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 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 exothermically welded connection as there is in most pressure connections.
The majority of exothermic welding 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.
Corrosion resistance too, is exceptional, due to the alloy’s very high copper content (in excess of 97%).