#AluminoThermicWeldingOfRailJoints
#ATweldingOfRailJoints
#RDSO AT Welding Manual
#FullProcedure
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In this video, detailed discussion of #Alumino Thermic #AT Welding of #Rail Joints (Full Procedure) as per #RDSO #AT Welding #Manual has been done with its significance, which will be useful for aspirants of UPSC ESE/GATE/PSU's/SSC-JE /State PSC JE/AE exams and #P.way Engineer on Site.
Following content has been discussed in this video:-
#Alumino Thermic #AT Welding of #Rail Joints (Full Procedure) as per #RDSO #AT Welding #Manual.
Stepwise Procedure of #AT #Welding of Rail Joints is as follows:-
1. Elimination of Fish Bolts & atleast 5 sleepers loosening from both ends i. e. 250 mm clear working space on either side must be there.
2. Alignment of 2 rails using 1 m straight edge.
Note:- a) Lateral Alignment = 0.5 mm when checked using 1 m straight edge.
b) Vertical Alignment = 3 mm to 4 mm for 72 UTS rails & 2 mm to 2.4 mm for high UTS rails.
3. Gap between rails shall be from 50 mm to 70 mm with 1 mm tolerance.
4. Fixing of Moulds followed by Carbon Dioxide Gas.
5. Preheating using High Silica Sand Mould & Bentonite clay (Carbon Dioxide dried).
Note:- a) Preheating is done by Compressed air fuel mixture.
b) Rails shall be free from corrosion & excess wear.
c) Preheating using blower must be done for 4 to 4.5 minutes for maintaining temperature of 580°c to 620°c.
6. Sparkler shall be ignited & inserted in portion ( Oxides of metals) at centre top to start the reaction. After reaction subsides, about 3 seconds shall be allowed for separation of slag from metal.
7. Post cooling should be atleast for 20 minutes.
8. After Cooling, cutting of extra part of cast iron mould within 3 minutes after opening of boxes using trimmer.
Note:- a) Opening of boxes shall be within 3 minutes from cast iron moulds.
9. Grinding of Joint using grinding machine.
10. Tolerance checking on finished heads:-
a) Vertical Alignment = 1.0 mm, 0 mm measured at end of 1 m straight edge.
b) lateral alignment = 0.3 mm measured at centre of 1 m straight edge.
c) Finished top surface = 0.4 mm, 0 mm measured at centre of 10 cm straight edge.
d) Head Finished on sides = 0.3 mm over gauge side of rail head measured at centre of 10 cm straight edge.
11. USFD testing of Joints for DFWO & DFWR identification.
Note:-
1. Gap between two rails should be within 25 mm before welding.
2. Total cost of one AT weld is approx.
Rs.7000/-.
3. UTS stands for Ultimate Tensile strength in Mpa.
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Video Link of Rail Cutting, Drilling & Chamfering of Bolt Holes:-
• DRILLING & CHAMFERING ...
Video Link of USFD testing of AT welded Rail Joints:-
• USFD TESTING of AT WEL...
Video Link of Short Welded Rails & Long Welded Rails:-
• SHORT WELDED RAILS (SW...
PDF Link of Manual for fusion welding of rails by the Alumino Thermic Process:-
drive.google.com/file/d/13aCl...