Rail Track Welding Machine

YH-6 Gas Pressure Rail Track Welding Machine for Sale

The YH-6 gas-pressure rail welding machine supplied by AGICO is mainly used for welding steel rails weighing ≤ 75kg, which covers a wide range of steel rail tracks. It employs a pressure-holding push-forging method, with a rail head positioning machine to ensure rail head straightness. An overpressure protection device is added during the return stroke to ensure safe operation. This rail welding machine features a unique design, reasonable operation, and does not occupy space under the rail.

YH-6 Track Welding Machine Specification

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What is Gas Pressure Rail Track Welding Machine?

A gas-pressure rail track welding machine uses an oxy-acetylene flame as the heat source for track welding. Besides the thermal welding method, it is a traditional track welding method with mature technology.
The complete welding process of steel rail has the following stages: first, the rail welding end face is preheated with a flame to reach its plastic temperature; then, pre-pressure is applied to ensure a tight fit between the end faces; next, low-pressure and high-pressure upsetting are performed to induce plastic flow in the metal and achieve metallurgical bonding; finally, the weld beads formed during the welding process are removed under pressure. The entire welding process is based on the plastic gas pressure welding, where pressure causes the metal atoms to diffuse and bond together.
 

YH-6 Rail Track Welding Machine Components

The complete gas pressure welding machine is a complete system that consists of the following equipment:

1. Clamping & Upsetting Unit -Provides pre-tightening force and upsetting force for the rails during welding.
2. Flash Trimming Machine - Used for removing weld flash (excess metal) after welding.
3. Heating Torch (Heater) - Used to heat the rail ends before welding.
4. Water Pump and Water Tank - Used for cooling the heating system; the water pump operates at 380V.
5. Control Box - Controls the pressure and flow rate of acetylene and oxygen.
6. Welding Torch Nozzle - Mixes the adjusted acetylene and oxygen gases and supplies the mixed gas to the heater.
7. Hydraulic Pump Unit - Provides sufficient hydraulic power; the motor operates at 380V.
8. Acetylene Manifold - Connects 4 acetylene cylinders to supply sufficient fuel gas for combustion.

Working Principle of Gas Pressure Rail Track Welding Machine

The gas pressure rail welding machine uses an oxy-acetylene flame for heating, applies the principle of plastic gas pressure welding, and employs a 3-stage pressure welding process. All test data of the YH-6 rail welding machine meet the standards of the Ministry of Railways, the weld head is well-formed, and it has the function of removing weld beads from the entire cross-section.

How to Operate YH-6 Rail Track Welding Machine

The operator of YH-6 rail welding machine should hold a "Rail Welder Operation License" issued by a technical institution recognized by the national railway authority. The welding process is approximately 5-5.5 minutes. Post-weld heat treatment should begin when the weld joint temperature drops below 500℃. The heating width should be 60mm±10mm, and the heating temperature should be 850～950℃. When welding heat-treated rails, air cooling or mist cooling is recommended for rail head cooling. After welding and heat treatment, the tensile force should be removed when the joint has cooled to below 300℃. Here are more operation details:

• Grinding: Grind the rail joint section to a slope greater than 0.2mm; the surface and surrounding area should be free of oxide scale and rust.
• Gas Fuel Preparation: Prepare 4 acetylene cylinders and 1 acetylene gauge, 1 oxygen cylinder and 1 oxygen gauge.
• Water Tank Preparation: Fill the water tank to 4/5 capacity, place the water pump into the water tank, plug in the power supply, and observe whether water flows from the pump inlet. If no water flows, change the power phase sequence.
• Connect Acetylene Cylinders: Connect the 4 acetylene cylinders using the acetylene cylinder connector, connect the acetylene gauge, and connect a 10mm inner diameter black acetylene pipe to the acetylene inlet of the control box. The acetylene outlet connects to the side port of the welding torch.
• Connect Oxygen Cylinder: Connect one oxygen cylinder to the oxygen gauge, using a 10mm inner diameter red oxygen hose， then connect the oxygen outlet to the straight end of the welding torch.
• Connect Welding Torch to Heater: Connect the mixed gas from the welding torch to the heater using a 16mm inner diameter mixing hose. The gap between the heater and the rail should be uniform around the perimeter.