Bahan kimpalan thermite rel

Rail thermite welding material also known as exothermic welding or aluminothermic welding, is a process that uses the intense heat generated from a chemical reaction to weld railroad tracks together. The material used in this process is a thermite composition, which typically includes:

Aluminum Powder: This is the fuel for the reaction. Aluminum is a highly reactive metal that, when finely powdered, reacts exothermically with metal oxides.

Seterika(III) Oxide (Fe2O3): This serves as the oxidizer in the reaction. When combined with aluminum powder, it reacts to produce molten iron and aluminum oxide, along with a great deal of heat.

The basic chemical reaction in thermite welding is as follows:
[ Fe_2O_3 + 2 Al \rightarrow 2 Fe + Al_2O_3 + Heat ]
This reaction is known as a reduction-oxidation reaction (redox reaction) where aluminum reduces the iron oxide to iron, and in doing so, gets oxidized to aluminum oxide. The reaction is highly exothermic, meaning it releases a significant amount of heat, enough to melt the iron.
In the context of rail welding, the molten iron produced by the thermite reaction is what fuses the rail ends together. The process involves the following steps:

Preparation: The ends of the rails to be joined are cleaned and aligned. A mold, known as a crucible, is placed around the joint to contain the molten iron.

Ignition: The thermite mixture is placed in the crucible and ignited, usually with a flammable primer or a sparkler-like igniter.

Reaction: The thermite mixture reacts, producing molten iron which flows into the gap between the rail ends.

Solidification: The molten iron solidifies to form a solid weld, fusing the rail ends together.

Penamat: After cooling, excess material is removed, and the weld is ground down to ensure a smooth, continuous rail surface.

Thermite welding is often preferred for rail applications because it produces a high-quality weld that is strong and durable, capable of withstanding the heavy loads and stresses associated with rail traffic. It also has the advantage of being portable and relatively easy to perform in the field, which is essential for repairing and maintaining railway tracks.

We can make mould to weld below steel rails:

PENGGUNAAN REL	JENIS REL	STANDARD
Rel untuk Keretapi	43 kereta api kg/m, 50 kereta api kg/m, 60 kereta api kg/m, 75kereta api kg/m, 60Kereta api N, 75Kereta api N	TB/T2344-2012, TB/T3276-2011
	Kereta api P50/Rel R50, Kereta api P65/Kereta api R65, RP60E1	GOST-R51685, GOST R51054-2014
	Kereta api S49, Kereta api UIC54, Kereta api UIC60	UIC860
	Kereta api JIS50N, Kereta api JIS60	JIS E1101
	Kereta api AS50, Kereta api AS60, Kereta api AS68	AS1085, BHP RT STD
	90Rel RA, 100Rel RE, 115Rel RE, 132Rel RE, 136Rel RE	AREMA
	Kereta api TR45, Kereta api TR50, Kereta api TR57, Kereta api TR68	ASTM A759
	Kereta api BS75A, Kereta api BS90A, Kereta api BS100A	BS11 STANDARD
	ISCOR 48 Kereta api, ISCOR 57 Kereta api	UIC860 menghasilkan standard
	45E1, 49Kereta api E1, 50Kereta api E2, 54Kereta api E1, 60Kereta api E1, 60Kereta api E2	EN 13674-1, EN13674-4
Tukar Rel	50Kereta api AT1, 60Kereta api AT1, 60Kereta api AT2, 60Kereta api TY1	TB/T3109-2013
Rel Kren	A45, A55, A65, A75, A100, A120, A150	DIN536
	Kereta api QU70/Kereta api KP70, Kereta api QU80/Kereta api KP80, Rel QU100/Rel KP100, Rel QU120/Rel KP100, Rel CR175	YB/T5055-2014/GOST53866-2010 ASTM A759-2000
Rel Grooved	59Rel R2, 60Rel R2	EN 14811:2006
Alat pembinaan kereta api	Mesin kimpalan kilat rel bergerak, Mesin kimpalan flash butt rel

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