Thermal welding system is an easy simple to use field/process for welding copper to copper or copper to steel, without the use of an external power source. Thermite connections utilize the high temperature reaction of powdered copper oxide and aluminum, which when ignited; produce aluminum oxide (in the form of slag) and superheated copper.

   The reaction takes place in a semi-permanent graphite mould where the materials are joint and positioned. When the total mass of powder becomes super-heated molten copper, it flows through the mould onto the conductors to be joined by melting a thin steel disc which previously has stopped the powder from dropping through the mould.

   This causes the conductors or surfaces to melt and form a fusion weld between them. The finished connection in the majority of cases sectional area of the conductors being welded and therefore:

1. Will not be affected by high current surges.
2. Will not loosen of corrode at the point of weld.
3. Has a current carrying capacity equal to or greater than that of the conductors welded?
4. Other efficiencies are:

• Will withstand repeated faults.
• Has a low labor cost.
• Requires no special skills.
• Can be checked for quality by visual inspection.
• Requires no external power or heat.
• Maintenance saving, as the welds are unaffected by oxidation and fault currents.