• Journal of Powder Materials
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• v.30 no.4
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• pp.332-338
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• 2023

Thermite welding is an exceptional process that does not require additional energy supplies, resulting in welded joints that exhibit mechanical properties and conductivity equivalent to those of the parent materials. The global adoption of thermite welding is growing across various industries. However, in Korea, limited research is being conducted on the core technology of thermite welding. Currently, domestic production of thermite powder in Korea involves recycling copper oxide (CuO). Unfortunately, controlling the particle size of waste CuO poses challenges, leading to the unwanted formation of pores and cracks during thermite welding. In this study, we investigate the influence of powder particle size on thermite welding in the production of Cu-thermite powder using waste CuO. We conduct the ball milling process for 0.5-24 h using recycled CuO. The evolution of the powder shape and size is analyzed using particle size analysis and scanning electron microscopy (SEM). Furthermore, we examine the thermal reaction characteristics through differential scanning calorimetry. Additionally, the microstructures of the welded samples are observed using optical microscopy and SEM to evaluate the impact of powder particle size on weldability. Lastly, hardness measurements are performed to assess the strengths of the welded materials.

• Journal of Welding and Joining
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• v.30 no.5
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• pp.40-45
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• 2012

Nowadays in Republic of Korea, whole amount of the thermite welding powder for rail joinning is dependent on import. However the demand of the thermite welding powder would be enlarge because some constructing high-speed train and city metro projects are currently in progress. In addition this is the main reason why we should develop the thermite welding powder, domestically. This study is focused on utilizing the recyclable materials like Al powders from cans and iron oxide scales from wire rods as the main components of the thermite welding powder. By minimizing Al content in weld zone by controlling the mixing ratio of the Al powder in the thermite welding powder, the excessive dissolution of the Si and Mn components came from the Al powders could be controled. The tensile strength of welding zone in welded rail was 740 MPa, with that the developed thermite welding powder.

• Journal of the Korean Society for Heat Treatment
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• v.36 no.1
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• pp.33-39
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• 2023

In this study, the effect of mixing condition of raw material powders possessing various particle size and particle size distribution on thermite reaction efficiency was investigated. When fine raw powders are used, rather the reaction yield tends to decrease due to agglomeration. In contrast, coarse raw powders make deteriorate the contact area between raw material powders containing Al reducing agent. To ensure the optimal thermite reaction efficiency, it is required to optimize a mixture condition of raw material powders prior to thermite reaction. From the current experiment, the maximum thermite reaction efficiency is 77%, which came from Nb₂O₅ + NiO +Al mixtures with size distribution from 9.25 to 22.63 ㎛.

• Tribology and Lubricants
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• v.15 no.2
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• pp.178-183
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• 1999

This paper presents friction and wear related results of thermite and gas pressure welded rails under various environmental contact conditions. A welded rail which was fabricated by thermite welding and gas pressure one has been tested over full range of test conditions in a pin-on-disk wear testing machine. The results show that the friction coefficient and wear rates of a welded rail are heavily dependent on the contact pressures and sliding environments for two welding methods such as thermite and gas pressure weldings.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 1999.06a
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• pp.345-353
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• 1999

This paper presents friction and wear related results of thermite and gas pressure welded rails under various environmental contact conditions. A welded rail which is manufactured by thermite welding and gas pressure one has been tested rail full range of test conditions in a pin-on-disk wear testing machine. The results show that the friction coefficient and wear rates of a welded rail are heavily dependent on the contact pressures and sliding environments for two welding methods such as thermite and gas pressure weldings.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.2 s.173
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• pp.431-437
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• 2000

In this paper, thermite and gas pressure weldings have been used to join rails in-track and analyzed as functions of hardness and wear characteristics. The wear rate of thermite welded rail is low compared with that of gas pressure welded rail, which is tested in a pin-on-disk wear tester. The hardness of thermite welded materials is relatively high and narrowly distributed between three zones; welded part, thermally affected zone, and base matrix. Wear of a welded rail may be a major factor in railroad maintenance costs and failures at the rail-rail huh joint.

• Transactions on Electrical and Electronic Materials
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• v.11 no.5
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• pp.234-237
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• 2010

Nanoenergetic materials were synthesized and the thermite reaction between the CuO nanowires and the deposited nano-Al by Joule heating was studied. CuO nanowires were grown by thermal annealing on a glass substrate. To produce nanoenergetic materials, nano-Al was deposited on the top surface of CuO nanowires. The temperature of the first exothermic reaction peak occurred at approximately $600^{\circ}C$. The released heat energy calculated from the first exothermic reaction peak in differential scanning calorimetry, was approximately 1,178 J/g. The combustion of the nanoenergetic materials resulted in a bright flash of light with an adiabatic frame temperature potentially greater than $2,000^{\circ}C$. This thermite reaction might be utilized to achieve a highly reliable selective area crystallization of amorphous silicon films.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 1998.10a
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• pp.234-243
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• 1998

In this paper, thermite and gas pressure weldings have been used to join rails in-track and analyzed as functions of hardness and wear characteristics. The wear rate of thermite welded rail is low compared with that of gas pressure welded rail, which is tested in a pin-on-disk wear tester. The hardness of thermite welded materials is relatively high and narrow distributed between three zones, welded part, thermally affected zone, and a base matrix. Wear of a welded rail may be a major factor in railroad maintenance costs and failures at the rail-rail butt joint.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 1998.10a
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• pp.59-66
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• 1998

This paper presents friction and wear related results of thermite and gas pressure welded rails under various environmental contact conditions. A welded rail which is fabricated by thermite welding and gas pressure one has been tested over full range of test conditions in a pin-on-disk wear testing machine. The results show that the friction coefficient and wear rates of a welded rail are heavily dependent on the contact pressures and sliding environments for two welding methods such as thermite and gas pressure weldings.

• Journal of the Korean Society for Nondestructive Testing
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• v.20 no.4
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• pp.314-321
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• 2000

A gap between a $Al_2O_3/Fe$ thermite and lower head vessel is formed in the lower-plenum arrested vessel attack(LAVA) experiment which is the 1st phase study of simulation of naturally arrested vessel attack in vessel(SONATA-IV). The gap measurement using a conventional ultrasonic method would be lack of a reliability due to the structure complexity and the metallurgical grain size change of the lower head HAZ occurred by a thermite $Al_2O_3/Fe$ melt or a $Al_2O_3$ melt at $2300^{\circ}C$. The grain echoes having false signals and lower S/N ratio signals are detected due to a multiple scattering, a mode conversion and an attenuation of a ultrasonic resulted from at the interface of increased grain size zone. In this test, the signals pattern was classified to understand the behavior of the ultrasonic in a multi-layer specimen of solid-liquid-solid of assuming that the thermite and the lower head vessel is immersed. The polarity threshold algorithm of frequency diversity gives us the enhancement about 6dB of the ratio S/N.