Exothermic Welding

Exothermic Welding

Exothermic Welding: The know-how and Advantages

Exothermic welding is a type of welding that uses heat to join two pieces of metal together. The process is simple and efficient, and it can weld a variety of metals, including aluminum, stainless steel, and brass. It is used on metal joints and is highly common in industries like rail and electrical for grounding connections.

Although this procedure has been in use for a while, recent upgrades and innovations have increased its efficiency. For instance, new powders and ignition techniques have been created, making it simpler to manage the welding process and achieve reliable results. Exothermic welding has also made it possible to weld previously incompatible metals. The procedure, also referred to as thermite welding or exothermic bonding, permanently connects conductors for earthing (grounding) or lightning protection.


We offer an advanced jointing technology of joining the conductors called Exothermic welding in which conductors fuse to form a joint. This type of jointing offers various advantages. The joint will not get loose, and hence the contact resistance will not increase. The current carrying capacity of the Exothermic joint is usually more than the conductor itself and it can with-stand very high mechanical forces that develop during the dissipation of fault current.

Grounding and Lighting Protection: The Foundation of Safety

Exothermic welding is an important part of the Grounding and Lightning protection system. This ensures that the electrical current from the exothermic reaction is discharged safely and doesn’t pose a risk to the operator or nearby objects. It also helps stabilize the arc and prevents it from wandering. The corrosion of underground conductor connections, which causes issues like loosening and separation, is one of the most significant issues that arise in grounding installations over time.

Arc welding requires constant arc maintenance, which should be obvious. If the Earthing Clamps or the area of installation becomes worn, contaminated, or otherwise ineffective, the force of the electrical arc will be restricted. By ensuring that the Earthing clamps and the surface are in good condition, welders can enable the required voltage and ensure that the work is as tidy and professional-looking as it should be.

The earthing pit chamber is a crucial element of secure and safe welding. Using an earthing pit chamber, it is feasible to test the effectiveness of earthing (as well as earthing resistance and associated data). It is secure and easy to maintain due to the design's high-impact pit, easy-lock lid, and UV stabilization. Numerous factors, including soil resistivity, fault current, current density on the electrode surface, etc., must be taken into account while designing a robust earthing system.

The earth ground resistance value of a ground system is initially low, but if the earth rods corrode, the resistance of the earthing system may increase and a dangerous potential may arise. Hence, the maintenance of earthing systems is the key to the earthing solution. Exothermic welding is a very essential welding technology in the process of developing lightning protection. Even though lightning cannot be stopped, a lightning protection system will intercept the hit and safely disperse it into the earth, sparing homes and businesses from great distress and trouble. Depending on their functioning, internal and exterior lighting protection systems make up the majority of a successful lightning protection system.

These devices are crucial for preventing both the secondary impacts, like damage to electrical equipment that is frequently irreparable and the direct effects of lightning, fire dangers, etc. on structures. Different design techniques are used in lightning protection systems to safeguard buildings or structures. An exothermic connection provides permanent conductivity throughout the entire segment due to molecular bonding between the metal surfaces. Exothermic connections allow electrical engineers to lower the danger of bonding and grounding system failures.

Connections made by exothermic welding produce a strong, long-lasting connection between the conductors that won't corrode or loosen, keep the resistance low, and need no external heat source or power source. Moreover, they have the same capacity to transport current as the conductor and can withstand several fault currents without malfunctioning. Thus, compared to mechanical connections in a facility, exothermically welded connections retain a high level of dependability. With the advancement of technology, the industry is on the cusp of innovation in lightning protection and grounding solutions.

JEF Techno offers an advanced exothermic welding technology that ensures that the joints don't get loose, thereby assuring that the contact resistance does not increase. Especially recommended for critical and sensitive applications, these superior joints provide excellent electrical connectivity without corrosion or degradation.

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