What potential issue could arise from not following the standard routine for aligning rail ends?

Not adhering to the standard routine for aligning rail ends can significantly elevate the risk of weld failure. Proper alignment is crucial in ensuring that the thermite weld creates a uniform and continuous bond between the rail ends. Misalignment can lead to gaps or uneven surfaces, which can result in weak points in the weld. A weld that is improperly aligned fails to distribute stress evenly across the joint, making it more susceptible to cracking or separation under load. This can compromise the integrity of the rail and lead to potential safety hazards or additional repairs.

In contrast, while increased welding time and higher costs could be potential side effects of misalignment, they are not as directly related to the integrity of the weld itself. Similarly, reduced accessibility for fittings is more of a logistical concern than a fundamental issue with the weld quality. The primary concern from a welding perspective is ensuring that the rail ends are aligned correctly to minimize the risk of failure.