Thermowelding is a powerful welding method for joining dissimilar metals. It gives effective results in joining various metal combinations such as copper-copper, copper-steel, steel-steel, aluminum-copper and aluminum-aluminum.
What is Thermowelding?
Thermowelding is a special connection method used in the field of electricity and electronics. This system creates an uninterrupted and robust transmission path in joints that need to be electrically connected. Generally made of metals such as copper, aluminum or brass, thermowelds are resistant to high temperature and pressure. In addition, thermowelding powder is a conductive material that liquefies with the help of high heat, allowing the conductors to fuse to each other.
The main advantages of this welding process include high strength and low resistance values, durability at high temperatures, uninterrupted transmission, easy assembly and disassembly.
How to Thermoweld?
Thermowelding is performed in 6 basic steps using a high temperature reaction of powdered copper oxide and aluminum. This process occurs at a theoretical temperature of 4600 F, resulting in a molten copper alloy.
For thermowelding, the crucible and conductors must first be cleaned and dried, then the conductors must be fully inserted into the crucible slots. After the crucible is closed with pliers, the disk is placed so that it completely covers the hole, preventing the powder from flowing. The specified amount of thermowelding powder is poured into the crucible and compressed gunpowder is added. After the lid of the crucible is closed, the reaction is started by igniting the gunpowder with a special lighter. When the process is completed, the crucible is opened with pliers and the soot on the connection is cleaned.
Importantly, since the crucible and conductors overheat during the reaction, they should not be touched with bare hands and should be allowed to cool down. It is also critical to adjust the correct amount of powder. Insufficient powder can lead to incomplete welding and breakage at the joints. This method can be applied without the need for an external electrical source or specialized equipment. The result is joints that do not rot, loosen or increase in resistance.
Thermowelding Types
Thermowelding systems are widely used in industrial plants and special projects. It is especially preferred in hydroelectric power plants, fuel stations and flammable material tanks.
Connection Types
Thermowelding connections provide long-lasting and reliable results in grounding systems. Thanks to the molecular level bonding feature, these connections show high performance without the risk of loosening.
Busbar Connections
Busbar connections made with thermowelding crucibles are of critical importance in electrical distribution systems. It is especially preferred in applications requiring high current carrying capacity. The connections provide uninterrupted transmission with low resistance values.
Busbar-Electrode Connections
Busbar-electrode connections are one of the basic components of earthing systems. These connections are highly resistant to corrosion and do not deteriorate in the face of moisture. They also offer superior resistance to repeated fault currents.
Busbar-Steel Surface Connections
Busbar connections to steel surfaces are realized using thermowelding powder. As a result of this process, a homogeneous and permanent weld is obtained at the connection points. However, additional measures such as corrosion tape are recommended to extend the life of the joint.
Cable-Bus Connections
Cable-to-bus connections made using a thermowelding pot offer high current carrying capacity. These connections provide much superior conductivity than normal mechanical connections. Connection resistances are very low, below 30 microohms.
Cable Connections
Cable-to-cable connections are realized by exothermic reaction method. These connections, made using thermowelding powder, do not loosen or wear out over time. In addition, the risk of corrosion at the connection points is minimized.
Cable-Electrode Connections
Electrode connections are essential components of earthing systems. These connections do not deteriorate against moisture and show high resistance against repeated fault currents. They are especially preferred in lightning protection systems.
Cable-Rebar Connections
Rebar connections are made using crucibles specially designed for cables with a cross section of 10-40 mm². These connections are critical for foundation grounding and equipotential bonding.
Cable-Steel Surface Connections
Cable connections to steel substrates provide bonding at the molecular level. However, additional protection measures such as corrosion tape should be taken to extend the life of the connection.
In all these connection types, correct application techniques and selection of suitable materials are of great importance. The connections last longer than the life of the conductors and offer the lowest possible earth transient resistance values.
Welding Powders and Accessories
Thermowelding equipment consists of specially designed tools for quality and safe welding processes. Used especially in industrial applications, this equipment is indispensable for achieving professional results.
Crucible Putty
Cracks that occur during the use of a thermowelding crucible cause the crucible to breathe and reduce the welding efficiency. Crucible putty closes these cracks and makes the crucible reusable.
Ladle Scraper
It is a special tool used to clean the residues left in the crucible after the welding process. Regular cleaning prolongs the life of the crucible and improves the welding quality.
Ladle Brush
After the use of thermowelding powder, the crucible must be cleaned with a special brush to prepare it for the next welding process. This process directly affects the weld quality.
Welding Crucibles
Graphite crucibles consist of a chamber, a drain hole and a welding cavity. The average lifetime is 50 welding operations. Crucibles are produced in different sizes according to the size and type of materials to be welded.
Crucible Pliers
Special pliers used to hold the crucible in place during the welding process. They are produced in different models according to the type of crucible and prevent the crucible from opening and prevent the welding dust from spreading.
Crucible Lighter
For occupational health and safety reasons, the ignition of welding dust must be done electronically from a distance. The electronic pot lighter offers a safer use than traditional lighters.
Welding Powder
It is a special welding material, usually containing copper and iron alloys, which is melted at high temperature to join metal surfaces. This method is particularly used for grounding systems, rail welds and conductor connections.
Regular maintenance and cleaning of all this equipment directly affects the welding quality. In addition, keeping the equipment in dry and clean environments prolongs their life and ensures their efficient operation.
Especially in lightning protection systems, mechanical connection and corrosion tape can be used together against the risk of breakage of thermoweld connections. However, in general grounding systems, thermoweld connection stands out as the most ideal solution. Correct training and application techniques are of great importance for the successful realization of the connections. Correctly applied thermowelding connections gain a homogeneous structure after cooling and the elements are completely fused.
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