SECTION 3.

13 SPECIFICATION FOR THE QUALITY ASSURANCE OF THERMITE

WELDING OF RAIL 2003
3.13.1

SCOPE (2003)

3.13.1.1 This specification covers thermite welding of steel tee rails weighing 115 lbs./yd. and
over for use in railway track.
3.13.1.2 For recommended practices for thermite welding of sections of rail other than described
in Paragraph 3.13.1.1 refer to the manufacturers instructions for the specific process
being used.
3.13.1.3 This specification covers mechanical properties, dimensional tolerances and test
procedures necessary for assuring the quality of thermite welds of all rails
manufactured to current AREMA specifications. The following is intended to cover
initial process qualification and routine quality assurance requirements and
procedures.
3.13.2 MANUFACTURE (2003)
3.13.2.1 The thermite weld shall be made according to the manufacturers instructions for the
specific thermite welding process being used. Details of such processes are to be
obtained from the manufacturer of the thermite welding kit.
3.13.2.2 Workers who perform thermite welding shall be trained to perform the operation by a
qualified instructor.
3.13.3 WELD INTEGRITY REQUIREMENTS (2003)
3.13.3.1 Ultrasonic Acceptance
The weld between the two joining rail ends shall be accepted if it has no reflective
surface greater than 1/8 inch.
3.13.3.2 Visual Acceptance
The outside weld surface shall be free from any detrimental discontinuities as
compared to a typical as cast surface finish.
3.13.3.3 Weld Hardness
The hardness of the weld metal shall be within +/- 30 BHN points of the manufacturers
specified hardness for the specific welding kit being used.
3.13.3.4 Weld Finished Dimensional Tolerances of the Railhead
3.13.3.4.1 Vertical Offset

0.060 inch maximum

3.13.3.4.2 Horizontal Offset

0.060 inch maximum

3.13.3.4.3 Horizontal Kink

0.025 inch maximum

3.13.3.4.4 Vertical Crown

+0.060 inch maximum, -0.000 inch maximum

3.13.3.4.5 Combined Horizontal Offset and Kink

0.060 inch maximum

3.13.3.4.6 Combined Vertical Offset and Crown

0.090 inch maximum

Where an allowable offset or kink exists, taper grinding to create a smooth transition is
recommended.
3.13.3.5 Weld Finish
The railhead shall be ground smooth on the running surface and the field and gage
sides. The base riser break off area shall be ground flush with the weld collar. Other
than the smoothing of the base riser break off area, the as cast geometry of the
thermite weld should be left intact.
3.13.3.6 Weld Microstructure
The presence of martensite is not acceptable at any location in the weldment.
3.13.3.7 Slow Bend Test Results
3.13.4 WELD INTEGRITY TEST PROCEDURES (2003)
3.13.4.1 Ultrasonic Testing
The thermite weld shall be tested ultrasonically in accordance with the most common
industry test practice for the ultrasonic inspection of rail.
3.13.4.2 Visual Inspection
The thermite weld shall be visually inspected by an experienced inspector familiar with
typical as cast surface finishes. The procedure for visual inspection shall be similar to
the procedure for magnetic particle inspection described in Article 3.11.4.4 of this
chapter.
3.13.4.3 Weld Hardness Testing
The thermite weld shall be tested for hardness by the hardness testing method
described in Article 2.1.3.2 of this chapter. The hardness test to verify weld metal
hardness is to be taken on the running surface at the center of the weld fusion zone.
3.13.4.4 Weld Finished Dimensional Tolerance Inspection
The thermite weld is to be inspected for dimensional tolerance using a 3 straight edge
centered on the weld and a taper gauge.
3.13.4.5 Weld Finish Inspection
The thermite weld shall be visually inspected in addition to the above to verify that the
base riser break off area has been smoothed.
3.13.4.6 Weld Microstructure Testing
If weld metal hardness exceeds 410 BHN, the weld shall be examined at 100X or
higher for confirmation of a fully pearlitic microstructure.
3.13.4.7 Slow Bend Testing
The thermite weld is to be slow bend tested in accordance with the slow bend test
procedure described in Article 3.10.3.6 of this chapter.

Rail Grade
Standard Carbon
High Strength

Modulus of Rupture
110,000 psi minimum
120,000 psi minimum

Deflection
0.90 inch minimum
0.60 inch minimum

3.13.5 FREQUENCY OF TESTING (2003)

3.13.5.1 Recent results of destructive testing of weld samples from a proven thermite welding
process accompanied by a certified Quality Assurance batch report for the welding
material being used is acceptable initial process qualification.
3.13.5.2 Quality Assurance testing utilizing non-destructive means included in this writing should
be made upon request.
3.13.5.3 Any process change should be announced by the manufacturer and welds produced
and tested for initial process qualification.