EDING HANDBOOK 9.3, CHAPTER 1S—OTHER WELDING AND CUTTING PROCESSES 575. pints in the track structure. In coal mines, the ling track is often welded to minimize mainte- d to reduce excessive coal spillage caused by ick. Crane rails in buildings usually are welded Eze joint maintenance and vibration of the build wily loaded rail car wheels pass over the joviat sizes. The installation of a thermite weld in a rail is shown in Figure 15.13 (A through F). The mold is aligned 50 that the center coincides with that of the rooe opening, which typically is 25 mm (1 in.) between the sail ends. The molds are fitted rogether (A), and packed ®B). The rail ends are preheated (C) in the range of fe mixtures are available for all types of rail ‘majority of rails are carbon-manganese (C- sls. However, the high-hardness and high- “rail steel used to reduce wear in curved track entain additional alloying elements, such as sn (Cr), molybdenum (Mo), vanadium (V), and Si). The addition of rare earth metals or alloys rease the amount of sulfur and phosphorous in J deposit, resulting in improved mechanical es. Specially designed thermite molds that allow sion of an alloy plug at the head of the rail are mcrease local hardness while maintaining desirable es in the web and base of the rail. Figure 15.12 weld in progress using a disposable crucible 3 with Preheat. Premanufactured two-piece ‘piece molds designed for single use generally red for the thermite welding of standard rail Figure 15.12—Thermite Welding of Rail with a Single-Use Crucible 600°C to 100°C (1100°F to 1800°F) with a gas torch flame ditected into the mold. A refractory-lined crucible containing the thermite charge is positioned above the mold halves after preheating is completed. The crucible also is designed for a single use, which minimizes size and weight for better ergonomics. The charge is then ignited to initiate the thermite reaction, (D). Tapping takes place (E) and the thermite reaction continues. Additional time is allowed for the steel and aluminum oxide to separate. The molten steel flows into the joint while the residual oxide spills into slag pans, and the pour is complete, (F). In most procedures, the metal is, center-poured (fed into the middle of the root opening), and then diverted to the outer legs to enter and fill the Foot opening, beginning at the rail base by way of a diverter plug. A self-tapping seal (thimble) is used in the bottom of the crucible. Approximately 20 seconds to 30 seconds after eee Progra courtesy of Tansponaten Teton en,