Thermite Welding Practice Exam

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• What temperature must the weld reach after the removal of the head riser and before further processing?
• What is the approximate maximum temperature produced by the reaction of the thermite material?
• For how many minutes should the crucible be left in place after the weld has completed pouring?
• The Orgo Head repair oxy/fuel torch height is how high above the rail surface?
• By how many inches must the flow (lip) be removed before performing a weld on head worn rail?
• What is the minimum length of rail required for thermite welding in curves?
• During the thermite welding process, excess weld material should be dealt with how?
• How long should torch cuts cool before initiating a saw cut on the same rail end?
• Is thermite welding permitted on rail ends that have already been repair welded?
• What essentially happens to the molds if the Orgo swivel arm screws are overly tightened?
• What is the primary concern when stacking boxes of thermite welding kits?
• What is essential to check after the mold packing is finished?
• What is the maximum temperature a pulling force can be applied to the closure weld?
• What is the minimum distance required from the edge of the tie to the end of the rail at the weld gap?
• What is prohibited when using the crucible during the weld process?
• What is the maximum distance that thermite welds are prohibited from a cadweld or copper bond wire installation?
• What is the appropriate action after the head riser is removed?
• What is the gap under each end of the magnetic straight edge for a properly crowned 136 lb rail?
• A 141 to 141 weld joint with a 3/8" difference is considered what type of weld?
• What should be done to the flow maximum prior to welding for best results?
• What is the maximum combined horizontal offset and kink allowed on the gauge side?
• What is the shelf life of Orgo and Boutet welding molds, charges, and crucibles?
• Within what temperature range must the rails be preheated for thermite welding?
• What is the effect of having uninspected equipment before welding?
• Which process involves removing material from the rail in preparation for welding?
• What is the maximum vertical offset allowed at ambient temperature during welding?
• What is the maximum allowable difference when taking final measurements using a taper gauge?
• According to specifications, a standard one inch Boutet weld is expected to pour to which side when welding on tangent track?
• When should you remove the mold cover on Orgo-thermite welds?
• How crucial is temperature management before beginning welding operations?
• What is the minimum preheat time for rail greater than or equal to 129 lbs with ¼" head loss?
• What shade of face shield is recommended during oxy-fuel torch operations?
• The Pandrol Head repair oxy/fuel torch height is how high above the rail surface?
• What should be the condition of rails before starting a welding procedure?
• What element is crucial for the solidification process in thermite welding to avoid defects?
• What should operators of oxy-fuel gas equipment inspect after assembly?
• What is not allowed when preparing ties for a thermite weld?
• At what state does propane exist under pressure?
• When should crucibles be charged in relation to the preheating of the rail ends?
• Torch cutting of rail for final gap preparation is:
• How is the thermite reaction characterized in terms of explosiveness?
• In Orgo-thermite welding, what is packed to ensure proper alignment?
• What is the maximum temperature that the rail base must cool to before placing pads adjacent to thermite welds?
• Employees shall be required to pass a written rules examination every __________ years.
• What is the primary purpose of the slag pans in the thermite welding process?
• What pressure should oxygen hoses be filled to when checking for leaks?
• In how many different areas can horizontal alignment of the head of rail be checked?
• What happens if moisture is present during the welding process?
• What factor may cause ejection of molten metal from the crucible?
• Upon welding in light moisture conditions, when must the thermite weld be covered?
• What must a welder perform to qualify for thermite welding?
• When cutting the rail ends in case of melting, what equipment is primarily used?
• How far must thermite welds be from existing thermite welds?
• Who is responsible for individual thermite welds?
• During which temperature range should finish grinding of the weld be performed?
• Which condition regarding thermite welding is strictly enforced?
• Which component is essential for the setup of Oxy-Fuel Gas Equipment?
• Oxygen hose filled to _________ psi when checking for leaks.
• What is the first step in the established packing routine for Boutet?
• What is the maximum acceptable time to wait before the pour begins in the thermite process?
• What is the maximum weld gap allowed during standard welding practices?
• Before beginning a day's use, what should be evaluated on oxy-fuel gas equipment?
• How high is the recommended torch height for Pandrol Head repairs above the rail?
• What action is required when torch cuts have been made?
• When the weld temperature is less than 400 degrees F, how high shall the weld be left at each end of a 36 inch straight edge?
• What is the term for the time from ignition until the molten metal begins to pour?
• What is the typical range of hydraulic flow for propane usage?
• Preheat flames approximately __________ inches out of the mold risers.
• How long after the welding should the head risers be checked?
• How many inches of rail flow need to be ground from the rail end prior to performing a weld on curve worn rail?
• Which part of the welding setup must be safeguarded to prevent shifting during the process?
• How many tie spikes or clips must be removed from each side of the weld crib?
