Repair insert for repairing metallic structure
First Claim
1. A rail and repair insert combination, said combination comprising:
- a rail length, the rail length having a rail head portion, a rail web portion, a rail base portion, and a void site, the void site being located within the rail length and extending into the rail head portion, the void site having a maximal site depth, a maximal site width, and a maximal site length; and
a repair insert, the repair insert being insertable into the void site for effecting a rail-to-insert interface, the repair insert comprising an upper insert portion and a lower insert portion, the lower insert portion comprising a maximal insert depth, a maximal insert width, and a maximal insert length, said insert depth being greater in magnitude than said site depth, said insert width being greater than said site width, and said insert length being greater in magnitude than said site length.
3 Assignments
0 Petitions
Accused Products
Abstract
A rail repair insert enables repair of rails and rail-like structures. A rail defect is initially identified and removed as contained within a volumetric material portion so as to form a contoured void while maintaining continuity of the rail opposite the void. A pre-formed insert is then placed into the void thereby effecting a rail-to-insert interface. Current is driven through the interface as force directs the insert against the rail. Resistance heat and pressure weld the insert to the rail. The flash welding aspects remove oxides and other impurities from the interface, and the forge welding aspects create a robust solid state weld. Excess material, whether flash, rail, or insert-based, is removed during the finishing processes to provide a virtually seamless rail repair. The solid state weld repair insert may be used to repair any number of targeted metallic rail-like structures.
33 Citations
26 Claims
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1. A rail and repair insert combination, said combination comprising:
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a rail length, the rail length having a rail head portion, a rail web portion, a rail base portion, and a void site, the void site being located within the rail length and extending into the rail head portion, the void site having a maximal site depth, a maximal site width, and a maximal site length; and a repair insert, the repair insert being insertable into the void site for effecting a rail-to-insert interface, the repair insert comprising an upper insert portion and a lower insert portion, the lower insert portion comprising a maximal insert depth, a maximal insert width, and a maximal insert length, said insert depth being greater in magnitude than said site depth, said insert width being greater than said site width, and said insert length being greater in magnitude than said site length. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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- 11. A solid state weld repair insert for use in repairing a targeted metallic structure having transversely widthwise-distinguishable first and second structural sections, the first structural section having an outer surface opposite the second structural section and a void site extending into at least the first structural section from the outer surface toward the second structural section, the void site having a maximal site depth and a maximal site length, the repair insert being insertable into the void site for effecting a structure-to-insert interface, the repair insert comprising transversely widthwise distinguishable first and second insert portions, a maximal insert depth, and a maximal insert length, said insert depth being greater in magnitude than said site depth, said insert length being greater in magnitude than said site length.
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21. A rail and repair insert combination, said combination comprising:
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a rail length, the rail length having an upper rail surface, a rail head portion, a rail web portion, a rail base portion, and a void site, the void site being located within the rail length and extending at least into the rail head portion from the upper rail surface, the void site being T-shaped in a first dimension, triangular in a second dimension, and rectangular in a third dimension, the void site having varied site widths in the first dimension, a maximal site depth in the first and second dimensions, and a maximal site length in the second dimension; and a repair insert, the repair insert being insertable into the void site for effecting a rail-to-insert interface, the repair insert being T-shaped in the first dimension, triangular in the second dimension, and rectangular in the third dimension and comprising an upper insert portion, a lower head-forming insert portion, a lower web-forming insert portion, varied insert widths in the first dimension, a maximal insert depth in the first and second dimensions, and a maximal insert length in the second dimension, said varied insert widths being respectively greater than said site widths, said insert depth being greater in magnitude than said site depth, and said insert length being greater in magnitude than said site length. - View Dependent Claims (22, 23)
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- 24. A solid state weld repair insert for use in repairing a targeted metallic structure having first and second structural sections, the first structural section having an outer surface opposite the second structural section and a void site extending into at least the first structural section from the outer surface toward the second structural section, the void site being T-shaped in a first dimension, triangular in a second dimension, and rectangular in a third dimension, said void site having a maximal site depth in the first and second dimensions and a maximal site length in the second dimension, the repair insert being T-shaped in the first dimension, triangular in the second dimension, and rectangular in the third dimension, said insert being insertable into the void site for effecting a structure-to-insert interface, the repair insert comprising first and second insert portions, a maximal insert depth in the first and second dimensions, and a maximal insert length in the second dimension, the second insert portion having a head-forming insert portion and a web-forming insert portion, the head-forming and web-forming insert portions having varied insert widths, said insert depth being greater in magnitude than said site depth, said insert length being greater in magnitude than said site length.
Specification