Thermite welding utilizes the intense exothermic reaction between aluminum and oxygen at high temperatures to generate extreme heat, melting metal into molten steel and enabling the welding of metallic materials such as rails. The core consumables include the following four items:
   

1. Thermite welding portion

Composition: Iron oxide powder (main reactant), aluminum powder (fuel for the exothermic reaction), and alloy additives (e.g., ferrosteel, ferromanganese, ferrovanadium) to enhance weld properties.

Description: The thermite welding portion is the material that undergoes the exothermic reaction, producing molten steel and slag at temperatures exceeding 2,500°C. It features portability (minimal equipment required), high efficiency (rapid welding process), and ease of operation, making it suitable for field applications including rail repair and splicing in railways, subways, tram lines, and industrial production lines. 

2. Sand Mould

Composition: Made of heat-resistant materials such as quartz sand or graphite.

Description: A refractory mold used to secure and support rails during the thermite welding process. It guides the molten steel into the joint area to form the welded connection. Preheating is mandatory to eliminate moisture and enhance thermal shock resistance.

3. One-shot Crucible

Composition: Fabricated from compressed and sintered quartz sand, with an outer iron casing.

Description: Serves as both the reaction chamber for the exothermic thermite reaction and a self-pouring system that automatically releases molten steel into the sand mould post-reaction via an integrated tapping mechanism. It features a single-use design to ensure consistent reaction efficiency and eliminate cross-contamination risks

3. Luting Sand

Composition: Formulated from a precisely blended mixture of quartz sand and bentonite.

Description: A refractory sealing material used to fill cavities between the sand mould and rail surfaces to prevent molten steel leakage (>2,500°C), and to maintain metallostatic pressure during solidification for defect-free joints.