What can happen if the rail is less than the required length during thermite welding?

If the rail is less than the required length during thermite welding, the process is considered unsafe for a few reasons. Thermite welding requires specific lengths and dimensions to ensure a strong bond and to accommodate the thermal expansion that occurs during the welding process. When the rail does not meet these requirements, it can lead to inadequate fit-up, resulting in weakened joints or structural failure once the rail is put into service. Additionally, insufficient rail length may hinder proper alignment, leading to misalignment of tracks, which poses safety risks for train operations. Therefore, safety standards in thermite welding necessitate that all components, including rail lengths, meet specific specifications to ensure both effectiveness and safety in the final weld.