Importance

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Abstract

A rail repair method enables repair of rails and rail-like structures. A rail defect is initially identified and removed as contained within a volumetric material portion so as to form a contoured void while maintaining continuity of the rail opposite the void. A pre-formed insert is then placed into the void thereby effecting a rail-to-insert interface. Current is driven through the interface as force directs the insert against the rail. Resistance heat and pressure weld the insert to the rail. The flash welding aspects remove oxides and other impurities from the interface, and the forge welding aspects create a robust solid state weld. Excess material, whether flash, rail, or insert-based, is removed during the finishing processes to provide a virtually seamless rail repair. The solid state weld repair methodology may be used to repair any number of targeted metallic rail-like structures.

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First Claim