cast iron tig weld

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Hsg for diesel injector pump testing equipment. Coupler turns inside this housing. Electric motor turns coupling that turns injector pump, coupler broke during test and broke this hsg. This equipment was manufactured in Turkey- go figure.Tacked parts with 99ni tig.Preheat in oven 750 degreestig using 309 fillerpull from oven- welded all of outside and half of inside in 5 mins, casting had lost 175 degrees at this point so reheat to 750, pull and finish weldingback in oven post heat to 750 for 20 minsturn oven down to 550 for 20 mins turn off oven and let coolI really pushed the process, shoulda post heated longer and cooled slower, wanted to see what I could get away with!Hsg was single walled, about .300 inch thick where broke, and was round in shape which allowed it to expand and contract- which is why I was able to weld without breaking it!Customer has one on order, this is just going to be used till new one comes in.last photo is proof of what I preach- weld from edge to mid point then from edge to mid point- boys and girls!Peter Attached Images
Reply:thats crazy i didnt think it was possible to weld cast that good. big respect
Reply:Why do you tack with a different filler, since you used TIG for both tacks and welds?No bevel necessary for .300?How do you get anywhere near 750* without baking yourself? Is welding in from the edges helpful for MS or alum?fwiw: hobby guy, keep it simple. Thanks for the lesson, especially that the round shape helped make it possible. 9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Is there a reason a replacement could not be fabricated from steel? One would think you should be able to get pretty close with a stub of pipe then shave to final dimention on a lathe.  No?-MondoMember, AWSLincoln ProMIG 140Lincoln AC TombstoneCraftsman Lathe 12 x 24 c1935Atlas MFC Horizontal MillCraftsman Commercial Lathe 12 x 36 c1970- - - I'll just keep on keepin' on.
Reply:Originally Posted by rocothats crazy i didnt think it was possible to weld cast that good. big respect
Reply:I would have used the 99ni personally. There isn't all that much weld there. I guess you said it is a temp deal though. Nice work. Cast is always a pain. Ever tried silicon bronze? It's really cheap and easy to use for those non critical apllications.
Reply:where i worked before they had ametalurgist and a welding engineersthey said ni44 was the best to tig cast
Reply:nice weld. I never welded cast the right way.  someday I will .Daye
Reply:Originally Posted by MondoIs there a reason a replacement could not be fabricated from steel? One would think you should be able to get pretty close with a stub of pipe then shave to final dimention on a lathe.  No?Yes----butI spent about 5 mins with flapwheel to get paint off, another  5-10 mins to tack and throw in oven, welded 5 mins first round and 2 mins second, removed from oven and used die grinder woth mounted stone to grind down high spots inside-5 mins, total 27 mins-- actually probably less.Bottom of casting had base machined to slide in bedway. Coulda cut the top (what looked like a piece of pipe) off welded in a pipe that was close and then machined to final size but it woula have taken quite a bit more time (done that more than once)Peter-Mondo
Reply:nice work!
Reply:mad props my friend, that looks amazing.I break things for a living...
Reply:Originally Posted by Norcalmikenice work!