What is Exothermic Weld ?

Exothermic welding is a procedure that accomplishes the molecular binding among two or more metallic conduits by a chemical reaction. This molecular binding enhances mechanical, electrical and anti-corrosion properties contrasted to any mechanical connection. Exothermic weld is a joining approach used to make perpetual connections between two metallic components. It includes a chemical reaction that creates heat, known as an exothermic reaction. This procedure is especially noted for the durability of the bond delivered and for protecting great electrical conductivity between the joined parts.

Exothermic welding is also known in the Market with Brand names such as AMIABLEWELD, CAD WELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD, BURNDYWELD etc


Learn how Exothermic Welding is done from below Video

How Exothermic Welding 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 join metal connections. Exothermic Welding is the most ideal approach to make long lasting, dependable and high conductivity connections for any establishment requiring an earthing framework. The exothermic reaction makes an extreme smaller than usual heater with temperatures surpassing 2,5000F, quickly producing liquid metal which flows into the weld hole, filling any accessible space. After waiting for sufficient time, the mould can be discharged and the finished connection is evacuated. The Exothermic Welding System is a welding procedure that uses an exothermic reaction to permanently join the metal connections. It utilizes a light-weight, clamp-on graphite mould to securely position and contains any weld if required.

Exothermic welding is also known in the Market with Brand names such as AMIABLEWELD, CAD WELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD, BURNDYWELD etc




Mould Selection Chart



When Exothermic Welding is require ?

The Exothermic Welding is mostly required if there is an inappropriate connection between conductors which often lead to the electrical malfunctions. A systematic connection should have following properties: -
  • Extensive administration life. Won't break down, erode or rot after some time, above or below grade.
  • Sustain electrical coherence and contact reliability.
  • Connector temperature ought to remain lower than that of the conductor when directing electrical current.
  • Capacity to withstand over-burden conditions without liquefying, or flaming.

The Exothermic Welding is designed - durable, homogeneous, and molecular bond that can't relax or erode, and will convey more current than the conductor. The Exothermic Welding Connection are strong molecular bonds; they don't extricate or erode over the lifetime of connection.Exothermic weld associates links, ground rods, terminals and structures; the subsequent molecular bond creates a perpetual connection that won't slacken or erode over the lifetime of the establishment. The hardware required to make exothermic connection is lightweight, compact and does not require outside force.
Only exothermic weld connections meet or exceed all of the above criteria. Exothermic weld 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 weld specifically supersedes its competition with its hermetically sealed metallized pouch which provides the product with an extensive shelf life and easy portability. Our AmiableWeld Exothermic Welding Powder is ISO Certified, CE and ROHS Compliance and IEEE Tested and Passed and is the preferred method for making copper-to-copper and copper-to-steel electrical connections.

Exothermic welding is also known in the Market with Brand names such as AMIABLEWELD, CAD WELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD, BURNDYWELD etc


Exothermic Weld Accessories :


