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On March 5, at Yanjiahe Station, the application of "flash-butt welding" technology achieved a resounding success, marking the realization of precise "welding and straightening integration". This groundbreaking construction not only demonstrates the successful implementation of new welding and straightening equipment in our section but also ushers in a new era of intelligent and precise rail welding, injecting powerful impetus into the high-quality development of our section.
In response to the steep slopes and sharp curves of mountainous rail lines, relevant departments and workshops of the Baoji Track Maintenance Section established a joint "Equipment & Operation" commando team. The team conducted advance simulation drills, optimized the railcar marshalling and marching plan, and solved the challenge of equipment transportation in confined spaces. On the construction day, the supervisor meticulously organized the work, refining the division of labor for each post and individual. The pre-work meeting included detailed construction briefings, with lean empowerment ensuring strict control of the process, clear standards for key procedures, and effective risk management measures. Technical personnel guided operators in precise construction through the "3 demonstrations and 4 practices" training method. After the skylight window was granted, the crew "seized every minute," efficiently completing equipment assembly, data debugging, and welding operations to successfully achieve the goal of "a debut of excellence" as planned.
For the first time, the construction team applied "flash-butt welding" technology in practice, innovatively using full-process railcar coordination to advance operations. Precise control of rail alignment was achieved via a digital control system, ensuring joint accuracy met millimeter-level standards and laying a foundation for high-quality welding.
During operations, technical personnel strictly followed standardized procedures, applying the flash butt welding system to five core processes: rail rust removal, precise rail alignment, automatic welding, flash removal and shaping, and normalizing treatment—forming a complete technological closed-loop. Actual measurement data shows that the duration for a single welding and normalizing process was kept within 3 minutes. It is estimated that 5–6 joint weldings can be completed within a single 3-hour skylight window, significantly improving operational efficiency. Professional flaw detection confirmed that all welds met quality standards, with structural strength and durability both exceeding those of the traditional manual thermite welding process. This provides a solid technical foundation for the long-term safe operation and efficient maintenance of rail lines.
The successful application of flash butt welding technology in our section not only offers a more efficient and higher-quality solution for rail welding but also breaks through the long-standing industry challenge of vulnerable thermite welds. By significantly improving welding joint quality, it provides a robust guarantee for railway transportation safety.
Source: Baoji Track Maintenance Section
