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#WELDA Day 5 - Weld repairing cast iron with cast iron filler rods
Welcome to the Greg's Garage #WELDA 2016 challenge.
Day 5 of @Greg's Garage #WELDA challenge, and I didn't make it to the shop to work on the lathe, but I found some footage of a weld repair I did some time back.
I used a cast iron filler rod to repair a cast iron part. My welding instructor showed me this technique, and I had to special order the rods for this job, as they are not a common item in the stores.
This is an alternative to the common method of using a high-nickel arc welding electrode.
Here is a link to the product I used:
www.cigweld.com.au/product/gas...
#welda #castiron #welding
You can check out all the participants on Greg's webpage: www.gregsgaragekc.com/welda
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Опубликовано:

4 авг 2016

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Комментарии : 103

@haroldkellams760 Год назад

Hey Matt, I'm blowen away. I've been repairing antique farm engines for a long time, very long time. Always used brass rod, flux, patience and experience. I've never known you could do something like you did. Very nice work, thanks a lot. Hal

@krankengineering 3 месяца назад

Thank you!

@clintdenman3037 Год назад

I was always taught that you should heat up a piece even to a small amount to help it penetrate and cure but hats off to you for even trying.

@deezynar 6 лет назад

Very clever to clamp it together first so the granularity in the two pieces will align, then tack them together, and THEN grind out the V grooves. That's great thinking.

@krankengineering 5 лет назад

Took longer to think about the repair process than to actually do the weld!

@PeakyBlinder 3 года назад

I used them rods but needed a sif cast iron flux, but I used them with oxy acetylene. A preheat and cool down is a must.

@TheBlueskyson 8 лет назад

Good job mate. Well explained and well shot. Thanks for the vid.

@krankengineering 8 лет назад

+TheBlueskyson thanks mate!!

@jonathanlittle3012 7 лет назад

Thanks for all of the information. I eventually want to be able to make my own cast iron repairs with my powertig welder. I understand it can be a difficult job if the proper technique and metal isn't used.

@TheBlueskyson 3 года назад

@Zander Ashton Try Mrs. Davison of Mozambique. I made 35K last month with her trading tips. ty

@sephangelo4603 3 года назад

Nice welds! Though I prefer to arc weld it with any electrode between preheating and burying in sand, sawdust or lime

@TomsToolRoom 8 лет назад

Very nice repair!

@krankengineering 8 лет назад

+TomsToolRoom thankyou!

@sweetpeaz61 4 года назад

I have several boxes of cast iron filler rods from the 1950s/1960s ...I think im going to go play now ive seen how well they flow with TiG ..great vid ty

@krankengineering 3 года назад

Give it a go, its super helpful. The rods I showed in this video aren't available anymore so the ones I have left are going in my underground nuclear proof bunker ha ha

@sweetpeaz61 3 года назад

@@krankengineering Yeah, tried them..they work brilliant..like you they are now safely tucked away for good jobs lol :)

@TgWags69 Год назад

@@krankengineering just slice off some strips of a brake disc.

@DannoTull 5 лет назад

I noticed a difference when you did the tack weld and the front / back weld that the arc was pulsing during the weld but not on the tack weld. could it be the aluminum in the vice is affecting the electric current?

@836dmar 3 года назад

Looks and welds like cast steel to me. Like old Ford parts, they weld great!

@eacosta747 3 года назад

⁰

@johnreese3943 4 года назад

Matt, Thanks for doing this video. Until today I did not know cast iron could be welded with TIG. I have welded a lot of cast iron using oxy/acy and cast iron rod with flux.The flux is getting expensive, about $28 US for a bout a 4 oz. jar. I will try TIG on my nexr cast iron repair. I am always concerned about a hard brittle zone behind the weld dur to mass quench effect. I expect it would be worse with tig than with oxy/acy. On critical work I have it normalized after welding. On work that has been submerged in oil I normalize first to burn out any absorbed oil, then I weld, and norrmalize after. Normalizing after welding is essential if the welds are to be machined. Again, Thanks. I learned something new.

@user-萬能焊條 4 года назад

Dear John, Greetings. I wish to buy torch rod for cast iron but machineable and color matched. Where can I buy the rod?

@krankengineering 3 года назад

I hope you are able to find some suitable rods, I can't get them anymore here in Australia, and plenty of people tell me they can't find them in their local area.

@bobweiram6321 2 года назад

@@krankengineering Why can't you grind up dome cast iron powder and mix it with a bit of flux as a substitute.

@bobweiram6321 2 года назад

Most fluxes are a total rip off. There's tons of recipes out there, but the secret ingredient is roach powder or boric acid. Muriatic acid mixed with zinc makes a great flux.

