A Basic Overview of Exothermically Welded Connections - Nvent

5/5/22, 6:05 PM A Basic Overview of Exothermically Welded Connections | nVent
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A Basic Overview of Exothermically Welded

Connections
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When constructing electrical protection systems, electrical grounding connections must remain
dependable over the life of the system. If bonds weaken, grounding, bonding and lightning protection
systems become susceptible to failures.
Exothermic welding, often known under by our brand name nVent ERICO Cadweld, is a method that
has been around since 1938 and offers a number of advantages over other types of connections.
Discover what exothermic welding is, when it should be used and how it compares to mechanical
grounding connections.
https://blog.nvent.com/a-basic-overview-of-exothermically-welded-connections/ 1/9
What
Contact UsIs Exothermic
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Exothermic welding is a process used for joining similar metals,

ANDsuch as copper to steel or copper to
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copper. It employs an exothermic reaction to form a molecular bond between the two pieces.
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The connection is produced in a purpose-designed graphite mold. The weld employs an exothermic
reaction of thermite (powdered metal) to heat the metal. Put simply, the exothermic process involves
a chemical reaction that releases heat and requires no external source of heat.
Exothermic Welding Chemical Reaction that Produces

Heat
3Cu2O +2Al → 6Cu + Al2O3 + HEAT
Copper Oxide + Aluminum → Copper + Aluminum Oxide (Slag) + Heat
Reaction Temperature approximately 2500°C (4500°F)
When executed correctly, an exothermically welded connection is homogeneous after cooling,

meaning a true weld has been formed and the elements are completely fused together. The
connection is permanent, irreversible and requires no additional means to hold
it together, as shown in the image below.
In the 1930s, Professor Charles A. “Pops” Cadwell, the namesake of nVent ERICO Cadweld, worked to
improve the installation or repair of signal bonds and track power connections to electrified train rail.
These welds took significant effort and equipment to complete. “Car A”, shown below, was used to
transport the equipment and personnel needed to make a single connection.
In 1938, Pops patented the Cadweld process, and enabled one man with 25 pounds of equipment to
replace all of this equipment previously needed. Shortly thereafter, exothermic welding for cathodic
protection applications was created, followed by high voltage power transmission and electrical
grounding and bonding connections.
Over the last 80 years, the equipment has been greatly enhanced to improve ease-of-use, product
safety and weld quality to increasingly justify its use and broaden its applications. Exothermic welding
is a significant invention that has accounted for more than 150 million connections.
How Does Exothermic Welding Compare to Mechanical

Connections for Grounding?
In general, exothermic connections are superior to mechanical connections for grounding due to the
permanent bond made between two materials. Especially for use with electrical connections, a
reliable connection is key.
Advantages of exothermically welded connections:
Maintain a lower resistance over time due to the fused connection.

Will not deteriorate with age due to a limited susceptibility to corrosion.
Lifespan exceeds that of the conductors it connects.
Eliminates any risk of loosening because of the molecular bonding.
ContactWill
Us resist repeated
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currents.
Offers the lowest possible earth path resistance.
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Can be quality controlled GROUNDING
by a visual inspection.AND BONDING CONTENT HUB 
Safe and easy to use with minimal training and protective requirements.
UL® listed to UL 467.
Exceeds the requirements of IEEE 837.
Disadvantages of mechanical connections:
Cause a point-to-point current flow (i.e. unequal current density).

Susceptible to corrosion, lowering resistance over time.
Require an anti-oxidant compound in order to prolong the lifetime of the connection.
How Is an Exothermic Weld Performed?

To illustrate the exothermic welding process, below are the directions using nVent ERICO Cadweld
Plus.
Components:
Graphite mold
Weld metal
Igniter
Mold clamps
Cleaning tools
Sleeves, shims, batting
Directions for performing an exothermic weld:

1. Insert Cadweld Plus cup into mold (may require use of a cover/baffle).
2. Attach control unit termination clip to ignition strip.
3. Press and hold control unit switch and wait for the ignition.
4. Open the mold and remove the expended steel cup—no special disposal required.
After learning the process, it typically only takes a few minutes to complete an exothermic connection.
Between the simple process and improved performance, exothermic welding becomes the preferred
method for most electrical professionals.
Learn More About Exothermically Welded Connections

The value of exothermic connections is pretty clear. If you want to learn more about the specifying,
installing or how to select the right Cadweld product and mold for your applications, click below to
visit Cadweld.com.
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5/5/22, 6:05 PM A Basic Overview of Exothermically Welded Connections | nVent

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Jun 25, 2019 ERICO