Abstract: A rail welding crucible and cap with burner-ignited reaction starter mix has a cap, an igniter core, and a crucible. The igniter core is a mixture of material that can be ignited by an oxygen/propane gas rail-preheating burner and forms the reaction starter mix for an aluminothermic reaction. The cap is mounted over the crucible and used to hold the igniter core in a desired position. A core-receiving hole traverses through the cap, from a first face to a second face. The igniter core is mounted within the core-receiving hole so that the igniter core can flow into a reaction cavity of the crucible. The reaction cavity is a receptacle within the crucible which serves as a temporary holder for a quantity of rail-bonding material that undergoes the aluminothermic reaction. The quantity of rail-bonding material becomes molten and flow onto the joint once the aluminothermic reaction reaches a desired phase.

Abstract: In forming an aluminothermic weld between adjoining rail ends, a sand mold is arranged around the rail ends disposed in spaced relation. The sand mold is formed at least in part of silica sand. The surface of the mold in contact with the rail ends and enclosing the space between the rail ends is formed of one of a combination of silica sand and zircon sand, a layer of zircon sand inwardly from a layer of silica sand, or a thin layer of a zircon mold wash on a surface formed of silica sand.

Abstract: In a hammer mill, such as used for pulverizing coal, or breaking and grinding scrap metal, rock, masonry, refuse and the like, the hammers are exposed to wear. In time, a part of the wearing surface of the hammer is worn away and the hammer becomes less effective. A worn hammer is returned to its original weight and dimensions by depositing a molten exothermic material on the worn surface. The worn hammer is supported and enclosed by a mold so that the worn surface faces upwardly. The exothermic material is ignited and flows into the mold chamber into contact with the worn surface until the desired hammer dimensions and weight are achieved. Excess exothermic material overflows from the mold chamber into a sump. The exothermic material deposits a weld on the worn surface of the hammer which is similar to Ni-Hard, a known wear resistant metal.

Abstract: This invention relates to an improvement in the process of mold welding two metal parts together having respective base sections, which includes enclosing the end sections of said metal parts in aligned end-to-end relation in a mold having an entrance gate, flowing molten metal through said entrance gate into said mold, and out of said mold at rates so related as to cause some of the metal admitted into the mold to be discharged from said mold while the rest of the molten metal accumulates as a metal bath to cause the molten metal during the early stage of its admission into the mold to preheat the metal parts, and conducting some of the said molten metal during said early stage from the entrance gate through a recess and directly onto said base sections in direct impingement with said base sections to promote better heat transfer between said molten metal and said metal parts, the improvement comprising discharging molten metal through at least two separate exit gates into separate discharge chambers located