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Exothermic Weld Thermite Welding

Exothermic / Thermite Accessories Exothermic Welding Powder
Exothermic / Thermite Accessories Exothermic Weld Accessories
Exothermic / Thermite Accessories Thermit Weld
Exothermic / Thermite Accessories Thermite Accessories

Exothermic Welding Powder

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Exothermic Welding Powder

Exothermic Welding powder is also known as exothermic bonding, thermite welding (TW), and Thermit welding. There are many advantages of using Exothermic Welding powder. 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. 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 Welding, Exothermic Weld PowderExothermic Welding Powder


  • It has a superior electrical conductivity than the conductors themselves.
  • It does not corrode oxide or degrade with time and is resistant to galvanic coupling.
  • It is able to withstand repeated electrical discharges.
  • It never increases its resistance.
  • It has higher mechanical and squeezing resistance than the conductors themselves.
  • It  offers  a  permanent  welding  and  a  low  resistance   connection,   essential  for  achieving longwearing and trustworthy  results in earthings
  • It guarantees the most common connections not only between copper cables but also for welding tapes and metallic pieces made of brass, stainless steel, and copper coated steel earth rods.

Exothermic Welding:
Exothermic Welding is a welding process for joining two electrical conductors that employs superheated 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 alumina thermic reaction between aluminium 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 aluminium 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 (because they can be reused), 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 (when performed outdoors).

In Exothermic Welding powder, aluminium dust reduces the oxide of another metal, most commonly iron oxide, because aluminium is highly reactive. Iron(III) oxide is commonly used:
Fe2O3 + 2 Al → 2 Fe + Al2O3

The products are aluminium oxide, free elemental iron, and a large amount of heat. The reactants are commonly powdered and mixed with a binder to keep the material solid and prevent separation. Commonly the reacting composition is 5 parts iron oxide red (rust) powder and 3 parts aluminium powder by weight, ignited at high temperatures. A strongly exothermic (heat-generating) reaction occurs that via reduction and oxidation produces a white hot mass of molten iron and a slag of refractory aluminium oxide. The molten iron is the actual welding material; the aluminium oxide is much less dense than the liquid iron and so floats to the top of the reaction, so the set-up for welding must take into account that the actual molten metal is at the bottom of the crucible and covered by floating slag.

Other metal oxides can be used, such as chromium oxide, to generate the given metal in its elemental form. Copper thermite, using copper oxide, is used for creating electric joints in a process called Cad welding:
3 CuO + 2 Al → 3 Cu + Al2O3


1) Graphite Mould
2) Mould Handle Clamp (Universal)
3) Steel Metal Disk
4) Exothermic Weld Powder
5) Ignite Powder (Starting Powder)
6) Gloves
7) Flint Gun
8) Brush (Soft and Hard)
9) Slag Removal Tool
10) File Card
11) Sealing Compound

Exothermic Weld Accessories

1) Graphite Mould
Graphite mould is made of high quality graphite suitable for high quality welding work and can be used for several times.

Following are the advantages.
1. A smooth metal connection that will not loosen or corrode.
2. It is not affected by high current surge or over current.
3. No need for the external welding machine.
4. Use only lightweight and cheap equipment.

When making a copper wire connection of Ground rod or other metal connection, place the weld powder intothe graphite mould. Just ignite to start the welding process. The result will be clean and smooth connection surface. It is also applicable for other metal such as: Iron, Galvanized
Steel, Railway track, Cast Iron, Bronze, and Brass. It can be used in various applications to have the certainly good connections in work. Such as Lightning and Surge Protection, Grounding in Electrical Work, Railway Construction, Cathodic Protection. The connection mould is designed to
last for an average of 60 to 100 connections. This will vary according to the care given the mould during use.

Exothermic Weld Mould

2) Mould Handle Clamp (Universal)
For most connections involving lugs, cable or rectangular bus, exothermic handle clamps are used.These will fit 90% of all standardexothermic molds. Normally we recommend one Handle for everytwo moulds


3) Steel Metal Disk
Steel discs are very important. The disc acts timing device to allow the welding powder to heat to proper temperature, the disc away allowing the molten copper to a point where it would weld metal toenter the weld gravity before ignition. One Metal is must for every shot


4) Exothermic Weld Powder
Exothermic Weld Powder is the most reliable and consistently-performing weld metal available
with us.  Quality validation steps are taken for every lot we produce.  Upon final acceptance,
our weld metal is specially packaged  in moisture-resistant plastic cartridges with special closure caps.  Then the cartridges and required metal discs are packaged in moisture-resistant boxes.
All sizes of weld metal are available.
Standards Size Packing available are – 50 Grams, 100 Grams, 125 Grams
150 Grams, 200 Grams, 250 Grams, 1 Kilogram

Moisture Free Packing in Foil

Exothermic-Weld-PowderMoisture Free Packing in Foil


5) Ignite Powder (Starting Powder)
Ignite Powder also known as Starting Powder is required and is must. Pour little Starting Powder on the Mould followed by the Exothermic Weld powder and again pour it little on the Top Side of Mould. Ignite starting powder with a spark gun.This resulting exothermic reaction reduces the
weld powder to molten copper alloy. The molten copper alloy melts the retaining disc and flows
into the weld cavity where it partially melts the conductors. Ignite Powder of 5 grams is sufficient for this Process.
Ignite Powder

6) Gloves
Gloves is required for safety purpose as the Exothermic Weld Powder melts at more than
1400 degree Celcius.


7) Flint Gun
It is designed with the advantages of safety and convenience. It is used to ignite Starting
Powder in order to result in exothermic reaction.
We recommend one Flint Gun for every 100 Shots


8) Brush (Soft and Hard)
Two Brush Required:
1) Soft Brush – Its used to Clean Mould Weld Cavity because its shape is very sensitive
and there should not be any damage while using Brush, so we recommend to use Soft
Brush to Clean Mould Weld Cavity
2) Hard Brush – Its used to clean other section of Mould
We recommend a Pair of Brush for 50 Connection

Brush to clean Mould

9) Slag Removal Tool
It is used to remove the metal Scrap from Mould

Slag Removal Tool

10) File Card
It is used to clean the objects to be welded

File Card Brush

11) Sealing Compound
Sealing Compound is used to fill the gap on the mould if any.

Sealing Compound


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