Exothermic Process

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An exothermic reaction is a chemical or physical reaction that releases heat. It gives net energy to its surroundings. That is, the energy needed to initiate the reaction is less than the energy released.

Exothermic Welding called often aluminothermic welding is a welding process for permanently joining materials that employs the exothermic reaction. This method was invented in 20 th century for connecting grounding conductors on molecular level.

The main components used in the exothermic welding process are cooper oxide and aluminum.

The reaction takes place in a graphite mold in which the elements to be welded have previously been introduced and at the required load. 

This results in a durable, compact and homogeneous bonding between the elements.

The key advantages of the process are:

Connections are unaffected by corrosive products to same degree as copper.

The conductivity of the welding connection is equal to or greater than two joined conductors.

The connection is resistant to overloads or surges.

No maintenance of the connection is required.

Connections done once for entire lifetime of the installation.

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During the exothermic  process, aluminum reduces copper oxide at approx. 2600 C, creating:

•Super heated copper (which forms the weld)

•Aluminum oxide ( the slag)

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        3Cu2O +2Al        6Cu + Al2O3 + Heat

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The key advantages of exothrmic connections over mecahnical connections are:

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•Connections are permanent and will not loosen or corrode with age

•A wide variety of uses and applications

•Safe and easy to use with minimal training requirements

•Connections are made with inexpensive, lightweight and portable equipment

•No external power or heat required

•The connections can be quickly evaluated by visual inspection

•The connections can carry higher fault current than the conductor that it joins

•The connections created low resistance so ther is no heating at the conenctions point

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Below are exmaples of exothermic connections

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