PROCEDURE FOR THERMIT WELDING

The various steps involved in the no pressure Iusion thermit welding oI metal parts are given
below. The mold is no repetitive in nature and is used Ior repair welds.

1. lean the Joint

Metal surIaces to be joined are cleaned thoroughly in order to obtain a strong weld. A length oI
125 to 150 mm back Irom the ends to be welded must be cleaned thoroughly to expose bright
metal on each side. The adjacent ends may be cleaned by a sand blast. An oxyacetylene torch
may be used to clean the metal surIaces by heating. During cleaning, all dirt, grease, loose
oxides, scale, etc., must be removed.

2. Allow Ior ontraction

AIter cleaning, the parts to be welded are to be lined up with a space oI about 1.5 to 6 mm
between the ends, depending upon the size oI the parts to be joined. This space makes up Ior
(i) the contraction oI the thermit steel in cooling and
(ii) the shrinkage oI the base metal which has been heated during the welding operation.

3. onstruct the Mold

AIter the parts have been cleaned and spaced properly, the next stage is the making oI the wax
pattern Irom which the mould will be Iormed and which must in shape constitute a replica oI the
eventual weld. The wax is placed in a container and heated until it reaches its plastic state. The
wax is then shaped around the parts that are being welded together. A hole or vent is made in this
wax Irom the heating gate to the riser to enable gases to escape when the weld is begun. It is
usually made by Iorming the wax round a cord oI about 6.4 mm diameter and withdrawing the
cord when the pattern has been made. A molding box is then placed around the portion to be
welded and a molding material* is rammed into the box. Ramming should ensure a tight contact
between the molding sand and the wax. The sand mixture must Iill the mold completely and be
rammed hard. The molding material should be about 100 mm tick between the wax pattern and
the molding box at all points. The mold should be provided with the necessary number oI
pouring gates, heating gates and risers depending on the size oI the weld. AIter the ramming has
been done, the molder should lightly rap the gate, riser and preheat opening patterns and draw
them out careIully. Wipe away any loose sand that might tend to Iall into the holes. The mould
walls and recesses will then need be trimmed, so that any broken surIaces may be patched,
obstructions in the pouring and other gates removed and the surIaces eIIiciently smoothed.
4. Preheating the Mold

The mold prepared as above is then preheated in order to:
(i) Melt away and remove the wax there by leaving a mold cavity in the exact shape oI
the weld.
(ii) (ii) Dry the mold thoroughly otherwise the superheated molten metal will Iorm steam
within the hold and cause porous weld.
(iii) (iii) Bring the parts to be welded to a desired temperature, in order to prevent chilling
oI the hot thermit metal.

5. rucible and its harging

Thermit mixture is charged in the container known as crucible or reaction vessel. This vessel is
oI conical shape and is lined with magnesia tar lining. The outside shell oI this vessel is made up,
oI sheet steel. Located at the bottom oI the vessel is a magnesia stone and a magnesia thimble
through which the tapping pin is suspended. First oI all, the thimble is inserted in the stone. The
thimble provides a channel through which the liquid thermit steel is poured. Every time a new
thimble is used Ior each reaction. The thimble is plugged by suspending the tapping pin through
the thimble and placing a metal disc above the pin. This disc is then covered with reIractory
sand. AIter drying the crucible, a small quantity oI the thermit powder is Iirst introduced, the
object being to avoid damage to the reIractory sand layer and to cushion oII the plugging
material in the bottom oI the crucible Irom the impact oI the Iull weight oI the thermit
charge. The rest oI the thermit is then careIully mixed and put into the crucible.

6. Igniting the Thermit Mixture

A low ignition point thermit in the Iorm oI a powder is placed on the top oI the thermit in the
crucible. To initiate the reaction, the low ignition temperature thermit is contacted with a hot rod.
This ignition immediately starts the reaction in the main thermit charge. The reaction is violent
enough to be readily audible, so that as soon as the noise ceases the reaction can be saIely
regarded as at an end. The chemical reaction may last up to 60 seconds. The crucible should be
tapped only aIter making sure that the reaction has been completed. The crucible works as a
bottom pour ladle and allows Iast removal oI the molten metal with no danger oI slag entering
the mold. The intense heat oI the molten metal melts the preheated ends oI the parts to be welded
and complete Iusion takes place.
7. Opening the Mold

The actual period Ior which the mold is leIt unopened depends upon the dimensions oI the weld,
being shorter (two or three hours) Ior small sections and longer (about Iour hours) Ior heavy
sections. The longer the mould can be leIt unopened, the better it is.

8. Finishing the weld

AIter removing the mold, the risers and gates are cut away with a cutting torch. In case oI shaIts
or parts requiring speciIic Iinished contour the same can be given by either machining
or grinding