• What must be done immediately prior to the alignment of rail ends during thermite welding?
• If weld batter develops in the rail head portion of a thermite weld, what action can be taken?
• What temperature should the rail head and base be preheated to if the rail temperature is between 0 and 40 degrees?
• The Pandrol Head Repair process requires the defect to be ground down leaving how much material above the web section?
• How high are the Orgo and Boutet Wide Gap Welds left at the heat lines?
• What is the first step in assembling Oxy-Fuel Gas Equipment?
• What issue can arise in the weld due to movement in the rail during the solidification process?
• Where should the Boutet diverting plug be dried during preheat?
• What type of regulators should oxygen and propane use during thermite welding?
• What aspect of torch operation should be checked first?
• What should be removed at 20 minutes after the pour?
• When the propane valve is slowly closed until sputtering stops, what operation has started?
• What is the effect of a prohibited weld on a project?
• What shade lens is required during the ignition and pouring of molten steel?
• What is the typical offset for a weld on the gauge side in the specified range?
• What is the maximum temperature below which no bluing is allowed during finish grinding?
• What is the gap range for a properly adjusted shear?
• During welding, the propane pressure at the torch valve should be:
• A 115 lb rail, properly crowned, will have a gap under each end of the magnetic straight edge of ___________.
• In torch operations, what indicates that propane is at a proper pressure?
• How far should the propane valve be opened when adjusting the torch?
• The welder is required to watch the ____________ preheat.
• How should the setting gauge be positioned in relation to the welding gap?
• In oxy-fuel welding, which component should be closed last during shutdown?
• What is the maximum thickness of railhead that can remain after performing an Orgo Head Repair Weld?
• Oxy-fuel hose type VD grade _____ is required.
• What is the maximum out-of-square tolerance for rail ends after saw cutting?
• What must be checked before releasing a hydraulic rail puller after welding?
• What should cracked boutet base bricks be repaired with before use?
• What should the torch height be above the top of the head of the rail for a standard 1" weld for an Orgo system?
• To what temperature must the weld metal and rail cool before allowing traffic to cross it?
• Rail ends that exhibit any batter at ______ inch or more prior to cutting weld gap shall not be welded.
• What is the maximum combined horizontal offset and kink allowed on the gauge side?
• What action is required if there are track clips near the weld crib?
• How quickly must the welding charge be ignited after removing the preheating torch?
• What is the main purpose of the written rules examination for employees?
• The Orgo Head Repair process specifies that 2" of the railhead must be completely removed down to which section of the web?
• Why is it important to center switch points before welding?
• How long is the Boutet crucible's bypass feature designed to pour?
• What minimum temperature must the weld be left at until it can be finish ground if it's between ambient temperature and 400 degrees F?
• A 115# to 132# compromise weld will have a ________" offset on the gauge side of the base.
• What is the welding gap size for both Orgo and Boutet Wide Gap Welds?
• Before welding in switches, what must be done to the switch points?
• When inserting the lit igniter, to what depth should it be placed into the weld charge?
• What can happen if the rail is less than the required length during thermite welding?
• What type of kit is required for a 136 to 136 weld joint with a 1/8" height difference?
• Where are wedges permitted according to thermite welding guidelines?
• What maximum distance is acceptable for the flow on the rail head before welding?
• What issue can arise from over-tightening the Orgo swivel arm screws?
• Which is necessary before performing a thermite weld on ties?
• Which statement is true regarding the alignment of rail during welding?
• What should welders do after packing the molds is complete?
• What is the first step in preparing for a thermite weld?
• What should the propane hose be filled to when checking for leaks?
• When should employees update their qualification list regarding thermite welding?
• How often must employees review thermite welding knowledge?
• What potential issue could arise from not following the standard routine for aligning rail ends?
• When must a welding portion bag that has been opened be used?
• How many inches should the preheat flames extend out of the mold risers?
• If a rail end has been torch cut, how many inches should be removed after thirty minutes?
• Rough grinding is considered complete when the excess weld material is reduced to what thickness?
• What is the term used for lightly tapping the bottom of the base of both mold shoes with a hammer during the welding process?
• To what specification should rail ends be crowned during alignment of Boutet and Orgo Wide Gap Welds on 136 lb rail?
• How frequently should torch height be checked during operations?
• Which component is essential in completing a thermite weld?
• What is the normal tap time range for a standard thermite weld?
• Propane under pressure remains in a ________________state.
• What is the recommended practice when aligning rail ends before welding?
• What is prohibited in the web and base areas of a thermite weld?
• After applying the Boutet field and gauge side molds, what is the next step?
• What is the maximum height the weld should be left after finishing ground on the running surface?
• What is the temperature at which base risers should be removed during the welding process?
• Is cropping of rail ends required after stopping and restarting the preheat process?
