Thermit Welding

is a welding process in which heat produced during an exothermic reaction is used to

weld two metal pieces (conductors) together.

No external heat source is required during this welding process, but only an external
heat source is needed to initiate the process.

thermite material ( mixture of a metal oxide, aluminium powder, and fuel) is used for
the welding process.

The chemical reaction that produces heat is an aluminothermic reaction. The reaction
of aluminium powder with a metal oxide to produce heat is called an aluminothermic
reaction.

This welding process is also known as exothermic welding, exothermic bonding and
thermite welding.

It was invented in the year 1898 by Hans Goldschmidt when he improved the
aluminothermic reaction.
 KEY POINTS
• Thermite welding is a type of fusion welding
process.
• It is also known as Exothermic welding or
bonding.
• This process is used to welding a heavy and
large structures.
• It requires no electrode and power supply.
 Principle
• In this process, welding is done by pouring
superheated liquid steel around parts to be
joined.
• A short molding process is to be done before
welding.
 What is Thermite / Thermit?
• A mixture of fine aluminum powder and iron
oxide that produces a very high temperature on
combustion, used in welding and for incendiary
bombs.

Thermite reaction involving aluminum is also

called Goldschmidt alumino thermic reaction.
Usually this reaction is triggered by burning
magnesium ribbon in presence of Barium
peroxide.
• By weight, 75% of iron oxide and 25% of fine
aluminum powder (OR)
• Fine aluminum powder and iron oxide should
have a ratio of 1:3 (by weight)

• We can also use copper or chromium instead

of aluminum.
 Working principle
In thermit welding process, a thermite material which is a composition of a metal
oxide, aluminium and fuel is used to achieve exothermic reaction. A reaction between
the metal oxide (mostly iron (iii) oxide) and aluminium powder is takes place. During
reaction the metal oxide reduces to free elemental metal and aluminium get oxidized
to aluminium oxide with production of a large amount of heat (about 3310 oC).

The heat generated melts the elemental metal ( Fe) and then this molten metal
poured into the mold to join the two metal pieces together.

During the aluminothermic reaction, the reduction of iron oxide and oxidation of Al
takes place. The large amount of heat generated during the process melts the iron and
aluminium oxide and we get molten iron and refractory slag of aluminium oxide. The
density of the aluminium oxide slag is much less than the liquid iron, so it floats above
the molten iron.

So during the welding process, the molten iron present at the bottom of the crucible
and slag floats above it.

If we talk about composition of the metal oxide and aluminium powder, then 5 parts of
iron oxide and 3 parts of aluminium powder by weight is mixed before initiating the
welding process.
• The ends of parts to be joined are kept parallel
with a uniform gap between them.

• That gap is filled with wax which becomes the

pattern.

• Molding sand is rammed around wax pattern.

Pouring gate, heating gate and risers are cut.
Main Parts of Thermit Welding

Crucible: It is that part which is capable to withstand in high temperature condition. In

thermite welding process, the crucible contains thermite material. The exothermic
process during the welding process takes place in the crucible. The molten iron
present at the bottom of the crucible and slag of aluminium oxide floats over the
molten metal. The crucible contains a taping device to discharge the molten metal to
the mold for the welding.

Thermite mixture: It is a pyrotechnic composition of metal oxide, aluminium powder,

and fuel.

Mold: A mold is created around the section to be welded. The mold consists of runner,
riser, slag basin, heating gate. The molten metal is poured into the mold for the joining
of the metal.

Taping device: It is device which is used to discharged or pour molten metal form the
crucible to the mold.
 Working

A mold is formed over and around the section to be welded. After the
mold is formed thermite material is placed in the crucible.

The thermite material is ignited by the use of flint sparker or magnesium

ribbon. An exothermic reaction takes place in the crucible called an
aluminothermic reaction.

During the reaction metal oxide i.e. iron oxide reduces to iron and Al
gets oxidized and forms aluminium oxide. A large amount of heat is
generated. This heat generated melts the iron and aluminium oxide and
form molten iron and slag of aluminium oxide.

The molten metal so formed is poured into the mold through taping
device. As the molten metal reaches the section, it fuses with the metal
pieces to be joined. After solidification, it forms a very strong weld
• Joints to be welded are preheated by a flame
(external source). Due to preheat wax melts
and goes out.

• After melting of wax, weld joints are

preheated due to flame.

• Then heating is stopped and heating gate is

closed.
• The mixture of aluminum and iron oxide is placed in a
crucible.

• Barium Peroxide is added to the crucible. Barium

peroxide arises by the reversible reaction of
O2 with barium oxide. The peroxide forms around 500°C
and oxygen is released above 820°C

• Mixture is ignited using a match stick (or) small

magnesium wire. So combustion takes place in the
crucible.

• Due to combustion, thermite mixture becomes

superheated liquid within max. time of 30 seconds.
• That superheated liquid (pouring metal) have
temperature of 2500--3000°C (around 5000°F)

• The reduction of ferric oxide by aluminum is highly

exothermic and therefore the iron formed will be in
the molten state.

• Aluminum is chosen as metal since it has strong

affinity towards oxygen and its oxide, Al2O3 is a
highly exothermic compound.

• Reaction takes place:

Fe2O3 + 2Al --------> Al2O3 + 2Fe + heat
• Crucible is placed directly above the joints to
be welded.
• After preheating of joints, liquid thermite steel
from the crucible is poured into mold between
the gap to weld.
• The molten metal solidifies and weld is
completed.
• This process is used to weld very large works
like joining of rails, pipes, broken teeth on
large gears and large frame work.
• This process is generally used for welding
ferrous metals.
ADVANTAGES:
-Very large size structure can be easily
weld
-No power supply and electrode needed

DISADVANTAGES:
-Skilled labor required
-Long process
Advantages
In thermit welding, the weld formed has high mechanical strength and excellent corrosion
resistance as compared with other forms of weld.
It is highly stable to repeated short circuit pulses and the electrical resistance remains
unchanged over the lifetime of the installation.
It does not require any external power source.
It can be used at the place where power supply is not easily available.

Disadvantages
It is a costlier welding process in comparison with other welding processes.
It requires the supply of replaceable molds.
Lack of repeatability.
It cannot be used in wet conditions or bad weather when working outdoors.

Application
The thermit welding process is mainly used for rail welding in railways. It is also used or
welding copper conductors and other metals that include cast iron, stainless steel,
common steels, bronze, brass and monel.