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The process of exothermic welding is 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 welding powder is placed into a high temperature Mold and ignited. This ignition process of the particles (exothermic reaction) creates extremely high heat and produces a molten metal slag. The 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. |
Exothermically welded connections produce a permanent connection equal in performance to any known mechanical or pressure type surface-to-surface contact connector. Because the connection produced is a molecular bond, an exothermically welded connection will not loosen or increase in resistance over the lifetime of the installation
As recommended by IEC and IEEE regulations, all earthing system connections should be made by exothermic weld. Connections should include, but not be limited to, all cable to cable splices, T s, X s, etc.; all cable to earthing rods, earthing rod splices cable to steel and cast iron, cable lug terminations, bus bar connections and cable to rail connections. |
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Advantages of Exothermic Welding:
• Current carrying (fusing) capacity equal to that of the conductor
• Will not deteriorate with age
• Permanent molecular bond that cannot loosen or corrode
• Will withstand repeated faults
Low labour costs
• No special skills required
• No external power or heat required
• Can be checked visually for quality
• Portable
• Exothermic Welding is applicable to materials other than copper, some of these are listed below!
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Exothermic Welding is applicable to materials other than copper, some of these are listed below: |
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• Common steel
• Copper-clad steel
• Bronze - Brass
• Wrought iron
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• Stainless steel
• Cast iron
• Brass
• Silicon Bronze |
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• Steel rail
• Columbium
• Commercially pure iron
• Galvanised |
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• Monel
• Niobuim
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