• Which method is acceptable for sharpening shear dies?
• What is the maximum allowable length of a rail on which thermite welds can be performed simultaneously on both ends?
• What temperature must the thermite weld cool below before it can be uncovered?
• What is considered an inappropriate action during thermite welding preparation?
• What is the key consideration for maintaining a proper welding gap during thermite welding?
• Where should igniters be stored in relation to thermite welding portions?
• What should be done immediately after the closure weld before applying a pulling force?
• The torch height for the Air Propane system is set based upon what at the interior platform of the molds?
• What type of defect can be caused by incomplete cooling during thermite welding?
• What is the term used for the area where the weld occurs?
• What is the maximum number of boxes that can be stacked over thermite welding kits?
• How many concrete tie pads need to be removed on each side of the weld gap?
• The liquid oxygen valve labeled _______________ should never be opened.
• What is the purpose of checking the height of the torch?
• At what point must vehicle traffic be stopped at a road crossing during thermite welding?
• After tightening the Boutet base plate screws, what is the next step to check?
• Cylinder valves on propane and oxygen cylinders should be ____________________ when in use.
• How many rail spikes should be driven down to eliminate ties on both sides of the joint?
• How often must employees pass the written rules examination, according to safety procedures?
• When compromising welds on rail ends of two different rail sections, the preheating time shall be for the time required for the ___________ rail's section.
• What is the maximum allowable difference in curve worn rail head width on the gauge side?
• What is the propane pressure set at for airpropane use at 8 to ______ psi?
• What should be done immediately after shearing if the rail temperature is 60°F and there's light rain?
• What is the first step for cutting rail using an oxyfuel torch?
• What is the minimum rail length for successful thermite welding operation in straight tracks?
• Which tool or method is advised against using for sharpening shear dies?
• What should the torch height be above the top of the head of the rail for a standard 1" weld for a Boutet system?
• What is one effect of light rain on the thermite welding process at a rail temperature of 60°F?
• What is a critical consideration in thermite welding to achieve the best quality welds?
• What is the minimum time the Orgo diverting plug should be preheated in seconds?
• What is the minimum temperature the base of the rail should be heated to in degrees Fahrenheit?
• When adjusting propane and oxygen valves, how should the oxygen valve be opened?
• How soon must preheating begin after the molds have been luted?
• What is one crucial action after completing the pouring of the weld?
• What type of welding is specifically noted for cooldowns and handling moisture conditions?
• Which factor should NOT be present to ensure a successful thermite weld?
• What effect can cold temperatures have on thermite welding?
• How far must the preheating be done on both sides of the weld gap?
• When are the slag pans removed after the weld has completed pouring?
• The welding gap must be checked at _________ locations.
• Rail ends shall be flame cleaned then cleaned with a wire brush for a distance of how many inches from the rail end?
• How far must thermite welds be placed from existing plant welds?
• What is the minimum distance the Orgo-thermite crucible should be placed from the weld crib?
• What is the minimum safe distance from which thermite welds should be placed in relation to existing welds?
• Mold sand should remain on the weld until it cools to what temperature?
• What temperature must the weld reach for finish grinding when the temperature is below 600 degrees?
• What is the minimum height difference that requires a special kit for a 136 to 136 weld joint?
• A thermite weld is prohibited when the difference in vertical height exceeds which measurement?
• What should be eliminated where practical during thermite welding?
• What method should be avoided when positioning the Boutet base brick on the rail base?
• When is it necessary to maintain a restriction on train traffic at weld locations?
• What should be checked before initiating the welding process with the molds?
• How much of the melted rail end must be cut off when a rail end begins to melt?
• Where is a Boutet ignitor placed during the welding process, unless using an electronic ignition system?
• Victor flashback arrestors are required between an __________________________ and the hose.
• What is a requirement when transporting oxygen and fuel gas cylinders on public roadways?
• At what rail temperature is thermite welding prohibited?
• What is the first step in the oxy-fuel shut down procedure?
• The use of a 1" grinding stone to bevel bolt holes is:
• What is the standard routine for aligning rail ends?
• What is the maximum temperature allowed for train traffic across a completed thermite weld?
• Notching of ties to allow for the performance of a thermite weld is:
• When should removal of the head riser begin?
• What tool is suggested for sharpening the cutting edge of hot cut chisels?
• Which of the following processes might result in excess heat during thermite welding?
• After completing the alignment of rail ends, what should be checked for correct tolerance?
• What is the minimum temperature for the rail head and base before welding in cooler conditions?
• Thermite welds are prohibited within how many inches of the edge of any hole in the rail?
• What must be removed after the completion of a thermite weld?
• How should the cutting edge of hot cut chisels be sharpened?
• What safety precaution needs to be taken while performing thermite welding?
• Why is it important to monitor the welding gap during alignment?