  • Exothermic Weld Powder:- We are a leading manufacturer and supplier of optimum quality Exothermic Welding Powder which is most consistent and reliable for performing weld metals. Exothermic weld powder is a combination of copper oxide and aluminium, wrapped by size in a plastic cartridge. This combination is non-flammable and non-toxic which offers smooth electrical connections.
    Features of exothermic welding powder are - accurate composition, no harmful effect, corrosion resistance etc.
  • Graphite Mould:- The Exothermic Weld Graphite Mould is utilized for making exothermic welding connections which controls the heading and speed of the liquid weld metal stream and the arrangement of the weld. This mould reasonable for superior quality welding work and can be utilized for a several times. It offers smooth metal connections that won't slacken or erode and has high resistant power which results in multiple times of utilizing it.
    Graphite Mould requires pre-warming with a butane light to guarantee that Graphite mould is thoroughly dry before each first joint or else, the mould may split or break or it will reduce the life span of the mould. After each joint delivered, always evacuate the slag with a suggested Graphite mould scrapper, then brush off the littler particles with a appropriate mould cleaning brush.
    Features of Graphite Mould are - longer lifespan, superior quality, durable, resistant to corrosion and many more.
  • Mould Handle Clamp (Universal):-We provide mould handle clamps which are used not only handling the moulds but also clamp the mould halves. The Exothermic Welding Handle Clamps offers grip to the mould and are comprised of high quality raw material. It can be used for multiple times and no need of repairing.
  • Steel Metal Disks:- Steel Disks behave as a timing gadget to permit the exothermic welding powder to heat to legitimate temperature. Steel Disk is intended to contain the exothermic reaction to the upper crucible of a mould unless the reaction is finished and prepared to weld.
  • Flint Gun:- Flint Gun is planned with the benefits of security and convenience. It is utilized to ignite Starting Powder with a specific end goal to bring about exothermic reactions. Flint Gun ignitor is simple and fast courageous ignition for exothermic welding, metal bodies and cutting lights. It utilizes standardized cigarette lighter flints.
  • Ignite Powder (Starting Powder):- Ignite Powder is commonly known as Starting Powder. Ignite Powder is used commonly to weld the metals. Sprinkle of small quantity of Starting Powder on the Mould followed by the Exothermic Welding powder and again sprinkling it little on the top side of Mould then burn the Ignite Powder with a spark gun.
  • Hand Gloves:-We offer high quality of Hand Gloves which is required for security reason as the Exothermic Welding Powder liquefies more than 1400 0 Celsius.
  • Brush:- We provide two types of Brush – Hard Brush and Soft Brush. Hard Brush is utilized to clear each sections of exothermic weld moulds whereas Soft Brush is used to clean exothermic weld mould cavity.
  • Flame Torch:- Flame Torch is very useful to remove moisture which are absorbed by graphite moulds from climate. This removal of moisture is done by heating the exothermic weld graphite mould efficiently both inside and outside.
  • File Card:- We manufacture File Card which is used to clean the exothermic objects before welding them.
  • Slag Removal Tool:- Slag Removal Tool is used to discard the metal scrap from exothermic moulds which is formed after welding procedure is done.
  • Sealing Compound:- Sealing Compounds are mainly used to fill the gap on the exothermic moulds .
    Features of Sealing Compound are - insoluble in water, high endurance, resistance to temperature with maximum durability.

Exothermic Weld Process :

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 material is placed onto a high temperature resistant mold & ignited.


The Exothermic Weld process is a technique for making electrical associations of copper-to-copper or copper-to steel in which no outside wellspring of warmth or force is required. In this procedure, conductors are readied, setin a purpose designed graphite mould, and exothermically welded to produce a permanent molecularly fortified electrical association. The strides illustrated beneath are a general show of a run of the mill welded association. These fundamental strides are utilized for every electrical association. Make certain to peruse and take after the instructions included with every mold before making a connection. Exothermic Welding connections provides execution better than all current surface-to-surface mechanical maintenance connectors.

  • Step 1:- Always wear protective safety glasses and gloves while working with exothermic welding products.
  • Step 2:- Gather all the proper material and equipment/accessories for the type of connection you are making. The typical Weld system requires a graphite mold, handle clamp, welding material, natural bristle brush for mold cleaning, wire brush for cleaning/preparing conductors, flint igniter, and propane torch. Check to ensure the graphite mold is not worn or broken, which could cause leakage of molten weld metal.
  • Step 3:- Slide the handle clamp into the pre-drilled holes with the proper orientation for the thumbscrews.

Exothermic welding process 1 to 3






  • Step 4:- Tighten the clamp thumbscrews onto the mould.
  • Step 5:- Close the grips to tightly lock the mold. Make adjustments to tighten/loosen the handle clamp.
  • Step 6:- The material to be welded (cable, rod, tape) must be clean and dry using the brush included in the set of accessories. Thus the oxide layer and superficial impurity is eliminated. Given that the graphite mould also absorbs moisture, this should be removed by preheating with a gas welding torch to avoid a porous welding. After the first welding is done, it is not necessary to re-heat the mould if the next welding is done within 15 minutes as it conserves the previously generated heat

Exothermic welding process 4 to 6






  • Step 7:- Place the conductors in the mould and close the handle clamps to avoid material leakages during the reaction.

    Note:- If there is even a minor gap between the two Conductors, apply Sealing Compound at the places where the conductors is passing out else at the time of Welding, the Powder will spread out as a flame resulting in improper joint.

  • Step 8:- Obstruct the tap hole with the metallic disk.
  • Step 9:- Empty the contents of the welding mixture package.

Exothermic welding process 7 to 9







  • Step 10:- Place the conductors in the mould and close the handle clamps to avoid material leakages during the reaction.

