August 02, 2023

But what is the basis for positioning aluminothermic welding as an optimal solution? What improvements can it bring over mechanical interconnections? Or what happens if we go directly to aluminum instead of copper?

These are questions that all electrical professionals ask themselves and on which the railway companies have already realized years ago the value that the use of aluminothermic welding would bring.

1. Maintaining Electrical Continuity:
In the railway system, electrical continuity is essential to ensure efficient and safe power transmission. Aluminothermic welding allows rails to be joined continuously, ensuring an electrical connection free of interruptions. This is especially crucial in areas of high electrical demand, such as stations or sections with signaling and electrification systems.

2. Strength and Durability:
Electrical connections subjected to constant loads and vibrations require high strength to avoid failures and accidents. Aluminothermic welding creates a perfect molecular bond, which guarantees greater structural resistance. This fatigue resistance and durability reduces maintenance and operating costs, in addition to reducing downtime for repairs.

3. Reduced Electrical Resistance:
Electrical resistance in connections can cause energy loss, increase operating costs and negatively affect train efficiency. Aluminothermic welding offers a highly conductive connection, minimizing electrical resistance and ensuring optimal power transmission between the rails.

4. Track Safety and Stability:
A stable and safe railroad track is essential to avoid derailments and accidents. Solid electrical connections created by aluminothermic welding reduce the risk of track deterioration and the formation of cracks that can affect the movement of trains. In addition, fewer mechanical joints and bolts minimize maintenance and vibration wear.

5. Cost improvement:
The use of aluminothermic welding allows for long-term cost improvement since it avoids failures, maintains properties and reduces unscheduled downtime. At the same time, KLK weld aluminothermic welding solutions include the possibility of direct connections using aluminum (InDuo Al Kit) or copper (ELPA Rail Kit) conductors and where our patented system works below the temperature limit of steel deterioration, this implies that not only will we create robust and perfect connections, but also that the quality of the steel will remain intact.

In short, electrical connections in the rail industry are a critical component to ensure efficient and safe operation. KLK’s aluminothermic welding is designed to be able to go the extra mile and stands out as a key technique for creating solid, durable joints in rail. Its ability to maintain electrical continuity, resist loads and vibrations, reduce electrical resistance and improve track safety make this technique an invaluable tool in the construction and maintenance of modern, reliable rail networks.