Thermite,Welding,Overview,Ther technology Thermite Welding Overview
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Thermite welding is a process that results from a chemicalreaction that is created through heating metal to a super high temperaturebetween two reducing agents, one of which will be a metal oxide and the otheraluminum or sometimes other types of reducing agents are used. This can be donewith pressure or without pressure. At this point the liquid metals will producea filler metal. The chemical reaction that isproduced will give off a temperature of 4500 degrees Fahrenheit or 2482 degreesCelsius. This metal that was created with high heat is found in a crucible thatis part of the weld joint. It is actually above this joint. This chemical reaction orexothermic reaction as it is also called, will be slow compared to otherprocesses; it takes about 20 or 30 seconds and it doesn't matter how manychemicals are part of the process -- it still takes about the same amount oftime. When the welder wants to weld twothings together, the two parts are lined up equally but a gap is made betweenthe two pieces of metal. Before the two pieces of metal are put together thereis a mold that is put between them so that the hot steel can go into the mold.Because this new metal is hotter than the base metal, the base metal will meltalong the edge of the pieces to be welded. From the crucible, the hot metalnow allows heat to be lost and this causes the metal that has been melted tobecome solid again and a process called coalescencehappens and this completes the weld. In the event that you have larger partsthat need to be welded, you may need to preheat them and this is done insidethe cavity within the mold. This is doneto bring these larger pieces to the correct temperature for welding and theprocess also help to make sure that the mold is dry. When you have smaller parts, thispreheating is usually not necessary. The mode that is used for thermite weldingis the automatic one which means that once the chemical reaction starts, theprocess continues until it is finished. The process of thermite weldinguses gravity to bring the metal down to the cavity between the two partsthrough the gap. This practice of welding is like pouring castings in foundrytype businesses. The basic difference between these two processes is that inThermite welding the temperature of melted metal is higher. After the metal filler cools youmay find extra filler on it and this can easily be removed by using a machine,grinding it or by using oxygen cutting. However, when the weld is finished youthe finished weld surface is usually very smooth and you don't have to worryabout doing any finishing. Thermite Welding is used a lot at the Railroadsto weld the rails together. A couple ofadvantages of this type of welding is that it that it doesn't need a powersource that is outside of the process because the heat is produced through thechemical reaction and you can join parts if they are larger and have heavysections.
Thermite,Welding,Overview,Ther