Abstract: In the heat treatment in the field of a thermite weld between rail ends, the rail ends and the weld are enclosed within a containment filled with an aluminothermic material mixture. The mixture is ignited and the rail ends and the thermite weld are heat-treated for a given period. After the given period, the aluminothermic reaction products and the containment are removed, and an air quench unit is placed about the weld and rail ends and compressed air is directed at the weld and rail ends for a given time period. After the removal of the air quench unit, the weld is allowed to cool to ambient temperature.

Abstract: In the heat treatment in the field of a thermite weld between rail ends, the rail ends and the weld are enclosed within a containment filled with an aluminothermic material mixture. The mixture is ignited and the rail ends and the thermite weld are heat-treated for a given period. After the given period, the aluminothermic reaction products and the containment are removed, and an air quench unit is placed about the weld and rail ends and compressed air is directed at the weld and rail ends for a given time period. After the removal of the air quench unit, the weld is allowed to cool to ambient temperature.

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: An aluminothermic reduction reaction mixture consisting essentially of an admixture of manganese dioxide (MnO.sub.2) and metallic aluminum (Al) with alumina (Al.sub.2 O.sub.3) added thereto. The reaction does not yield a metallic phase, but produces a single phase comprising a galaxite containing slag.

Abstract: A simple method of producing a rim-stabilized steel ingot without requiring the use of special equipment wherein a rimming-type steel is teemed into an ingot mold and thereafter allowed to rim for a suitable period of time, and then adding a particulate mixture of aluminum and an exothermic material to the top of the molten metal so that the exothermic mixture will ignite, melting and superheating the aluminum content which is driven into the molten steel at the ingot core.

Abstract: A method of producing a refractory lining in a cylinder or tube by initiating an exothermic reduction reaction, such as an aluminothermic reduction reaction, within the cylinder and causing the reaction products to coat the interior of the tube substantially uniformly. The product of the method, a ceramic-or refractory-lined cylinder, is also disclosed.

Abstract: A refractory lined, abrasion resistant tuyere for a metallurgical furnace is produced by causing an aluminothermic reduction reaction within a cylindrical metal shell, such that the metallic reaction product forms a layer within the cylinder and the slag reaction product forms a second layer overlying the first layer thereby providing an abrasion resistant refractory lining.

Abstract: A method of forming a high-temperature abrasion-resistant hard facing or coating on a ferrous metal substrate by employing an aluminothermic reduction reaction. The resultant article has a hard facing layer containing from 2 to 8 percent boron. Hard faced composite articles made by the invented method, such as sintering machine crash decks, coke pusher ram shoes and grizzly bars are also disclosed.

Abstract: A refractory lined cylinder or tube is produced by causing an aluminothermic reduction reaction therein, such that the metallic reaction product forms a layer within the cylinder and the slag reaction product forms a second layer overlying the first layer thereby presenting an abrasion-resistant refractory lining.

Abstract: A method of repairing erosion cavities in large steel articles, such as slag and cinder pots by employing a plurality of successive aluminothermic reduction reaction charges without using containment perimeters and without preheating the article. The resultant repaired article has a metallurgically bonded plug in the eroded surface.

Abstract: A method of producing a refractory lining in a cylinder or tube by initiating an exothermic reduction reaction, such as an aluminothermic reduction reaction, within the cylinder and causing the reaction products to coat the interior of the tube substantially uniformly. The product of the method, a ceramic-or refractory-lined cylinder, is also disclosed.

Abstract: A method of cladding copper or copper alloys to a steel substrate by an aluminothermic reduction reaction utilizing an exothermic reaction material which is principally a mixture of calcium-silicon alloy, aluminum, cupric oxide and a metal.

Abstract: A method of repairing large castings, such as ingot molds and mold stools, by employing an aluminothermic reduction reaction without using containment perimeters and without preheating the casting. The resultant repaired article has a metallurgically bonded plug in the hole or eroded surface with a thick abrasion-resistant slag covering over the deposited metal.

Abstract: A method of forming a high-temperature abrasion-resistant hard facing or coating on a ferrous metal substrate by employing an aluminothermic reduction reaction. The resultant article has a hard facing layer containing from 2 to 8 percent boron. Hard faced composite articles made by the invented method, such as sintering machine crash decks, coke pusher ram shoes and grizzly bars are also disclosed.

Abstract: Hot rolled steel is pickled with chlorine gas at temperatures between about 1250.degree.to 2500.degree.F.

Abstract: A method of forming a high-temperature abrasion-resistant hard facing or coating on a ferrous metal substrate by employing an aluminothermic reduction reaction. The resultant article has a hard facing layer containing from 2 to 8 percent boron. Hard faced composite articles made by the invented method, such as sintering machine crash decks, coke pusher ram shoes and grizzly bars are also disclosed.

Abstract: A method of forming a high-temperature abrasion-resistant hard facing or coating on a ferrous metal substrate by employing an aluminothermic reduction reaction. The resultant article has a hard facing layer containing from 2 to 8 percent boron. Hard faced composite articles made by the invented method, such as sintering machine crash decks, coke pusher ram shoes and grizzly bars are also disclosed.

Abstract: A method of repairing large castings, such as ingot molds and mold stools, by employing an aluminothermic reduction reaction. The resultant repaired article has a metallurgically bonded plug in the crack, hole, break, or eroded surface. An alternative repair method of big-end-up ingot molds is disclosed which comprises forming a ceramic lining on the bottom of the mold.

Abstract: A method of repairing large castings, such as ingot molds and mold stools, by employing an aluminothermic reduction reaction without using containment perimeters and without preheating the casting. The resultant repaired article has a metallurgically bonded plug in the hole or eroded surface with a thick abrasion-resistant slag covering over the deposited metal.