A specialized substance called exothermic welding powder, commonly referred to as exothermic welding compound or thermite welding powder, is used to make excellent electrical connections between metal conductors. Industries including telephones, railroads, electricity distribution, grounding systems, and others frequently employ this procedure. Exothermic welding is primarily used to create dependable, low-resistance electrical connections that can tolerate a variety of environmental factors and support large current loads.

The exothermic welding procedure operates as follows:

Preparation: The metal conductors that need to be linked are first prepared in the exothermic welding process. To establish a strong connection, these conductors, which are often made of copper or aluminium, should be cleaned and prepared.

Mold Assembly: The conductors are held in place during the welding procedure using a specialized graphite mold. The conductors and the exothermic welding powder can both fit inside the mold.

Exothermic Reaction: Exothermic welding powder is made up of a combination of reducing agents and metal oxides, usually iron oxide and aluminium oxide. The combination undergoes an exothermic reaction upon ignition, producing a sizable amount of heat and energy.
Exothermic reactions produce extremely high temperatures, which melt welding powder and conductors to form pools of molten metal. The molten metal forms a solid and extremely conductive junction as it flows into the mold and around the conductors.

Cooling and Solidification: Following the completion of the welding reaction, the molten metal starts to cool and solidify inside the mold, forging a durable connection between the conductors.

Finishing: After the connection has cooled and hardened, the mold is taken out, and any extra material is cut off or eliminated for a neat and polished finish.

Exothermic welding has a number of benefits over conventional electrical connection techniques such mechanical crimping or compression fittings: