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Thermit welding

Thermit welding process

 Thermit welding is a chemically reaction welding process. The weld joint is produced by pouring of superheated molten metal around the joint to be welded, applying with or without of pressure. Thermit welding basically called a mixture of finely divided metal oxide and a metal reducing agent as aluminium.


Thermit welding principle:


The necessary heat  for joining metal of thermit welding is obtained from chemical reaction of metal oxide and metal reducing agent. Usually iron oxide is used as a metal oxide and aliminium or magnesium is used as metal reducing agent. The strong chemical attraction of aluminium for oxygen is the basis for thermit process. First the thermit mixture is ignited by a burning magnesium ribbon. The ignited temperature of thermit is about 12000C. When ignited in one spot of mixture, the heat reaction spreads through the mass. The aluminium merging with the oxygen of metal oxide and setting free the iron, which is deposited on joint portion into the mold as a highly superheated liquid metal. If theoretical temperature is about 30000C of thermit, due to chilling effect of crucible the temperature is reduced about 25000C. So it is sufficient for welding temperature.

The thermit reaction is required about thirty second to ignite and it is non-explosive process.

Thermit Welding Diagram

Some chemical reaction:


3Fe3O4 + 8Al 9Fe + 4Al2O3 (719.3 Kcal)

Fe2O3 + 2Al 2Fe + Al2O3 (181.5 Kcal)

3MnO + 2Al 3Mn + Al2O3 (403 Kcal)

3CuO + 2Al 3Cu + Al2O3 (275.3 Kcal)


Thermit welding application :


It has large application in railway track repairing on the spot.

It is used in large frame like locomotive frame welding.

Thermit welding is used in crank shaft welding.


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