<div dir="ltr"><div class="gmail_default" style="font-family:tahoma,sans-serif">Steel Dynamics said they were looking at friction welding of the rails although I didn't ask the obvious question of how they would obtain the friction since spinning the parts doesn't seem possible. Perhaps some sort of high frequency vibration?</div><div class="gmail_default" style="font-family:tahoma,sans-serif"><br></div><div class="gmail_default" style="font-family:tahoma,sans-serif">The process used in the video is very similar to what is done at Steel Dynamics.</div><div class="gmail_default" style="font-family:tahoma,sans-serif"><br></div><div class="gmail_default" style="font-family:tahoma,sans-serif">Howard</div></div><br><div class="gmail_quote"><div dir="ltr" class="gmail_attr">On Tue, Dec 3, 2019 at 10:22 AM Gene Dotson <<a href="mailto:gdotsly@watchtv.net">gdotsly@watchtv.net</a>> wrote:<br></div><blockquote class="gmail_quote" style="margin:0px 0px 0px 0.8ex;border-left:1px solid rgb(204,204,204);padding-left:1ex"> Our process at Rockwell for welding spindles on to axle tubes was simply<br>
called butt welding in our processes. The axle tube and spindle were clamped<br>
in their own vice like device and held in stationary precise location. They<br>
both were heated to very near melting temperature by a large high frequency<br>
induction coil, then high pressure cylinders forced the spindle onto the<br>
axle tube. The intensive pressure added the extra temperature to melt the<br>
mating surfaces, completing the weld which was then quenched by a spray of<br>
water and quenching fluid.<br>
<br>
A later method was friction welding. The axle beam was clamped<br>
stationary in a holding fixture. The spindle was located in a fixture that<br>
was on a rotating spindle and rotated at high speed with pressure exerted on<br>
the mating surface creating a very high temperature. At near melting<br>
temperature, a quick application from an induction coil completed the<br>
heating process at which point the spindle was stopped with molten metal at<br>
junction of spindle with pressure at which time the weld was quenched<br>
completing the process.<br>
<br>
Gene<br>
<br>
<br>
<br>
-----Original Message----- <br>
From: Carl Gogol<br>
Sent: Saturday, November 30, 2019 7:47 AM<br>
To: 'Antique Tractor Email Discussion Group'<br>
Subject: Re: [AT] Welding Rails<br>
<br>
Rails are thermite welded in the field<br>
Carl<br>
Manlius, NY<br>
<br>
-----Original Message-----<br>
From: AT <<a href="mailto:at-bounces@lists.antique-tractor.com" target="_blank">at-bounces@lists.antique-tractor.com</a>> On Behalf Of James Peck<br>
Sent: Saturday, November 30, 2019 7:27 AM<br>
To: Antique Tractor Email Discussion Group <<a href="mailto:at@lists.antique-tractor.com" target="_blank">at@lists.antique-tractor.com</a>><br>
Subject: Re: [AT] Welding Rails<br>
<br>
That certainly looks like resistance welding.<br>
<br>
Steve Offiler AT List member Mechanical Engineer (<a href="mailto:soffiler@gmail.com" target="_blank">soffiler@gmail.com</a>);<br>
Interesting, but not very helpful:<br>
<br>
<a href="https://www.youtube.com/watch?v=f9i4aMYTv8o" rel="noreferrer" target="_blank">https://www.youtube.com/watch?v=f9i4aMYTv8o</a><br>
<br>
James AT List Member (<a href="mailto:jamesgpeck@hotmail.com" target="_blank">jamesgpeck@hotmail.com</a>); You have got me curious. I am<br>
going to guess resistance welding if you say that the rail ends are pushed<br>
together.<br>
<br>
<a href="https://en.wikipedia.org/wiki/Electric_resistance_welding" rel="noreferrer" target="_blank">https://en.wikipedia.org/wiki/Electric_resistance_welding</a><br>
<br>
Howard Pletcher AT List Member AT List Member (<a href="mailto:hrpletch@gmail.com" target="_blank">hrpletch@gmail.com</a>); The<br>
process is mostly automated and details are hidden by the equipment. The<br>
rail joint comes into the welding station, the operator cleans the ends, the<br>
door closes, and there’s 2 seconds of arcing. My understanding is it begins<br>
with a small gap between the ends and as the steel begins to melt from the<br>
arc, it is shoved together with high pressure. I assume the rails are<br>
clamped between (large) contacts to apply the current—should have asked for<br>
more details.<br>
<br>
Mentioning dimming city lights, they melt 120 tons of scrap in an electric<br>
arc furnace in a batch. They said this uses the same current as the city of<br>
Fort Wayne. Fortunately they are on their own distribution lines so the<br>
lights don’t go out.<br>
<br>
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