Research and Development
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, a special weld metal material is placed into a high temperature resistant mold and ignited. The process of igniting the particles creates extremely high heat and molten metal
(exothermic reaction), and produces a molten metal slag.
This liquid copper metal flows into the weld cavity, filling any available space and completes the weld. The weld is then allowed to cool and solidify before it is removed from the mold.
The mold is ready for the next weld after a brief cleaning with a brush. This entire process takes only seconds to complete.
Exothermic welded connections produce a permanent connection, superior in performance to
any known mechanical or pressure type surface-to-surface contact connector.
Because the connection produced is a molecular bond, an exothermic welded connection will not loosen or increase in resistance over the lifetime of the installation.
IEEE and NEC standards specifically allow all grounding system connections to be made by
Connections should include, but not be limited to, all wire to wire splices,Tee´s, X´s, etc.; all wire to ground rods, ground rod splices, wire to steel and cast iron, terminal lugs, bus-bar connections and wire to rail connections.
Exothermic welding is applicable to materials other than copper, some of these are listed