Our AMP Weld Exothermic welding process is an aluminothermic chemical reaction between aluminum and copper oxide. In the exothermic reaction the aluminum reduces the copper oxide to produce copper metal (molten), aluminum oxide (slag), and the liberation of a large amount of heat. The molten copper generated from the reaction is used to fuse conductors together and form an electrical connection. The connections have an ampacity that exceeds that of the conductors being joined. The connection will never increase in resistance and will have a service life that exceeds that of the conductors joined.
The primary applications include electrical grounding and bonding where permanent connections are required. The process is also used for power connections. This technology is field-proven to provide permanent and reliable electrical connections.
Our AMP Weld Exothermic Grounding Connectors has been successfully tested and qualified to the high standard established in the latest revision of IEEE 837-2014.
The IEEE protocol incorporates procedures for two separate evaluations of each grounding connection:
Mechanical testing, which subjects the connection to severe electromechanical forces via the application of extremely high asymmetric test currents.
Sequential testing, which exposes the connection to a series of environments replicating hostile field conditions.
Testing included various combinations and configurations of conductors including:
Cable-to-cable, cable-to-ground rod and cable-to-structural steel plate.
Tees, parallels and end or straight connections.
Premium weld material
Complete fusion of copper conductors
Harsh environment testing protocol
Tubes filled by mass not by volume
Double cavity tubes avoiding intermix and spill of materials
Question: What is TE's AMP Weld Exothermic welding process?
Answer: Our AMP Weld Exothermic welding process is an aluminothermic chemical reaction between aluminum and copper oxide. In the exothermic reaction, the aluminum reduces the copper oxide to produce copper metal (molten), aluminum oxide (slag), and the liberation of a large amount of heat. The molten copper generated from the reaction is used to fuse conductors together and form an electrical connection.
Question: When should I use Exothermic welding process?
Answer: Our process should be used when you need to produce permanent electric connections for joining applications such as copper to copper and copper to steel.
Question: How is the Exothermic welding process performed?
Answer: The welding is done using a semipermanent graphite mold with premium grade exothermic welding material (powder). The Exothermic Grounding Connectors are placed into the opened mold and then the mold is locked using the mold handle clamp. The molded lid is opened and the steel disk is inserted into the mold followed by the welding material. Some of the starting material is sprinkled on top of the welding material. The lid is closed and the remaining starting material is poured on top of the lid. A flint igniter is used to initiate the reaction, which is completed in a few seconds.
Question: Can the Exothermic welding process be done on-site?
Answer: The Exothermic welding process is easy to perform on-site and requires no external power source to perform the process. Our Exothermic welding material is a proprietary blend of copper oxides, aluminum and alloy elements to produce the highest yield of usable weld metal available in the market.
Question: Can the component used for the Exothermic welding materials be transported easily?
Answer: The welding and starting materials are packaged by size in double cavity plastic tubes. The two materials are in separate chambers which ensures there is never intermixing of the welding and starting materials. Steel disks are packaged along with the tubes in plastic boxes. These materials are nonexplosive and are not subject to spontaneous combustion.