Thermowelding process is used in various welding applications through high temperatures generated by the reaction of copper oxide with aluminum.


Reaction Formula: 3CuO + 2Al  Heat effects and 3Cu+Al2O3

In this process, all components are used as powders or granules. Once the reaction is initiated by an external heat source, aluminum reduces the oxygen from the metal-oxide which will result in a liquid, superheated aluminum-oxide (Al(2)O(3). Since these two components are different in density, they separate automatically and the liquid metal can be used for the production of alloys, special metals or for multiple welding applications.


The reaction takes place in a graphite mould where the parts to be welded are placed. After the powder is ignited, molten metal from the aluminothermic reaction flows around the pieces. The reaction connects them as one solid piece. Exothermic reaction process takes just few seconds. In preparing the joint for thermowelding, the parts to be welded must be cleaned, aligned, and held firmly in place. Thermowelding is then applied around the joint in the size and shape of the intended weld. A mold made of graphite is built around the joint to hold the molten metal after it is poured.



The  system may be used in welding copper to copper and/or between the following materials:

Steel, stainless steel, rail steel, copper clad steel, galvanized steel, brass, bronze





Thermowelding process provide a perfect connection for proven results such as: 

• No possibility of corrosion at the point of the weld
• Connections are not affected by high current surges. Tests have shown that the electrical conductor will melt before the connection when subjected to very high short-circuit currents.
• Connection conductivity is at least equal or greater than the conductors welded together.

Other Benefits

· Safe and easy to operate.

· Excellent tensile strength

· Horizontal connection of the grounding grid

· Easy to operate with minimum training

· A graphite mould could be used for 70 or more different connection types

· Low cost

· No maintenance cost


International Standards & Certificates: UL, RoHS, CE, IEEE Std.80, UL467 and IEEE837.




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