The thermOweld® Process
The thermOweld® connection process is a simple, efficient method of welding copper to copper or copper to steel. One advantage is that NO outside power is required when using the thermOweld® exothermic process. The thermOweld® process uses high temperature reaction of powdered copper oxide and aluminum.
The reaction takes place in a semi-permanent graphite mold. These molds should last for approximately fifty or more welds if proper care is given. The reaction takes place very rapidly, therefore the total amount of heat applied to the conductors or surfaces is considerably less than that of brazing or soldering. This is important to remember when welding to insulated cable or
thin wall pipe.
This system is very field friendly, since it is light and portable and requires no outside power source. It requires very little time or skill to obtain an efficient, maintenance free connection when using the thermOweld® process.
The thermOweld® process has been used to weld materials other than copper for electrical purposes. Materials welded include:
- Stainless Steel
- Plain Steel
- Nichrome V
- Galvanized Steel
- Silicon Bronze
- Steel Rail
- Cast Iron
- Copper Clad Steel
When welding to galvanized steel it is recommended to resurface exposed bare steel.
The thermOweld® connection is a molecular weld. The weld has the same melting point as copper. This factor along with the increased cross sectional area of the connection and the following insure:
- thermOweld® connections are not a$ected by a high current surge. Tests have shown that the electrical conductor will melt before the thermOweld® connection, when subjected to high short circuit current. Consult IEEE Standard 837.
- thermOweld® connections will not loosen or corrode at the point of weld. There are no contact surfaces or mechanical pressures involved.
- thermOweld® connections have a current-carrying capacity equal to or greater than that of the conductors.
thermOweld® Weld Metal is packaged in moisture-resistant plastic cartridges that have tight #tting caps. These cartridges and the necessary steel discs are then packaged in boxes that are shrink-wrapped. This insures the weld metal will arrive in good condition, always dry, and ready for a positive ignition every time.
thermOweld® Weld Metal comes in four types; one for welding copper to copper or copper to steel, copper to rail, copper to cast iron and one for welding copper to steel for cathodic protection. The size and weight (in grams) of the cartridge are marked on each individual cartridge.
thermOweld® Weld Metal is available to be shipped via ground, air or ocean freight. All sizes of weld metal are eligible for thermOweld’s SDS (Same Day Service) shipment.