Thermite Track Welding

Thermit welding, also known as aluminothermic welding, is a process used to join two sections of rail together. It is a popular method of rail welding due to its ability to create a strong and durable weld, as well as the fact that it can be performed in situ, without requiring the removal of the rails from the track. The welding process involves the use of a thermit mixture, which is a blend of powdered aluminium and iron oxide, to create a molten pool of steel that is used to fill the gap between the two rail sections.

Advantages of Thermite Welding

There are several advantages to using thermite welding for rail track construction and maintenance. Some of these advantages are summarized in the table below:

Advantages of Thermite Welding	Explanation
High strength and durability	Thermite welding produces a strong and durable weld that can withstand heavy loads and stresses. The molten steel produced by the thermit reaction is of high quality, with no porosity or inclusions, resulting in a high strength joint.
Long-lasting	Due to the high quality and strength of the weld, thermite welding is a long-lasting solution for rail track construction and maintenance. A well-executed thermite weld can last for decades without needing to be repaired or replaced.
In situ welding	One of the key advantages of thermite welding is that it can be performed in situ, without requiring the removal of the rails from the track. This means that the welding process is more efficient and less disruptive to train services.
No special equipment needed	Thermite welding requires relatively simple equipment, and can be performed with a basic setup consisting of a mold, igniter, and preheating equipment. This means that it is a cost-effective solution for rail track construction and maintenance.
Suitable for all rail types	Thermite welding can be used on all types of rails, including steel, manganese, and carbon rails, making it a versatile solution for rail track construction and maintenance.

While there are several advantages to using thermite welding for rail track construction and maintenance, there are also some limitations to the process. One of the main limitations is that it is not suitable for welding curved or twisted rails, and it may not be suitable for use on heavily trafficked rail lines.

In summary, thermite welding is a popular and effective method of rail welding that offers several advantages over other methods. Its high strength and durability, long-lasting results, in situ welding capabilities, and versatility make it a cost-effective and efficient solution for rail track construction and maintenance.

Thermite Powder/Thermite Welding Powder

It is thermal welding supplies. A prepared package containing the correct quantity of Thermite Welding Powder for the type of weld to be made. Thermite powder is a pyrotechnic composition usually consisting of metal powder and metal oxide. Thermite welding powder is not usually explosive, but it does create extremely high temperatures in a very small area for a short period.

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Sand Mould for Thermit Welding

Thermite Welding Supplies: Sand Mould For Track, the primary material is SiO2(Silicon dioxide). It binds up the two ends of the rail and makes up an inner space to contain the liquid steel from the portion powder reaction.

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Luting Sand for Thermit Welding

Thermite Welding Supplies: Luting Sand Main material is SiO2(Silicon dioxide). It is used to seal the gap of the sand mold to avoid liquid steel leaking. 1770~2000℃ Refractory temperature, 3kg/weld.

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Crucible Lining for Thermit Welding

Magnesium oxide crucibles are Thermite welding supplies. Magnesium Oxide Crucible Lining are sintered in very high temperature, so it should be protected from any moisture at all time, otherwise it may cause failure when welding.

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One Shot Crucible for Thermit Welding

Thermite Welding Supplies: One Shot Crucible of inner crucible is MgO, outside is steel plate barrel. It is used as the reacting container of portion powder.

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Rail Shearing Machine

Rail Shearing Machine is a mechanical device that is used to cut and remove the excess or unwanted part of the rails after Thermit Welding.

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Rail Grinding Machine

Rail Grinding Machine is a type of equipment used in rail welding. It is used for profile grinding on the rail welding and rail damage maintenance, the grinding surface is smooth and clean and also keeps the original rail head profile size. Applicable to all types of rail laying scenes and repairing welding jobs.

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Rail Cutting Machine

It is a railway track maintenance equipment, it is not only cutting rail fast, high quality, and low wear. It relies on the rail clamped tightly locking. It is suitable for railway maintenance and repair, broken rail repair, and welding cutting in long rail.

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Orbital welding is the first choice for high-quality connecting pipes. In most cases, it uses TIG welding (tungsten inert gas) to weld around the pipe guided by a mechanical system.

Do You Know The History of Exothermic Welding?

Exothermic welding is a chemical process which enables the molecular bonding of metals in a long-lasting way. It is applied to metal joints and its use is very widespread in sector such as rail and the electrical sector, in the grounding connections.

How to Use Exothermic Welding?

Exothermic welding, also known as exothermic bonding, thermite welding (TW), and thermit welding, is a welding technique that permanently joins conductors using molten metal. An exothermic reaction of a thermite composition heats the metal, and no external source of heat or current is required. An aluminothermic reaction between aluminium powder and metal oxide releases heat.

Characteristics of Aluminothermic Welding of Rails

In the aluminothermic welding process, molten steel is poured into a mould surrounding the gap between the rail ends to be joined. The rail ends are connected by the liquid metal. The principle of aluminothermic welding is based on an exothermic chemical reaction of aluminium powder and iron oxide, producing sufficient heat to cause melting.

Dazhen, Tongrang, Tonghuo Line and Tongliao New Zealand Railway Construction and Maintenance Project

Under Tongliao Works Section of the Shenyang Railway Bureau, using rail aluminum welding material of Beijing CRS Metallurgical Machinery Co., Ltd, which is widely used in the basis construction and daily maintenance.

ZTK-1 Aluminum thermit welding kits Beijing High Speed Rail works section

Under our work section of Beijing-Shanghai high-speed rail Langfang section (3#54244698 turnout), There are 84 welding joints of ZTK-1 aluminium thermit welding kits, which is supplied by Beijing CRS, now it’s keep serving 6 years.

Thermit Welding project In Indonesia

Indonesia's railway is narrow gauge and some area on mountain or hill, the customer carried out strict inspection on the appearance and internal quality of the welding head. The performance of the materials and equipment's are satisfactory/up-to the mark.

Crane Rail welding project in Vietnam

Costumers and applications are based on Railway industry where in both, Croatian and Bosnian Railways. The local train speed is running at 50km/h and would increase to 70km/hour. Thermit welding is a good choice to customer. The goods has shipped to Vietnam, Cai Lai in the year of 2016.

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