Furseweld Furse
Furseweld exothermic welding system


The Furseweld exothermic welding process is a simple, self contained method of forming high quality electrical connections.

The compact process requires no external power or heat source making it completely portable.

Connections are made inside a semi-permanent graphite mould using the high temperature reaction of powdered copper oxide and aluminium.

This is how it works:

The Mould (1) features a Crucible (2), a Tap Hole (3) and a Weld Cavity (4). The conductors (5) and (6) to be joined, are located in the weld cavity as shown, and the mould is closed. A steel Retaining Disc (7) is located in the bottom of the crucible to retain the Weld Powder (8) and Starting Powder (9) which are poured in on top.

Mould Cross Section

Ignited with a spark gun, the starting powder sets off an exothermic reaction in the weld powder, reducing it to molten copper alloy. This instantaneously melts the retaining disc, and flows down the tap hole, to the weld cavity, where it partially melts the conductors, before cooling to leave a fusion weld of great mechanical strength and electrical integrity.


Mould Cross Section

The majority of Furseweld connections have at least twice the cross sectional area of the conductors being joined, and an equivalent or greater current carrying capacity.

Because the connection is a fusion of high conductivity , high copper content alloy, it will withstand repeated fault currents, and will not loosen in the way that mechanical connectors can.

Corrosion resistance too, is exceptional, due to the alloy's very high copper content (in excess of 90%).


Furseweld weld powders are contained in plastic cartridges, and are packed in plastic boxes of 10 or 20, depending on their size.

Different joints require different powder sizes, and relates to the powders nominal weight in grams.

The weld powder packaging also contains the retaining discs and starting powder. The retaining discs are contained in a separate bag within the box. The starting powder is compacted into the bottom of the cartridge, underneath the weld powder, and is released by tapping the cartridge base firmly.

Furseweld powders are suitable for making connections from copper to copper and from copper to steel.


Furseweld graphite moulds are dedicated to producing one type of connection. With care, they should be capable of producing up to 75 connections each.

Each mould carries a tag which gives the mould part number, the weld powder size for use with the mould and the conductor sizes for which it is intended.


Handle clamps provide a means of both handling the mould, and also of clamping the mould halves together (or of clamping the mould to the surface to which a connection is to be made).


A flint gun is required to start the reaction.

Cleaning tools for conductors, surfaces and moulds include:

  • Cable Brush - for cleaning cables and other circular conductors such as rods
  • Mould Scraper - for removing slag from the mould crucible, after firing
  • Mould Brush - for final mould cleaning
  • File Card Brush - for cleaning conductors and surfaces

Standard Tools

  1. Handle Clamp
  2. Powder Boxes and Cartridges
  3. Mould
  4. Mould Brush
  5. Flint Gun
  6. Mould Scraper
  7. Retaining Discs
  8. Cable Brush
  9. File Card Brush

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