Exothermic Welded Connectors

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Exothermic Welded Connectors 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, granular metallic particles are placed into a graphite mold and ignited. This reduction of these particles (exothermic reaction) creates high heat in excess of 1400 degrees Celsius, and produces molten copper. The molten copper to flows into the weld cavity, filling any available space and completes the weld. The weld should then be allowed to cool and solidify. The mold is removed and made ready for the next weld. This entire process takes only 20 seconds to complete. Exothermically welded connections produce 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 exothermically welded connection will not loosen or increase in resistance over the lifetime of the installation. All grounding 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 ground rods, ground rod splices, cable to steel and cast iron; and cable lugs. Exothermic welding is applicable to materials other than copper, some of these are listed below. Common steel Stainless steel Steel rail Monel Copper-clad Steel Cast iron Columbium Niobium Bronze Brass Pure iron Wrought iron Silicon Bronze Galvanized and Bethanized steel 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 labor costs √ No special skills required √ No external power or heat required √ Can be checked visually for quality √ Easily portable !.

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INSTRUCTION MANUAL A guide for the safe use of exothermic connections AN EASY GUIDE TO MAKING EXOTHERMIC CONNECTIONS The parameters and criteria set out in this handbook are based on the experience gained over the years of using Exoweld© products for installation work, as well as our ongoing research and development at our manufacturing plant, to develop better exothermic technology. The exothermic welding process is a simple, This bond will not loosen over time or deteriorate self-contained method of forming high quality with age. The connection’s current carrying electrical connections. The compact process capability is to that which it is being connected. In requires no external power or heat source, making other words, there is no increase in resistance in it completely portable. an exothermically welded connection as there is in most pressure connections. Connections are made inside a semi-permanent graphite mould, using the high temperature The majority of exothermic connections have at reaction of powdered copper oxide and aluminium. least twice the cross sectional area of the conductors being joined, and an equivalent or An exothermic connection is actually a molecular greater current carrying capacity. Because the bond formed between two metals such as connection is a fusion of high conductivity, high copper to copper, copper to steel and steel to copper content alloy, it will withstand repeated steel. Copper oxide and aluminium are combined fault currents, and will not loosen in the way that and ignited. The result is an exothermic reaction mechanical connections can. that produces molten, super-heated copper and aluminium oxide slag.
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