@200xcBruce 7 лет назад

May have wanted to clamp to a flat backing plate to absorb some warping heat

@azmansugi-dora2753 5 лет назад

I have a same situation about a cast iron bracket that snapped. Just wondering if you can help me welding it back together.

@eazyrider6122 4 года назад

It wouldn't be impossible to make a casting mould since you already have the part. Ive welded cast using stainless rods and preheat the project. But in this case i would make a green sand cast as its a small part and machine after. No big deal.

@FactsMattersUSA 6 лет назад

Good job

@mikemcilroy4995 5 лет назад

Any word on how long the repair lasted?

@leonardpearlman4017 6 лет назад

First time I've seen Cast-iron TIG! Looks more than OK, probably doesn't hurt at all to have a little weld reinforcement. The only way I've ever tried to handle something like this is by brazing, and here would be so glad that the break is small and isolated like that.... I'm definitely going to look for those rods! Thought the clamp/tack idea was clever, you can be pretty sure you kept the original geometry and the part will still work.

@agassizbeekeeper 3 года назад

I've never tig welded cast before. My tig welding experience is very limited. Did you have it set to pulse?

@charliemarks6096 6 лет назад

Very nicely done. I was wondering if I could use my everlast mig welder to perform similar repairs.

@krankengineering 6 лет назад

+Charlie Marks you could weld it with a mig but it probably won't last. The normal ER70 wire in a mig is not a good match for cast iron.

@txsviking 8 лет назад

That's the way to do it! Cast iron normally doesn't distort with heating and cooling like other metals.

@krankengineering 8 лет назад

Yeah I wasn't sure what to expect, first time doing it in the real world (outside what I learned in welding school). Seemed to go well enough. Cheers!

@PeakyBlinder 3 года назад

Very useful thanks 🙂

@krankengineering 3 года назад

Glad it was helpful!

@shoes121255 2 года назад

Is this better than tig brazing it with silicon or aluminum bronze filler?

@Ice_Industrial_Auto 6 лет назад

How much did that pack of rods cost?

@billpickelheimer8142 3 года назад

Most steering arms are actually cast steel , look at color of the Sparks when grinding

@bidds07 2 года назад

If you put a 10 shade lens to put in front of your phone so we can see the bead too

@Mr59425942 Год назад

looks like cast steel?

@MrMarcaap 6 лет назад

Hey Matt, have you ever tried silicone bronze filler for trig welding cart iron?

@krankengineering 6 лет назад

+MrMarcaap I have some silicon bronze but this is a filler used for brazing, not true "fusion welding". I generally use silicon bronze for joining dissimilar metals or where I need to join stuff together but I don't want to pour heaps of heat into it (to minimise the chance of distortion). I use these cast iron filler rods or high nickel stick welding rods (with lots of preheat) for cast iron.

@user-ks5ff 6 лет назад

Were the rods you used in the video actually Electrodes? cause I only seem to be able to find Electrodes not cast Tig rods.

@fasousa4798 5 лет назад

4:00 look at it moving...

@LifeSavingDefense 2 года назад

Can you gas weld with this rod

@lesschattermoresplatter5769 2 года назад

It seems to me like the concave part on the back could’ve used a lot more filler. But… I’m no welder.

@Bikes_Buggies Год назад

This is crazy, I didn't see any preheat, no peening, and the welds are beautiful. Why on EARTH is this not common for cast repair?? I've never even heard of cast filler rod. This makes nickel rod just look stupid.

@krankengineering 3 месяца назад

My welding teacher showed me the materials and process. It works well. I agree, why use Ni when this is available?

@stephaniebrady1596 2 года назад

Welded cast iron many years ago as a maintenwnce welder. Boy does it smell awful when you are welding it.

@darrenheaver80 6 лет назад

Hi Matt, great vid and interesting. I have a job that our welders at work was going to do for me which involves adding cast iron build up to the sides of a engine block to create a full fusion weld to create a boss for another set of head bolts. They have offered to do it to save me the time and stress of doing it at home, they was going to do it using a gas torch & cast iron filler rods & cast iron flux. Do you think your method would be just as effective & as strong ? I don't think they could of ever tried doing it with tig as they did not mention it as an option. Does the surrounding metal machine back ok ? Or does it harden up like when you use arc rods. I would appreciate your opinion ! Only just found your channel but will be adding it to my list of subscriptions.

@krankengineering 6 лет назад

+Darren Heaver hi Darren. I would expect some heat distortion in the block unless this was done slowly over a long period of time. I haven’t tried machining these filler rods but they are simply cast iron so I can’t imagine any problems machining it. Arc filler rods are completely different metallurgy which is why they machine differently to the parent material. I think either gas torch or TIG would get you the same result. Sounds like a challenging job. But your welders sound like they have a plan to get it done. Good luck!

