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The Thermit Welding Process | Thermit Welding (GB) | Supporting railway infrastructure
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ESTABLISHED WORLDWIDE
In 1837 Theodore Goldschmidt founded the Goldschmidt Company in Berlin to supply chemicals to the textile
industry, and established a research and development facility investigating processes for refining metals and
their oxides. In March 1895, Dr Hans Goldschmidt was granted German Patent #96317 for a "process to
manufacture metals and alloys" based upon the reduction of heavy metal oxides by a more reactive metal such
as aluminium.
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Aluminium
>
Aluminium Oxide
Iron
Heat
3FeO
2Al
>
Al2O3
3Fe
880 kJ
Fe2O3
2Al
>
Al2O3
2Fe
850 kJ
The process was first used to provide the thermal energy for a method for forge welding rails in 1899, when a
number of welded joints were installed in the Essen Tramway. The process was first used in the UK to weld
tram rails installed in Leeds in 1904.
Further development leading to the addition of alloying elements to the basic Aluminothermic reaction produced
a steel with a compatible metallurgy to the parent rails, thus enabling a full fusion welding process to be
developed. While early welds were produced by casting the Thermit steel into hand produced moulds
encompassing the two rails to be joined together, subsequent development lead to the introduction of pre
formed refractory moulds designed to fit specific rail profiles.
While the basic Aluminothermic process still forms the heart of the Thermit welding processes, continuous
development coupled with modern production technology, statistical process control and quality assurance, has
resulted in processes which more than match the service demands of modern high speed, high axle load
railway systems.
Conventional "Flat bottom" or "Vignole" Rails
Special Section Railway rails
Grooved Tram Rails
Heavy Section Crane Rails
Electrical Conductor Rails
In addition, products are available to suit special types of track support, confines spaces, environmental
restrictions, and for joining rails of differing types or with differing degrees of wear.
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The Thermit Welding Process | Thermit Welding (GB) | Supporting railway infrastructure
In each case, should products not be available from our own manufactured stock, we will either design and
manufacture the products to suit, or call on the extensive range available from within the Thermit Group.
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Once correctly installed, the finished weld is expected to last the life of the
rail, with no further maintenance.
It is estimated that over 100,000 Aluminothermic welds are manufactured in track each year, with a total
population in excess of 1.8 million. The processes are used throughout the year on site with no heavy
equipment other than that which may be carried to site by the two man welding team. All the equipment, ancillary
tools such as lighting, gases and consumables can be transported to site by small commercial vehicles.
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The Thermit Welding Process | Thermit Welding (GB) | Supporting railway infrastructure
WELD TYPES
SkV-E
SkV-L
SkS
SrZ
CRW
Replacement of
standard welds,
removal of rail
defects. Composite
joints between
different rail profiles
Joining of heavy
section crane rails
Installation of
grooved tram rails
and joining them to
conventional rails
Joining of low
resistance electrical
conductor rails
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