    Note:- If there is even a minor gap between the two Conductors, apply Sealing Compound at the places where the conductors is passing out else at the time of Welding, the Powder will spread out as a flame resulting in improper joint.

  • Step 11:- Obstruct the tap hole with the metallic disk.
  • Step 12:- Empty the contents of the welding mixture package.

Exothermic welding process 10 to 12






  • Step 13:- After at least 2 minutes of the bonding, open the mould by undoing the handle grip. Remove the mould from the joint and clean the joint for any slag. Once open, clean the slag sticking to the mould with the relevant tool and clean the cavities.The mould will be ready now to use again without having to reheat it as it is already warm.

SAFETY INSTRUCTIONS:

  • Do not use worn or broken equipment which could cause leakage. Sealing compound should be used in case of fine leakages.
  • Only equipment and materials should be used to make connections.
  • Make connections in conformance with instructions and all governing codes.
  • Avoid contact with hot materials.
  • Do not connect items except as detailed in instruction sheets. Failure to comply with these instructions may result in improper and unsafe connections, damage to items being welded or even injury to body or property damage.
  • When using Weld do not use welding material package if damaged or not fully intact.
  • Personnel should be properly trained and must wear safety glasses and gloves.
  • Advise nearby personnel to stand at least 7 to 10 Foot away of welding operations site.
  • Do not smoke when handling starting material.
  • Provide adequate ventilation to the work area.
  • Remove or protect the inflammable material from the operation site to safeguard against fire hazards.
  • Avoid direct eye contact with "flash" of light from ignition of starting material.

  • Exothermic welding is also exported worldwide with Brand names such as AMIABLEWELD, CAD WELDING, EXO WELDING, FURSE WELDING, THERMO WELDING, KUMWELLING, TECTO WELDING & BURNDY WELDING.


    Advantages of using Exothermic Welding:




    • It guarantees the most common connections not only between copper cables but also for Weldinging tapes and metallic pieces made of brass, stainless steel, and copper coated steel earth rods. Current carrying (fusing) capacity equal to or greater than the conductor.
    • It offers a permanent Weldinging and a low resistance connection, essential for achieving longwearing and trustworthy results in earthing.
    • It does not corrode oxide or degrade with time and is resistant to galvanic coupling.
    • It has higher mechanical and squeezing resistance than the conductors themselves.
    • It has a superior electrical conductivity than the conductors themselves.
    • Permanent molecular bond that will not loosen or corrode.
    • It is able to withstand repeated electrical discharges.
    • No external power or heat required.
    • Can be checked visually for quality.
    • It never increases its resistance.
    • Will withstand repeated faults.
    • Will not deteriorate with age.
    • No special skills required.
    • Easily transportable.
    • Low labor costs.

    Exothermic weld system from AmiableWeld provides precision engineered molds for optimal results which gives about 30 to 100 Joints from one Graphite Mold.
    Features include simplicity, corrosion resistance, extended shelf life, high conductivity, portability, ease of use, and it requires no external heat or power source.

    Exothermic welding is also supplied worldwide with Brand names such as AMIABLEWELD, CADWELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD & BURNDYWELD.


    Why Use Exothermic Weld ?

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

    Exothermic welding is also supplied worldwide with Brand names such as AMIABLEWELD, CADWELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD & BURNDYWELD.

    bond that cannot loosen or corrode, and will carry more current that the conductor.

    The Exothermic Weld 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.

    Exothermic welding is also supplied worldwide with Brand names such as AMIABLEWELD, CADWELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD & BURNDYWELD.


    Advantages and Disadvantages of Exothermic Weld:

    Compared for some other forms of welding, exothermic bonds employ a greater mechanical toughness. The weld can be proof against corrosion. You simply won't notice an increase in electrical excess weight despite repeated small signal pulses; your weld is highly firm. The procedure is more costly, however. The task requires replaceable moulds, is not easily repeatable.

    Exothermic weld 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 weld metal ink cartridge, semi-permanent graphite crucible pattern, and an ignition company that connects your container with a cord. Exothermic weld 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.

    An exothermic weld has higher mechanical strength than other forms of weld, 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 also supplied worldwide with Brand names such as AMIABLEWELD, CADWELD, EXOWELD, FURSEWELD, THERMOWELD, KUMWELL, TECTOWELD & BURNDYWELD.


    OUR SUMMARY:
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    Amiable Impex
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    Reviewed Product
    Exothermic Welding
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