A new method has been found for thermite welding life extension by improving the weld's soundness. Thermite welds are essential but known as weak links in several applications, including, but not limited to railroad tracks, welds in oil and gas pipelines, and other industries due primarily, but not limited to, fatigue cracking initiated at voids (gas and/or shrinkage) within the weld. Gas porosity is the result of the precipitation of gases during solidification, and shrinkage pores are due to thermal contraction combined with lack of melt feeding in a solidifying casting. Porosity and their effects cannot be improved by post weld treatments. Therefore, improving the fatigue resistance of welded rails, pipes, etc. is a major goal. Thermite welds are similar to castings and have comparable solidification pathways. Perhaps castings are usually a final product or a standalone component, while the thermite weld is used to join components or parts. Vibration is here proposed as the innovative method to reduce defects in thermite welds used in rails, pipe welds among other applications. The vibration can be induced into the weld by means of mechanical energy, pneumatic energy, hydraulic energy, sound waves (including but not limited to ultrasound), electrical energy, magnetic energy, electromagnetic energy their combinations and any other potential source that can generate vibration in the weld. Preliminary testing has clearly demonstrated that vibration provides significant advantages in the soundness of thermite welds. The vibration protocols have been identified for mechanical vibration, and they can vary for other vibration methods. Vibration methods are widely used in the casting process for aluminum alloys, cast irons and steels.