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.

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.

A mobile device for heating a rail (12) of a railroad (2) is made up of a heating module (34) comprising at least one heating zone (28) and at least one radiating heat source (46) directed towards the heating zone (28), and of a transport vehicle (16) for transporting the heating module (34). A heating unit (36) of the heating module (34) comprises infrared-radiation electric lamps (42) able to emit radiation that is concentrated in the near-infrared, and which are equipped with a primary reflector (48) oriented in such a way as to reflect the infrared radiation emitted by the radiation source (46) towards the heating zone (28). The heating unit (36) also comprises a secondary reflector (50) having a concave reflective surface surrounding the heating zone (28) and able to return towards the heating zone (28) rays reflected by the rail and that pass between the infrared-radiation electric lamps (42).

A mobile device for heating a rail (12) of a railroad (2) is made up of a heating module (34) comprising at least one heating zone (28) and at least one radiating heat source (46) directed towards the heating zone (28), and of a transport vehicle (16) for transporting the heating module (34). A heating unit (36) of the heating module (34) comprises infrared-radiation electric lamps (42) able to emit radiation that is concentrated in the near-infrared, and which are equipped with a primary reflector (48) oriented in such a way as to reflect the infrared radiation emitted by the radiation source (46) towards the heating zone (28). The heating unit (36) also comprises a secondary reflector (50) having a concave reflective surface surrounding the heating zone (28) and able to return towards the heating zone (28) rays reflected by the rail and that pass between the infrared-radiation electric lamps (42).

The present invention relates in particular to a mold (M) for aluminothermic welding of a metal rail (1), which comprises at least two substantially identical pieces or shells (4), configured to be temporarily assembled opposite one another and on either side of said rail (1) to enclose the head (10), web (11) and foot (12) of this rail (1), each piece or shell (4) having an upper opening (43), which opens onto an internal cavity (44) bounded by walls (45, 46, 48) configured to enclose the head (10), the web (11) and the foot (12) of said rail (1), characterized by the fact that said internal cavity (44) comprises a compressible sealing coating (5) only against the walls (451, 46, 48) configured to enclose said web (11), foot (12) and underside of the head (10), with the exception of the rest of the head (10) and the underside of the foot (12).

The present invention relates in particular to a mold (M) for aluminothermic welding of a metal rail (1), which comprises at least two substantially identical pieces or shells (4), configured to be temporarily assembled opposite one another and on either side of said rail (1) to enclose the head (10), web (11) and foot (12) of this rail (1), each piece or shell (4) having an upper opening (43), which opens onto an internal cavity (44) bounded by walls (45, 46, 48) configured to enclose the head (10), the web (11) and the foot (12) of said rail (1), characterized by the fact that said internal cavity (44) comprises a compressible sealing coating (5) only against the walls (451, 46, 48) configured to enclose said web (11), foot (12) and underside of the head (10), with the exception of the rest of the head (10) and the underside of the foot (12).

A rail lifting head (10) comprises a head gate member (20) defining a gate aperture (22), a rail support member (24) removably secured to the gate member (20) and adapted to support a rail vertically within the gate aperture (22), and a head cartridge (100) which is removably secured to the head gate member (20). The head cartridge (100) includes two opposed vertical rollers (128) which support a rail laterally within the gate aperture and a fixing (112) which secures the head cartridge (100) to the head gate member (20). The rail support member (24) is removable from the head gate member (20).

A rail lifting head (10) comprises a head gate member (20) defining a gate aperture (22), a rail support member (24) removably secured to the gate member (20) and adapted to support a rail vertically within the gate aperture (22), and a head cartridge (100) which is removably secured to the head gate member (20). The head cartridge (100) includes two opposed vertical rollers (128) which support a rail laterally within the gate aperture and a fixing (112) which secures the head cartridge (100) to the head gate member (20). The rail support member (24) is removable from the head gate member (20).

A translatable, ultra-high pressure liquid jet system includes a translatable frame configured to maintain mechanical contact with a rail. The liquid jet system includes a liquid jet processing head affixed to the frame and configured to maintain a distance from the rail and provide a liquid jet that contacts the rail. The liquid jet system also includes an ultra-high pressure liquid pump in fluid communication with the liquid jet processing head. The ultra-high pressure liquid pump is configured to supply pressurized liquid to the liquid jet processing head.

A self guarded frog copper weld fixture has a rail form and a pair of transverse locator arms. The rail form is configured to abut with a damaged rail frog and define a proper repaired geometry for the rail frog. A pair of locator arms transversely and vertically locate and secure the rail form against one of the rails of a damaged rail frog, by applying an opposing force against a second one of the damaged rail frog rails. Any wear will present as small gaps between the rail form and rail frog. The transverse locator arms are pivotal with respect to the rail form, and so may be rotated from transverse to the rail form to align longitudinally for compact transport or storage, and may also be reversed to allow either one of the longitudinal vertical side edges of the rail form to be abutted to the rail frog.