@bigbothoee8617 2 года назад

Would it be strong ? As was thinking of welding a car hub assembly

@krankengineering 2 года назад

As a general rule, nothing that has been weld repaired is as strong as the original. You've changed the metallurgy with the filler rod, and messed up the microstructure of the metal around the weld. Both of these are "stress concentrations" which means the same load the original part would withstand MAY NOT be withstood by a welded part. Its impossible to know for sure without destructive testing.

@subhankarrana8090 3 года назад

Tig welding cast iron filler rod no and name plz

@davidcraft4909 2 года назад

wow, what is that a 1/2" diameter rod, that thing is huge. If they made 1/16" or 1.6mm rods for that I bet it would be easier to use.

@krankengineering 2 года назад

Hey mate, its a cast iron filler rod, probably would be easier in smaller sizes but the cast iron seems to "wash" off the tip pretty well. This was the only size available from my local supplier. Cheers!

@papalilburn 6 лет назад

Are you "pulsing" the electrode or is it the camera?

@krankengineering 6 лет назад

Geez I can’t remember but most likely I have the welding machine set up to pulse.

@edcamilleri6261 4 года назад

Can you still get this item where did you purchase it

@krankengineering 3 года назад

CIGWELD here in Australia, they were special order but no longer listed on their website 😢

@e.olivia4142 4 года назад

UP OR Bridage de la pièce !!!!! top

@torl8924 5 лет назад

did you test it for strength?

@krankengineering 5 лет назад

How would you suggest it be tested?

@SamJ6131 Год назад

No preheat!

@warrenbuitendag5286 5 лет назад

is it just me or is the piece actually moving that much at 4:02 ?!

@MikeBaxterABC 4 года назад

Yep, it was walking right out of the vice!! :)

@Herbybandit 3 года назад

Nice one, I've not seen cast rods in years. Are you using helium? It seems to be really effecting your voice at times 😁

@reynaldogarza2579 Год назад

That’s funny!

@josepeixoto3384 4 года назад

If the 4 6mm(?) threaded holes need to be coplanar with the M10(?) at the end,it may break again; i guess a simple jig could have been made,and careful welding alternating sides?; i am saying this from a mechanic's point of view; i cannot weld shite, i rely on others like you for that.

@krankengineering 4 года назад

Hi Jose, yes possibly a jig would help, however the fracture was a clean break and the parts fit back together perfectly. I didn’t have any of the other parts from the assembly - just the one broken part - so I have no idea how critical the tolerances were.

@pinghigh728 6 лет назад

What welding machine is this?

@krankengineering 6 лет назад

UNITIG AC/DC 200

@jbs4radio 6 лет назад

How'd it hold up after that weld?

@krankengineering 6 лет назад

+Jared Sams never heard from the owner again so I take that as a good sign 👍

@jbs4radio 6 лет назад

Matt McLeod I was just curious. That's the first time I've seen those cast rods. I typically use Nickel, Aluminum Bronze, or Silicon Bronze.

@weldweld5629 5 лет назад

They got to be a nickel rod no such thing as an actual cast iron welding rod but good stuff

@dalegribble60 6 лет назад

My eyes! Why didn't you say when you were going to spark up!? RU-vid flashed my eyes!

@krankengineering 6 лет назад

+Bill Dozer lmfao. Are you the same Bill Dozer off the 33 forum?

@dalegribble60 6 лет назад

I would have to say nope.

@MikeBaxterABC 4 года назад

The only thing i would have done way different is insist to see either the individual sub assembly that parts bolts to ... OR preferable the entire machine, It might have been easy to fix with a couple mild steel brackets or something, just bolted on.

@GregsGarage 8 лет назад

I KNOW that wasn't easy.

@krankengineering 8 лет назад

+Greg's Garage hey Greg, it was more of a mental challenge to work out the steps to get it done. Only get one chance so can't stuff it up...the welding itself wasn't that hard.

@veegee24 2 года назад

No preheat?

@krankengineering 2 года назад

What preheat temperature would you suggest?

@veegee24 2 года назад

@@krankengineering at least 150ºC. Easily done with a propane torch. TIG brazing with aluminum bronze A2 is the way to go though because its coefficient of thermal expansion is very close to cast iron. It's a foolproof way to repair cast iron.

@veegee24 2 года назад

@@krankengineering So actually, clamp it like you did, then use a die grinder to cut a large V groove along the top side of the crack. The depth should be right into the middle of the part such that when you do the same to the other side, you will have achieved 100% penetration with the aluminum bronze filler. And it's _very_ strong, with the ultimate tensile strength being higher than the cast iron itself.