EXOTHERMIC
Welding Process
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THE EXOTHERMIC WELDING PROCESS
 

The Exothermic Welding 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 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.

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, maintence free connection when using this Exothermic Welding Process.

 

 

The Exothermic Process has been used to weld materials other than copper for electrical purpose. Materials welded include :

Stainless Steel Copperweld Nichrome V
Galvanized Steel Silicon Bornze Copper Clad Steel
Columbium Plain Steel Everdur
Kama Steel Rail Cor-Ten
Brass Bronze Niobium
Chromax Cast Iron Monel

When welding to galvanized steel it is recommended to resurface exposed bare steel. The Exothermic Welded Connection is a molecular weld. The weld has the same melting point as copper. This factor among with the increased cross sectional area of the connection and the following insure :

1.
The Exothermic Welded connection will not be affected by a high current surge. Tests have shown that the electrical conductor will melt before the exothermic connection when subjected to high short circuit current . Consult IEEE Standard 837.
   
2. The Exothermic Welded connections will not loosen or corrode at the point of weld. There are no contact surfaces or mechanical pressures involved. An Exothermic connection becomes an integral part of the conductor.
   
3. Exothermic connections have a current carrying capacity equal to or greater than that of the conductor.