CATHODIC PROTECTION CONNECTIONS

Exothermic welding
VS
Pin Brazing

Prepared by
Hussain Al Khumairi
Introduction
Exothermic or thermite welding and Pin Brazing are two methods used in cathodic protection to get a
connection from the steel surface (structure to be protected). In this essay, we will examine how these
two techniques affect the connection efficiency and the impact on the steel surface due to the connection
process.

Exothermic welding
Exothermic welding, also known as exothermic bonding, thermite welding (TW), and thermit welding, is a
welding process that employs molten metal to permanently join the conductors. The process employs an
exothermic reaction of a thermite composition to heat the metal, and requires no external source of heat
or current.

procedures of Exothermic Welding

• Assembly the mold with handle clamp.
• Clean the pipe surface with a cable clen brush, preheat the mold and cable with a butane torch.
• Fit conductor (cable) and place the mold on the pipe surface snugly as shown in the figure.
• Pour a recommended size of weld metal powder into the crucible.
• Loosen starting powder from the bottom of tube pour 2/3 of it on top of the mold lid.
• Ignite the starting powder at the lid opening. Complete connection

Explanation video: Click here.

Pin Brazing
Pin brazing is a process of joining two metals together by melting a filler metal (known as the brazing
alloy/brazing pin) between them. The brazing alloy is melted by using a torch to heat the metals to the
melting point of the filler metal. The filler metal then flows into the joint and forms a strong bond between
the two metals.

procedures of Pin Brazing bonding method

-Ensure the batteries are fully charged, correctly installed and in good working order.

-Grinding, a bright steel finish is essential for attachment and good contact of the earth device.

- Bright steel finish is essential for attachment and good contact of the cable lug

- The gun is adjusted so that when manually depressed against the cable lug in the case of direct brazing
the adjustment indicator or collar are flush with the flat triangular face at the rear of the gun.

- Press the pin brazing gun against the lug and pipe and hold for approximately two seconds.

- Remove the gun and allow the joint to cool.

Explanation video: Click here.

 Comparing Exothermic Welding and Pin Brazing for
Cathodic Protection Connections

Criteria Pin Brazing Exothermic Welding

External Power Source Need No Need

Applicable in any condition,

Weather Not Applicable
Rain, snow

Metallurgical Effects Affect within normal range Affect within normal range
Safety Safe Safe
Trained Easier to operate harder to operate
Operating temperature 600 C 1400 C

Outcomes:
• Using thermal bonding to the exterior pipeline wall of a pipeline filled with highly flammable
hydrocarbons requires consideration.
• Thermite welding has more chance to impact the Internal coatings due to the high operating
temperature especially for thin surface .
• Testing showed that the inner wall temperature rises more with thermite welding than with pin
brazing.
• Neither method's results were sufficient to give any reason for concern.