Abstract: The invention provides a new and improved process and exothermic reaction mixture for use in the process for producing molten weld metal. The molten weld metal is used in joining one non-ferrous metal piece with at least one other metal piece. The process and exothermic reaction mixture have distinct advantages over the prior art. These advantages include a higher filler metal yield, reduction of odor, and a higher quality corrosion resistant weld. These advantages are accomplished by a process wherein a reactant mixture is provided which has a reducing agent, a filler metal which does not react with any of the compounds of the mixture, and two or more metallic compounds which are exothermically reduced by the reducing agent. The metallic compounds subsequently form a compound, with the reducing agent, having a high heat of formation which provides an exothermic reaction with sufficient heat to melt the filler metal.

Abstract: The invention provides a method and means of producing weld metal for use in joining two or more aluminum containing pieces. The method includes the steps of providing a novel mixture of reactants comprising silicon, a reducing agent, a metallic compound which is exothermically reduced by the reducing agent, and a filler metal that does not react with the metallic compound. The mixture of reactants is then exothermically reacted so as to form the weld metal for joining the metallic pieces. At least about 90 percent by weight of the weld metal is produced by the silicon and the filler metal and at least about 90 percent by weight of the weld metal has a chemical composition substantially similar to that of at least one of the metallic pieces being joined.

Abstract: The invention provides a method and means of producing weld metal for use in joining two or more metallic pieces. The method includes the steps of providing a novel mixture of reactants comprising a reducing agent, a metallic compound which is exothermically reduced by the reducing agent, and a filler metal that does not react with the metallic compound. The mixture of reactants is then exothermically reacted so as to form the weld metal for joining the metallic pieces. At least about 90 percent by weight of the weld metal is produced by the filler metal and at least about 90 percent by weight of the weld metal has a chemical composition substantially similar to that of at least one of the metallic pieces being joined.

Abstract: An improved thermite reaction containment vessel and method of using the same includes a filter assembly which serves to filter the gases evolving from the thermite reaction and reduce the amount of smoke, fume and the like by-products emitted. In one preferred embodiment the filter assembly comprises a primary filter and a secondary filter. An air gap may be provided between the primary and secondary filter so as to provide additional cooling of the gases before they enter the secondary filter. The invention further provides a remote electrical ignition system which is capable of igniting thermite reaction materials without the use of a starting material. The ignition system may include an ignition fuse having an aluminum core and an outer coating comprising palladium and ruthenium or hot wire.

Abstract: An improved thermite reaction containment vessel and method of using the same includes a crucible in which the exothermic material is contained and which is connected at its lower end via a tap hole to a weld chamber in which the parts to be welded are positioned. On top of the crucible is positioned a baffle assembly which includes a plurality of expansion chambers which allows the escaping gas to expand and be reduced in velocity. As the gases move from one expansion chamber to the next the gases change direction. The expansion, direction change and the large surface area of the baffle assembly allows the gases to slow and cool before being exhausted leaving behind molten metal spatter or flame and greatly reducing the amount of smoke exhausted since particulate matter is accumulated on the baffle interior surface. Several forms of baffle assembly are disclosed using inverted stacked metal cups.