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How to Make Thermate Weld

The thermite reaction, in use since the 19th century, allows a complete bond to form between two separate iron pieces, essentially melting the two pieces together into one. Though several chemical reactions fall into the thermite category, the iron/aluminum combination remains the most common as of 2011. The following chemical reaction illustrates the entire process: Fe2O3 + 2Al -> 2Fe + Al2O3

Things You'll Need

Iron (III) oxide powder (also called red ferric oxide)
Aluminum metal powder
Magnesium ribbon
Two iron parts to weld
Blowtorch

Instructions

- 1
  
  Iron (III) oxide powder has a rust color. Aluminum metal power is a dull grey.
  
  Mix approximately 9 g of iron oxide powder with 4 g of aluminum metal powder --- both thermite reactants.
- 2
  Fold a piece of paper into a tray shape to hold the thermite powder by bending the edges up on all four sides. The shape of the tray should match the shape of the desired weld. Place the paper on the two pieces of iron to weld together, and pour the thermite powder evenly into the tray.
- 3
  Insert a 2-inch piece of magnesium ribbon into the thermite so it sticks out like a fuse. Lay another strip of the magnesium ribbon as long as the weld across the surface of the thermite.
- 4
  Use the blowtorch to ignite the magnesium ribbon fuse and step back. This reaction will occur extremely quickly with extreme amounts of heat. Once the smoke clears, the two iron pieces will have a new weld.

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