning, wire brush for cleaning/preparing conductors, flint igniter, and propane torch and Sun Glass. Check to ensure the graphite mold is not worn or broken, which could cause leakage of molten weld metal. 

STEP - 3:  
Slide the handle clamp into the pre-drilled holes with the proper orientation for the thumbscrews.

STEP - 4:  
Tighten the clamp thumbscrews onto the mould.

STEP - 5:  
Close the grips to tightly lock the mold. Make adjustments to tighten/loosen the handle clamp.

STEP - 6:  
The material to be welded (cable, rod, tape etc.) must be clean and dry using the brush included in the set of accessories. Thus the oxide layer and superficial impurity is eliminated. Given that the graphite mould also absorbs moisture, this should be removed by preheating with a gas welding torch to avoid a porous welding. After the first welding is done, it is not necessary to re-heat the mould if the next welding is done within 15 minutes as it conserves the previously generated heat.

STEP - 7: 
Place the conductors in the mould and close the handle clamps to avoid material leakages during the reaction.

Please Note – If there is even a minor gap between the two Conductors, apply Sealing Compound at the places where the conductors is passing out else at the time of Welding, the Powder will spread out as a flame resulting in improper joint

STEP - 8:
Obstruct the tap hole with the metallic disk.

STEP - 9:
Empty the contents of the welding mixture package.

STEP - 10:  
Empty 50% of the starting powder above Exothermic Welding Powder (Don’t Mix, just scatter) and than Close the Mould Mouth and than the rest 50% Starting Powder, Sprinkle it on the Mould Mouth nearby the small hole given on the top of the Mould Mouth.

STEP - 11:  
Ignite the starting powder extended on the top/side of the mould using the flint igniters.

STEP - 12:  
Once started, the reaction will take 3-4 seconds during which it is recommended to stand clear of the mould. 

STEP - 13:  
After at least 2 minutes of the bonding, open the mould by undoing the handle grip. Remove the mould from the joint and clean the joint for any slag. Once open, clean the slag sticking to the mould with the relevant tool and clean the cavities. The mould will be ready now to use again without having to reheat it as it is already warm.

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