Repair Engine Block
Repair Engine Block — Sep 27, 2010 This engine block was completely finished machined. The weight of this block is approximately 28,000 lbs. It had a very large sand inclusion on the fire deck. Read Full Case Study
Casting Repair
Casting Repair — Nov 15, 2010 The foot broke off this 2,340 lb. casting, which was then sent to Metal Surgery for repair. Read Full Case Study
Sign Up For Case Study Newsletters

Cast Iron Welding

Cast Iron Welding

A thorough evaluation of the iron casting area to be upgraded will determine whether the metal stitching process or the welding process will be utilized.

Considerations will involve:
  • Location of area to be upgraded.
  • Effect of the application of heat on casting dimensions.
  • Ability to preheat.
  • Type of upgrading to be performed (cracking, lack of stock etc.)
  • Economics of metal stitching versus welding.

If the decision is made to weld, and material specifications are not available, a metallurgical analysis will be preformed and proper procedure written. The welding procedure generally used is that listed in American Welding Society’s Standard D11.2-89, “Guide for Cast Iron Welding”. Certified welders will perform the necessary upgrading.

Cast Iron Welding

Preheating is applied with a confined heating area, torches or ceramic heating pads (electrical). Welding modes are SMAW, GMAW, or FCAW (Shielded Metal Arc, Gas Metal Arc, Flux Cored Arc).

When post-heating or stress relieving is required, ceramic heating pads generally are used.

All welds are ground to conform to the base metal contour and are inspected visually and/or using the inspection techniques of liquid penetrant and magnetic particle testing.