Railway Thermit Welding

Railway Thermit Welding !
1. Preparation of Rail Ends: Rail ends are precisely cut and cleaned to ensure a perfect match. All rust, debris, and contaminants are removed from the welding area. (Alignment tolerance: < 1mm)
2. Mold Assembly: A refractory mold is clamped around the rail gap. This mold creates the cavity where the molten steel will form the weld. (Gap setting: 22-25mm)
3. Preheating: The rail ends are preheated using oxy-acetylene torches to approximately 600°C. This removes moisture and ensures proper fusion.
4. Thermit Reaction: The thermit mixture (iron oxide and aluminum powder) is ignited in a crucible. An exothermic reaction produces molten steel at 2500°C.
5. Pouring: The thermit mixture (iron oxide and aluminum powder) is ignited in a crucible. An exothermic reaction produces molten steel at 2500°C. (Pouring time: 15-20 seconds)
6. Cooling & Finishing: After 5-6 minutes of cooling, the mold is removed. Excess material is trimmed and the weld is ground to match the rail profile. Cooling time: 20-25 min, Speed tolerance: ±5 km/h