A Mobile Electric Flash-Butt (EFB) Welding apparatus that incorporates an automated geometry system which creates field/mobile EFB welds with proper vertical alignment, within a definable distance. The system has a first pair of adjustable reference points on a left side of a mobile welding apparatus. The system has a second pair of adjustable reference points on the right side of the welding apparatus. The system has a first lifting mechanism positioned between the first pair of adjustable reference points and a second lifting mechanism positioned between the second pair of adjustable reference points. The welding line is positioned between the first and second pair of adjustable reference points and is the location of the weld. The system allows for comparatively shorter inserts than previously utilized.

A moulding assembly for aluminothermic welding of metal rails includes at least one mould part configured to come into contact with at least one other mould part and rails to be welded to form a mould cavity in which the ends of the metal rails to be welded are arranged and into which a molten metal is cast to weld the metal rails, wherein each mould part comprises includes a seating configured to be placed in contact least one of the rails, the seating including a groove into which a sealing product made of intumescent material is applied.

A railway rail induction-welding device is provided which includes a device support and a railway rail alignment means for aligning opposing railway rails in three mutually perpendicular directions, the railway rail alignment means being supported by the device support. The railway rail alignment means includes first and second railway-rail clamping elements to horizontally and longitudinally align the opposing railway rails when gripped by the first and second railway-rail clamping elements, with at least one of the first and second railway-rail clamping elements being movably supported by the device support, and a vertical lifting means for moving each railway-rail clamping element vertically to align the opposing railway rails. A railway rail clamping and lifting module, a vehicle a railway rail induction-welding device, and a method of inductively welding opposing railway rails together are also provided.

A device for welding a rail joint of a track, comprising two rail clamping devices spaced from one another in a rail longitudinal direction which are connected to one another via push rods to press rail ends apart prior to welding. In this, it is provided that at least one rail clamping device is coupled to a transverse displacement device for flush-aligning the rail ends after being pressed apart.

A welding unit for welding rails of a track includes a first sub-unit which is displaceable on unit guides in a rail longitudinal direction relative to a second sub-unit by using displacement cylinders. Each sub-unit includes clamping cylinders disposed underneath the unit guides and coupled to clamping jaws for clamping the rails. The two sub-units are connected by the displacement cylinders in that a cylinder body of the respective displacement cylinder is connected to one sub-unit and a piston rod of the respective displacement cylinder is connected to the other sub-unit. Thus, it is not necessary to support the displacement cylinders relative to a transverse beam disposed at the front.

A welded rail according to an aspect of the present invention includes: a plurality of rail portions having a head portion and a web portion and having a height h; and a welded joint portion that joins the rail portions together, in which the rail portion has a predetermined chemical composition, a HAZ width of the welded joint portion is 60 mm or less, in a region of 0 to (⅔)×h from a head top portion outer surface in a cross section of the welded joint portion which is parallel to a longitudinal direction and an up-down direction of the welded rail and passes through a center of the welded joint portion and of ±5 mm in the longitudinal direction from a welding center, an area ratio of a martensite structure is 0.0006% or more and 0.1000% or less, and in the region, the number of martensite structures having a grain size of 20 to 200 μm is 3 to 80.

A method for joining materials such as metal alloys that includes a first component, wherein the first component includes a first alloy having a known austenization temperature below which martensite forms when the component is heated and then cooled at a predetermined rate of cooling; a second component, wherein the second component includes a second alloy; and a welding apparatus operative to create a weld between the first and second components without crossing the austenization temperature of the first alloy. The method also includes the steps of validating the characteristics of the weld created between the first and second components in real-time during the welding process; modifying the welding apparatus to prepare the surface of the first component prior to welding to assure proper alignment of the first and second components; and/or physically modifying the second component to enhance the welding characteristics and durability thereof.

A welding unit for welding together two rails of a track includes two rail clamping assemblies which can be moved towards one another in a longitudinal direction of the rail along unit guides by compression cylinders. Each rail clamping assembly is equipped with clamping jaws which are displaceable in pairs in a pressing plane and each of which has a contact surface provided for application to a rail web. The clamping jaws are each constructed as clamping levers which are pivotable in the pressing plane about a lever pivot axis. The contact surface intended for application to the rail web is disposed at a first lever end spaced apart from the lever pivot axis. The two contact surfaces of each rail clamping assembly are each positioned closer to the oppositely disposed rail clamping assembly than the two lever pivot axes.

Railway rails are welded in situ by induction welding with an insert (3) between the ends of the rails (1) being welded. The insert (3) compensates, at least in part, for the loss of rail length that occurs in the welding process. Preferably the ends of the rails are pushed apart (e.g. by the length of rail consumed in the welding process) before the insert (3) is placed in position, thereby allowing a longer insert to be used. Induction heating may be performed with a split head (5) that can be opened so as to be placed around a rail in situ and then closed to carry out induction heating.

An improved process for repair of worn and damaged surfaces of railway structures such as frog and diamond transition surfaces, rail head surfaces and wheels. A worn or damaged surface is prepared using a robotically-controlled laser to melt or gouge away metal using controlled laser energy and air pressure to remove existing worn or damaged surfaces. The process further utilizes laser cladding, laser weld overlaying, or laser additive manufacturing, of formulated powder, wire or stick welding material to worn surfaces that have been prepared for material build-up to original dimensions and similar metallurgical properties.