What is exothermic welding?

Exothermic welding, also known as exothermic bonding, thermite welding, or aluminothermic welding, is a welding process that uses a chemical reaction to create intense heat and join two metal components together.

The process involves placing a mixture of metal oxide and aluminum powder in a high-temperature crucible, which is ignited with a spark or flame. This chemical reaction produces molten metal at a temperature of over 2,500°C (4,500°F), which is poured into a mold surrounding the two metal components to be joined.

As the molten metal solidifies, it forms a strong and permanent bond between the two metal surfaces. This type of welding is commonly used for joining copper conductors, steel rails, pipes, and other metal structures where a reliable, durable, and long-lasting connection is required.

Exothermic welding offers several advantages over traditional welding methods, including a high degree of conductivity, low resistance to electricity, resistance to corrosion, and the ability to weld dissimilar metals. However, it requires specialized equipment, training, and safety precautions due to the high temperatures involved in the process.