Tig welding cast steel

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I have a cracked exhaust manifold that I plan to repair tonight.  It's an aftermarket manifold.  It's cast steel, not iron, and it has some level if nickel content.I plan to stop drill the cracks and ground out the cracks.  I'm also going to preheat it.  But I have no idea which filler to use.  What say you guys?"There are two types of people in America - those who try to classify everyone into two types and those who don't."
Reply:No need to preheat if it's steel. How do u know it has nickel in it? If it is in fact steel, I'd use 309 filler. Otherwise cast I'd use nickel99
Reply:The manufacturer claims it has nickel in it.Why 309 over 304?  (just curious)"There are two types of people in America - those who try to classify everyone into two types and those who don't."
Reply:I would braze it.... Less stress to deal with.... Basically it will stress relieve while your brazing. Brass will have more give than steel filler and no HAZ to speak of.Lincoln SA200's... at least 15 - 20. They come and go. Growing partial to the "Short Hoods" in my old age. Last count on Short Hoods was 13 in possession.
Reply:309 and just enough heat to make it work...And it will.309 can be almost called "Weld All Filler" for different metals..BESIDES Aluminum......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by SuedePflowThe manufacturer claims it has nickel in it.Why 309 over 304?  (just curious)
Reply:I have never seen a cast steel manifold, so I googled it. The only aftermarket cast steel manifold I could find was cast stainless steel, if thats what you have a compatable stainless filler should work. I have used 309 and other high nickel fillers on cast steel parts such as a cast vise. May I ask where did you get the cast steel manifold, and which cars are using them?PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:Yeah, ignore my 304 comment.  I have 308 filler in my shop and for ome reason I was thinking it was 304.  Monday brainfart. castweld, it's for a Mitsubishi Eclipse turbo car.  As far as I know, there are at least 4 different cast manifolds like this.  I did try welding it today and it didn't go well.  When I struck an arc, it just wanted to crater the surface and spatter back.  I had the surface cleaned well, but maybe it was pulling crap though the crack.  Whatever it was, something was way wrong.  I'm going to clean it inside an out and try again."There are two types of people in America - those who try to classify everyone into two types and those who don't."
Reply:The cast will usually sputter and pop leaving craters until you flow in some 309, then it's smooth sailing, just build from there. If the weld area is dirty you may need to run the torch over it to help clean out all the shi7 then wire brush it really well and repeat. What I usually do it take it down to shiney metal with a carbide burr.Welding/Fab Pics: www.UtahWeld.com
Reply:PsudePflow, I welded a Mitsu turbo manifold several years back. This manifold had a divider cast on the inside close to the crack which was top to bottom down the middle. I ground it (its sparks were cast iron) and pre heated it, spray welded, then post heated it. It came back about a year later carcked and the young man wanted to weld it again. Seems a new manifold was expensive and he could not find a used one. I refunded the first repair and told him the chances of it cracking again were too great. I am going to guess the manifold you are fooling with is cast iron, spark test it and we will all know. Cast steel or cast stainless steel would weld much better than cast iron. CI manifolds that are old or used at elevated temps (towing or turboed) errode faster than low load typical apps. The iron errodes but the carbon does not. The thinner (weigh it against a new one) manifiold has much more carbon content. Carbon does not weld, a few percent in cast or steel can be tolerated but when the content is too high its tough to get anything to wet-out or stick. When tig acts the way you described, I turn to spray or braze, braze on a high heat app like this is likely to fail. Sometimes a stick ni 45 or 55 will work better than a tig on that app, has something to do with the flux.Sorry to be so long winded but I have been at the welding engine stuff for many years- been there still doing that. PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:^^You should see the OP's crazy manifold and turbo setup. It's amazing!Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Originally Posted by Gamble^^You should see the OP's crazy manifold and turbo setup. It's amazing!
Reply:Those manifolds are a dime a dozen and junk. I have seen so many of those DSM manis crack. Like mentioned weld it and it will just crack again and again. Get another used one or a tubular.
Reply:Originally Posted by MikeGyverThe cast will usually sputter and pop leaving craters until you flow in some 309, then it's smooth sailing, just build from there. If the weld area is dirty you may need to run the torch over it to help clean out all the shi7 then wire brush it really well and repeat. What I usually do it take it down to shiney metal with a carbide burr.
Reply:Originally Posted by SuedePflowI'm in Berrien County, in the bottom corner of the state.This is what Gamble was referring to.  It's a compound turbo system I build in '09 and ran on my little 2.0L.
Reply:Well, as it turns out, there were three vesions of the cast manifold that I have.  They were having issues with the first two versions cracking because of the pot metal they were using.  This explains why I'm not able to weld on it.  Apparantly the third version was a high nickel cast stainless version.  Too bad I didn't have that one..."There are two types of people in America - those who try to classify everyone into two types and those who don't."
Reply:Since it's a known issue with their castings, do they plan on replacing it?
Reply:Originally Posted by BCTimberwolfSince it's a known issue with their castings, do they plan on replacing it?