Process for manufacturing a submarine power cable and power cable so manufactured

A process for manufacturing a power cable comprising:

• providing a power cable core including an electric conductor and having an outer diameter;
• providing a copper foil having a width such that, after folding of the copper foil to provide a copper sheath around the power cable core, the copper sheath has an inner diameter from 5 to 15 mm greater than the outer diameter of the power cable core;
• providing a protective strip over the power cable core in a position substantially matching a welding die, the protective strip having a radially inner and outer surface and being made of copper with a coating, at least on the radially outer surface, made of a metal or a metal alloy having a melting temperature in a range between 90° C. and 250° C.;
• folding the copper foil around the power cable core so as to bring two longitudinal copper foil rims to contact one another;
• welding the two contacted longitudinal copper foil rims with a welding die to obtain a copper sheath in form of a tube with a welding seam and having a diameter;
• reducing the diameter of the copper sheath to put it into direct contact with the power cable core and the protective strip;
• heating the protective strip and the copper sheath at a temperature higher than the melting temperature of the coating of the protective strip so that the coating fuses in the welding seam and the protective strip contacts the welding seam;
• and
• extruding a polymeric sheath around the copper sheath.