CuSi On Engine Block

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Has anyone tried to mig or tig braze an engine block? I've had good luck recently with silicon bronze on cracked cast iron stuff.I bought a Dodge diesel yesterday and didn't notice that it has a block that is notorious for the water jacket walls cracking due to pressure and cavitation. There are no signs of cracks right now but I seem to have Murphy's Law luck with vehicles.Some people pin the crack but it seems like brazing would be an acceptable method, doesn't it? I've heard of people repairing exhaust manifolds with CuSi, this area definitely won't get that hot.
Reply:Do not try to braze or weld that 5.9 block. What year of diesel did you get.  I am presuming you are talking about the infamous 53 block.   Do a search on dodge diesel 53 block. Then check to make sure your truck hs that block. I have owned a 97 dodge with the 53 block for 20 years . It has not cracked.  Not all the 53 blocks were effected. The issue is from blocks cast in mexico that had the cooling jacket core shift in the mold when it was poured.  Not all of them did.  If it ain't broke don't fix it. If it is cracked I would use the stitch-n-lock kit to repair it.  There are no if ands or buts , if you try to weld or braze it it will become unfixable.  The problem is that the block will be very thin in the cracked area but have thick sections near it.  If you try to weld or braze it the thin section will expand but the thick sections will not and it will cause more cracks from the stresses.Last edited by thegary; 06-22-2020 at 04:41 PM.
Reply:

Originally Posted by thegary

Do not try to braze or weld that 5.9 block. What year of diesel did you get.  I am presuming you are talking about the infamous 53 block.   Do a search on dodge diesel 53 block. Then check to make sure your truck hs that block. I have owned a 97 dodge with the 53 block for 20 years . It has not cracked.  Not all the 53 blocks were effected. The issue is from blocks cast in mexico that had the cooling jacket core shift in the mold when it was poured.  Not all of them did.  If it ain't broke don't fix it. If it is cracked I would use the stitch-n-lock kit to repair it.  There are no if ands or buts , if you try to weld or braze it it will become unfixable.  The problem is that the block will be very thin in the cracked area but have thick sections near it.  If you try to weld or braze it the thin section will expand but the thick sections will not and it will cause more cracks from the stresses.
Reply:I've been out of the loop for some time, however, while driving and repairing diesel engines I've noticed that they (diesel) have a problem with cavitation.  I was instructed that the cavitation happens with the diesels while operating vibrate from the internal explosion causing air bubbles forming on the cast iron blocks.  Those bubbles let go and when they do that they carry a tiny piece of the cast with it.  The engineers developed some stuff called NALCOOL that treats the coolant and reduces this problem.  Does it stop altogether, I don't know.  I've used the product in all of my diesels and didn't have a problem with cavitation.  Piece of mind,,,YEP.  just my 2 cents.
Reply:The 53 block problem only affects the 24 valve Cummins between 1999 and 2001, as far as this website states.  http://www.cumminshub.com/cummins-53-block.htmlIn response to the cavitation concerns, this generally doesn't apply to the 5.9 Cummins because the cylinder bores are integral to the block, not sleeved.  Cavitation happens with wet sleeve engines like PowerStrokes and CAT engines when the coolant additives that prevent cavitation are used up.MillerMatic 185 AutoSetMiller Maxstar 90Miller Dynasty 210DXSmith HBA-30510LP Cutting Torch / RosebudArcAir K2000, K3000
Reply:Cast Iron hasn't much tensile strength at all. ALL WELDED METAL SHRINKS. As the welded portion shrinks, the portion that stayed cool will not. As cast iron is very porous, it gets lots of impurities. This makes it difficult to get good fusion. You have to try repeatedly to get a good bond. I'd suggest opening the crack wide enough to "butter" both faces with 308L stainless TIG before you attempt to join them. Let them cool before joining. Keep the whole thing hot a while.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:

Originally Posted by gwoade

The 53 block problem only affects the 24 valve Cummins between 1999 and 2001, as far as this website states.  http://www.cumminshub.com/cummins-53-block.htmlIn response to the cavitation concerns, this generally doesn't apply to the 5.9 Cummins because the cylinder bores are integral to the block, not sleeved.  Cavitation happens with wet sleeve engines like PowerStrokes and CAT engines when the coolant additives that prevent cavitation are used up.
Reply:Not saying they can't have the 53 block, just that the problem shouldn't affect the '97 and '98 trucks.  I have a '98 12 valve with a 53 block and it also has no problems.MillerMatic 185 AutoSetMiller Maxstar 90Miller Dynasty 210DXSmith HBA-30510LP Cutting Torch / RosebudArcAir K2000, K3000