What is Exothermic Welding? Working and Uses

What is Exothermic Welding?

Exothermic welding is a welding process that produces an electrical connection between two conductors. It is also known as “thermite” welding, as it involves the reaction between two metals, usually copper and aluminum, to form an alloy. This process is extremely useful for industrial applications due to its quickness, cost-effectiveness, and durability compared to other traditional welding methods. Let’s break down how exothermic welding works and some of its uses.

How It Works?

Exothermic welding requires three main components: graphite mold, copper oxide reducer (CER), and exothermic mixture. The exothermic mixture consists of metal powder (usually aluminum), metal oxide (usually copper oxide), and a catalyst. When these react together they create an exothermic reaction that melts the metal powder and creates a molten alloy. This molten alloy then flows into the graphite mold which contains the two conductors that need to be welded together. The CER ensures that all residual oxides in the graphite mold are burned off during the initial heating stage of this reaction.

The process is fairly straightforward; first place your conductors into the graphite mold, then add your CER followed by your exothermic mixture. At this point, you can insert a spark or flame igniter which will start the exothermic reaction when needed. Once everything has been set up correctly you can activate the igniter to start welding! In just seconds, you have a strong electrical connection between both conductors without any additional finishing work required afterward.

Uses For Exothermic Welding  

Exothermic Welding has many uses in industrial environments such as joining cables, grounding systems, lightning protection systems, and more. In addition, because it can be used in wet weather conditions without issue it is perfect for outdoor installations where traditional methods like soldering might not be suitable due to rain or moisture in the air/ground/soil environment. Aside from industrial applications, Exothermic Welding also has uses in hobbyist projects such as jewelry making or fabricating small items at home with minimal equipment needed compared to traditional methods like soldering or brazing with a torch setup, etc.


In conclusion, Exothermic Welding offers many advantages over traditional methods such as being fast, easy to use even in wet weather conditions, and producing strong electrical connections without any additional finishing work required afterward making it significantly more cost-effective than other approaches. It has many applications both industrially as well as for hobbyist projects at home so if you are looking for a reliable way to make electrical connections then consider giving Exothermic Welding a try! 

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