Thermite welding fuses metal cables with intense heat for railway applications.

During the process of thermite welding, a thermite mixture is poured into a crucible placed above the joint between two copper cables set at a 90-degree angle. The thermite mixture consists of powdered aluminium and iron oxide, which reacts exothermically when ignited by a fuse. This reaction generates intense heat exceeding 2500°C, causing the metals in the cables to melt and fuse together. The device used to secure the cables during this process is typically a mould or holder designed to maintain the correct alignment for successful welding. Thermite welding is commonly used in railway applications due to its ability to create strong, durable joints between metal components.