Eastern Railroad Discussion > Welding Project and More Eqyptians - Lake Erie Land

Thursday September 14, 2023
Vermilion OH 

Images 1- 3. A quick walk this morning over to town and I spotted a welding crew setting up on Track 1 on the Lake Shore Line to do a thermite weld. They were using a degradable crucible  (the container like device) as opposed to a single-use crucible. Thermite welding is a process that joins the two pieces of rail using a thermite reaction that creates molten metal. After it is ignited it sends up a plume of dense gray / white smoke, which is quickly replaced by a big open flame as seen here. Temps will reach about 2200 - 2400 degrees (fahrenheit) seen here as heat distortion. Welds of this type can be pretty expensive, but a good way to go that guarantees little trouble into the future.



 



Edited 2 time(s). Last edit at 09/14/23 17:49 by train1275.

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4. The weld done, and the sand moulds are knocked off.

5. The completed weld.

6. Later in the afternoon sitting over at the docks by the Nickel Plate, and a Kingfisher is either searching for a snack or watching the tracks for something special. I don't think his name is Horus, but something is up ......



Edited 1 time(s). Last edit at 09/14/23 16:33 by train1275.

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7. ....  here comes new locos bound for Eqypt on Train 981. Maybe this is what the Kingfisher was watching for. I think this is the 3rd shipment of new units for Eqypt I've seen recently. They must have a pretty modern fleet by now. NS 4251 provides the power as they head towards Bellevue.

8. - 9. Well they are crossing a river but it is not exactly the Nile. May they have a good and safe journey.

 



Edited 1 time(s). Last edit at 09/14/23 16:34 by train1275.

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How must a newly welded cool down, before it is ready to trains to operate over it?  At what speed?  

Yeah, how long after knocking off the molds is pic 5?

Anyone know when US RRs started doing that regularly?



Edited 1 time(s). Last edit at 09/14/23 17:05 by timz.

MEKoch Wrote:
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> How must a newly welded cool down, before it is
> ready to trains to operate over it?  At what
> speed?  

My understanding* is that the weld has to cool to 700 degrees (f) before heavy equipment such as tampers or regulators can move over it and train traffic. It also has to cool to under 700 degrees before finish dressing (grinding) can take place. I am not aware of any speed restrictions after that point unless it is a premium alloy rail, then it is recommeded for 30 mph for 24 hours. The weld collar on the web is not to be ground, as noted in the photos.

*Corrections and additional info welcome.

timz Wrote:
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> Yeah, how long after knocking off the molds
> is pic 5?
>
> Anyone know when US RRs started doing that
> regularly?

I guess about 4 hours. I was on a quick walk in the late morning and didn't get back into town until mid afternoon, long after the welding crew had left.

The process of exothermic welding of rails dates back to Germany in the 1890's. I'd guess it's been a regualr process here in the U.S. for the last 40 or so years. There are a number of technical papers written on it in the mid 1980's. 

How many new GEs were in that train?

GN1969 Wrote:
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> How many new GEs were in that train?

sorry, I forgot to include that ... there were 10.
(if I counted right)