The Exothermic Welding Connection process is a simple efficient method of Welding copper to copper or copper to steel. One advantage is that NO outside power is required when using the Exothermic Welding. The Exothermic Welding Process uses high temperature reaction of powdered copper oxide and aluminum.

Exothermic Welding consists of copper oxide and aluminum oxide, 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 Weldinged and the joint type required. We guarantees all types of joints, not only copper cable unions but also to Welding tapes, brass metallic pieces, stainless steel, steel ground rods covered with copper, etc. It is especially useful for joining dissimilar metals.

Exothermic Welding is a simple, cost-effective and permanent Welding connection that uses a high-temperature exothermic reaction to create a molecular bond. It does not require an external heat or power source. Exothermic Welding is the universally preferred method for making permanent copper-to-copper and copper-to-steel electrical connections. Its performance is superior to all existing surface-to-surface mechanical connectors. Exothermic Welding works when others won’t!

How it Works

The Exothermic Welding System is a Welding process that utilizes an exothermic reaction (a chemical reaction that releases energy in the form of very high temperatures and light) to permanently joins metal connections. Exothermic Welding uses a light-weight, clamp-on graphite mold to safely position and contains any Welding required. The exothermic reaction creates an intense miniature furnace with temperatures exceeding 2,500 °F, instantly producing molten metal which flows into the Welding cavity, filling any available space. After waiting adequate time after the initial process, the mold can be released and the finished connection removed.


Electrical Connector Requirements

Improper connections between conductors are often the reason for electrical malfunctions. A proper connection should have the following characteristics:

Capacity to withstand overload conditions without melting, burning or failing.

Sustain electrical continuity and contact reliability.

Connector temperature should remain lower than that of the conductor when conducting electrical current.

Extensive service life. Will not deteriorate, corrode or decay over time, above or below-grade.

Only exothermic Welding connections meet or exceed all of the above criteria. Exothermic Welding is recommended by IEEE and IEC. It has been shown to be the best choice where safety, reliability, longevity and current carrying capacity are critical. Exothermic Welding specifically supersedes its competition with its hermetically sealed metallized pouch which provides the product with an extensive shelf life and easy portability. Exothermic Welding is CPRI Tested and is the preferred method for making copper-to-copper and copper-to-steel electrical connections.

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 Welding 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. Exothermic Welding is a simple, economical method of making permanent, very high quality electrical connections - the process uses the high temperature reaction of copper oxide and aluminium, within a semi-permanent graphite mould, to form electrical connections mainly between copper to copper or copper to steel.

Exothermic Welding requires no outside source of power or heat - the system is also light and portable ideal for field use. Making an exothermic Welding joint is a simple procedure which requires a mould, Welding powder, handle clamp and exothermic Welding tools.

Exothermic Welding connections are tolerant to repeated fault currents, highly conductive, permanent and demonstrate excellent corrosion resistance - most exothermic Welding connections have at least twice the cross-sectional area of the conductors being jointed.

Exothermic Welding is a very efficient and cost efficient method of making large or small numbers of high quality electrical connections. Exothermic Welding is a simple self-contained system that uses the high temperature reaction of powdered copper oxide and aluminium, within a mould, to form permanent electrical connections. The Exothermic Welding exothermic Welding system requires no external power or heat source, creates high quality electrical connections, is completely portable, can be used safely with minimum training, is cost-effective and can be used for over 45 standard connection configurations. Exothermic Welding  connections have several advantages in that they are tolerant to repeated faults, are highly conductive, do not loosen and have excellent corrosion resistance because of the very high copper content (>90%) of the alloy.

An Exothermic Welding connection produces a joint (or connection) superior in performance to any known mechanical or pressure type surface-to-surface contact connector. By virtue of its molecular bond, an Exothermic Welding connection will not loosen or increase in resistance over the lifetime of the installation. Connections are often the weak point in ground circuits, especially if they are subjected to high currents and corrosion. The capacity of a grounding circuit to protect property and personnel depends on the quality of its connections. Only an exothermic Welding connection can provide the permanent, low-resistance connection needed to create a long-lasting, reliable grounding network.

Exothermic Welding is a process that achieves the molecular binding among two or more metallic conductors by a chemical reaction.  This molecular binding improves mechanical, electrical and anti-corrosion properties compared with any mechanical connection. Exothermic Welding is the best way to make permanent, reliable and high conductivity connections for any installation requiring an earthing system.

Exothermic Welding is often used to join copper conductors. The Welding process joins two electrical conductors by use of superheated copper alloy. An exothermic reaction requires no external heat or current source. The reaction occurs between a copper thermite compositions that heat the copper. The chemical reaction is aluminothermic, occurring between aluminum powder and copper oxides. The reaction reaches very high temperatures. Reactant powders and a spark is all that is needed for a high energy reaction.

Exothermic Welding System

Earth electrode and protective conductors are joined by exothermic Welding process that employs superheated copper alloy to make permanent & maintenance free joint, avoiding unreliable screwed joints. The Welding system is UL 467 approved. Molding kits for all types of Grounding connections are available.

