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Thermite Welding: The Unstoppable Reaction for Metal Joining

Discover the power of thermite welding, a combination of Iron Oxide and Aluminum that creates molten metal at 2500˚C. Learn its history, applications, and challenges compared to traditional welding methods. Explore its uses in welding train tracks with no removal required and its portability. Find out more about thermite's strength through a weld bend test comparison with SMAW, MIG, and TIG welding techniques. Sources for further information included.

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Thermite Welding: The Unstoppable Reaction for Metal Joining

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  1. Thermite! You wouldn’t like it when it’s angry! Drew Moug, Ginny Raymond, Michael “Miguel” Schantz, Lorenzo Tulipano ENGR 45, 11 May 2009, SRJC

  2. The Basics Thermite is a combination of Iron Oxide (rust) and Aluminum that, when it reacts, creates an unstoppable reaction that produces molten metal at temperatures reaching 2500˚C. The reaction is as follows: Fe2O3 + 2Al --> Al2O3 + 2Fe

  3. A Little History • The Thermite reaction was discovered, and later patented, by German chemist Dr. Hans Goldschmidt. • The Doctor realized the application in welding, and the first commercial use of Thermite was welding two pieces of train track together in 1899. • This would serve to be the primary use of Thermite

  4. About Thermite Welding • Ideal for welding train tracks • No track removal necessary • Very portable

  5. Raw Data

  6. SMAW MIG TIG Thermite

  7. Problems with Thermite Welds • The weld can be porous, resulting in weaker welds than traditional welding, as seen here

  8. Weld Comparison Bend Test • In order to see the relative strength of a Thermite weld, we compared it to three other types of traditional welds; shielded metal arc weld (SMAW), metal inert gas (MIG), and tungsten inert gas (TIG). • All of our welds were done with ¼ in. thick mild steel (<.29% Carbon), and the welds are approximately 3 in. wide. • After the welds were completed, we tested them in a bend/flexural strength test, where we recorded force and deflection distance. • Stress, strain, and the flexural modulus were calculated with the following equations: Raw data has been omitted due to its extensive size.

  9. Weld Comparison Bend Test (Results)

  10. Weld Comparison Bend Test MIG SMAW TIG Thermite

  11. Sources • eHow: http://www.ehow.com/how_2081916_make-thermite.html • University of Illinois: http://fcp.mechse.illinois.edu/media/pdfs/Lawrence%20presentation.pdf • Wikipedia: • Thermite: http://en.wikipedia.org/wiki/Thermite • Carbon Steel: http://en.wikipedia.org/wiki/Carbon_steel

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