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Frequently Asked Questions
What kind of joint does this produce?
A fused one, not a fastened one.
Molten copper flows around the conductors.
Everything solidifies as one piece.
No interface remains.
That is the whole point of it.
Why does a mechanical clamp not last as long?
Because it keeps an interface.
Interfaces loosen and oxidise.
Moisture gets in and stays.
Resistance climbs invisibly.
The clamp still looks fine.
How is the reaction started?
With an ignition source in the mould.
The charge sits above the joint.
It produces molten copper in seconds.
Gravity does the rest.
No external power is involved.
What tooling does it require?
A mould for each joint geometry.
Graphite, and reusable many times.
A different cable size means a different mould.
Plus the correct charge weight.
The moulds are the real inventory.
Can the finished joint be checked?
By inspection and by measurement.
A good weld looks continuous.
Porosity shows on the surface.
Resistance can be measured across it.
A poor one is cut out, not reworked.
What are the hazards?
Heat, flash and fume.
The reaction is genuinely violent.
Moisture causes ejection of metal.
Moulds and conductors must be dry.
This is trained work.
Where is it the wrong choice?
Where the joint must come apart.
Test points need disconnection.
So do bonds that are inspected.
Confined spaces resist the fume.
And a single joint rarely justifies a mould.