When Exothermic Welding is Used

Exothermic Welding is most commonly used for permanently joining copper conductors. It is the only acceptable means of bonding copper to galvanized cable. It can also be used on stainless steel, cast iron, steel, brass, bronze, and more. If joining two dissimilar metals, exothermic Welding is a good option. You'll find thermite Welding under the names of exothermic Welding.

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 Weldings if proper care is given. The reaction takes place very rapidly; therefore 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.

Exothermic 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 aluminothermic reaction between aluminum 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 aluminum 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 Weldinged, forming anelectrically conductive Welding 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 Welding formed has higher mechanical strength than other forms of Welding, 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.

Exothermic Welding is a joining technique used to create a permanent connection between two metallic components. It involves a chemical reaction that generates heat, known as an exothermic reaction. This process is particularly noted for the durability of the bond produced and for preserving good electrical conductivity between the joined components.

Creating a bond by exothermic Welding typically involves heat created by a chemical reaction between some type of heavy metal oxide and a reducing agent. For example, iron oxide is a commonly used metal oxide and aluminum is a common reducing agent. These reactants produce heat extremely rapidly when ignited, thereby achieving the high temperatures needed for Welding.

Such heating is generally initiated once the parts to be joined are fitted together in a mold which contains the materials and the reaction as it takes place. Filler metal in liquid form is produced by this reaction and mixes with melted metal from the parts being joined to form a bond shaped by the mold. Molds used in exothermic Welding may be made of graphite, ceramic, or other appropriate materials.

Exothermic Welding connects cables, ground rods, terminals and structures; the resulting molecular bond produces a permanent connection that won't loosen or corrode over the lifetime of the installation. You should use exothermically Weldinged connections when: you require long life/permanent connections; you expect high current faults; or corrosive conditions exist.

The equipment required to make exothermic connections is lightweight, portable and does not require outside power. The resulting bond is a permanent joining of metallic parts that form an electrically conductive path. This will ensure electrical continuity and the capacity to conduct any potential current safely.

These permanent connections will carry as much, or more, current as the conductor. These connections eliminate bimetallic corrosion at the point of the Welding. All strands of the conductor will equally share the current load.

Exothermic Welding system from Altec provides precision engineered molds for optimal results. Permanent molecular bonding is the preferred method for making copper to copper and copper to steel electrical connections. It is a connection using a high-temperature exothermic reaction that does not require an external heat or power source. Its performance is superior to all existing surface to surface connectors. Features include simplicity, corrosion resistance, extended shelf life, high conductivity, portability, ease of use, and it requires no external heat or power source.

Why Use Exothermic Welding

The Exothermic Connecting created a permanent, homogeneous, and molecular bond that cannot loosen or corrode, and will carry more current that the conductor.

The Exothermic Welding Connection are solid molecular bonds, they do not loosen or corrode over the lifetime of connection. The ame cannot be said about other methods; such as brazing, crimp, split bolt, or compreion type connections.

Advantages and Disadvantages of Exothermic Welding:

Compared for some other forms of Welding, exothermic bonds employ a greater mechanical toughness. The Welding can be proof against corrosion. You simply won't notice an increase in electrical excess weight despite repeated small signal pulses; your Welding is highly firm. The procedure is more costly, however. The task requires replaceable moulds, is not easily repeatable, which enable it to be impeded by means of poor weather conditions if the work is done out of doors.

Exothermic Welding may also be done far from others. That reduces dangers to employees. A igniter is used with widespread graphite molds or a palatable made drop within Welding metal ink cartridge, semi-permanent graphite crucible pattern, and an ignition company that connects your container with a cord.

Exothermic Welding is usually used for Welding copper conductors but is suitable for Welding a wide range of metals, including stainless steel, cast iron, common steel, brass, bronze, and Monel. It is especially useful for joining dissimilar metals.

Because of the good electrical conductivity and high stability in the face of short-circuit pulses, exothermic Weldings are one of the options specified by the grounding conductors and bonding jumpers. It is the preferred method of bonding, and indeed it is the only acceptable means of bonding copper to galvanized cable. The NEC does not require such exothermically Weldinged connections to be listed or labelled, but some engineering specifications require that completed exothermic Weldings be examined using X-ray equipment.

An exothermic Welding has higher mechanical strength than other forms of Welding, 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.


Superior electrical conductivity to the conductors themselves.

Does not corrode, oxidize or degrade with time and is resistant to galvanic coupling.

Able to withstand repeated electrical discharges.

Never increases its resistance.

Has greater mechanical and squeezing resistance than the conductors themselves.



In exothermic Welding, aluminium dust reduces the oxide of another metal, most commonly iron oxide, because aluminium is highly reactive. Iron 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 Exothermic Welding:

3 CuO + 2 Al → 3 Cu + Al2O3

Exothermic Welding Powder Specification:

Exothermic Welding powders are generated with several chemical substance after aluminum heating reaction under high temperature and Welding is done by melting mold and heating sealing is done completely between same metals such as copper, between different metals such as copper and steel to realize the real molecular association.


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Reviewer Amiable Impex
Review Date 26-08-2016
Reviewed Item Exothermic Welding
Author Rating ★★★★★

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