Method to produce thermite welds by applying first and second vibrations

A method for producing a thermite weld, the method comprising:

• applying a first vibration to molten thermite material within a mold at a first orientation, wherein the first vibration includes a first vibration frequency between about 1 Hz and about 200 Hz and a first amplitude, the mold is between a first piece and a second piece to be welded, and the first vibration is produced by a first vibrator on the first piece at a distance of about 2 m to about 3 m from the mold;
• and
• applying a second vibration to the molten thermite material within the mold at a second orientation, wherein the second vibration includes a second vibration frequency between about 1 kHz and about 50 kHz and a second amplitude, and the second vibration is produced by a second vibrator on the second piece at a distance of about 2 m to about 3 m from the mold;
• wherein the first vibration is applied to the molten thermite material until the molten thermite material goes below a liquid-to-solid transition temperature and the second vibration is applied to the molten thermite material at intermittent periods of time until the molten thermite material goes below the liquid-to-solid transition temperature,
• the first vibration and the second vibration have constructive or destructive interactions within the molten thermite material resulting in a composite vibration waveform based on interference patterns, harmonics, and sub-harmonics,
• the first and second vibrations enhance the elimination of gas and shrinkage pores within the molten thermite material, and
• the first vibration enhances grain refinement in the thermite weld without damaging the mold.