Welding Cast Iron

admin

Hello all!Just joined and made an intro,I have a question and have searched the forums!I have a huge headache over my Audi S4, I broke the cast Iron mounts (part of the block) for the power steering pump and wondering if theres any hope! I'd rather not spend $2,000+ in labor!Seems to be pretty thick, and there is a lot of tension from the serpintine belt so It needs to be strong. I have no welding experience and I'm just mainly wondering if a shop can pull it off by making new brackets?Thanks in advanceDan
Reply:The cast can be welded back if it is not in a thousand pieces. Engine blocks are of good quality cast. Do not...I repeat "DO NOT use brazing!!!!!!!! The only draw back to welding in place is the pre-heat that will be required to weld it correctly. It will require a 350 to 400 deg F pre-heat and careful welding using the Ni-rod 55. Which is expensive but the best and strongest. You cannot weld it fast and its best to ping it with a chipping hammer to midigate out the stresses or it will just crack out as it cools. I have welded plenty of engine blocks and heads using Ni-rod 55...... good luck.A young green pipe welder asked an old salt one day...How can I make the weld on the bottom of the pipe look like the top.......The old salt replied....Screw up the top......
Reply:Heres a picture of the damageI don't even have the other peices.
Reply:I think you should PM castweld on this one. He's our resident cast iron repair guru.                                   MikeOl' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:You sure thats castIron
Reply:Originally Posted by krackaHeres a picture of the damageI don't even have the other peices.
Reply:Sure does'nt look like cast iron,but Im not there.Looks like aluminum in the picture.Lots of prheat w/blowtorch for sure.You do'nt happen to have an exothermic/oxy setup,do you?If you did I would'nt even bother with the rod.Good luck,panhead
Reply:without being up close and personal it does look like aluminum. how about some up close clear pics? without the other pieces it is going to be costly. i wouldn't think it could be done in place.Last edited by jbmprods; 12-06-2011 at 08:01 PM.225NT bobcatAEAD200LEScott 125mm175, mm252 w 30A, PT225mm211, TA 181iHyper Therm 380, cut master 529100X & XX, Digital Elite6 Victor setssmith little torch, meco midget kalamazoo band sawsteel max saw evoulution circular saw
Reply:I'm with the rest on looks like alum.  See if you can find someone local to at least check the metal type.  If it is Alum. it will be an easier fix!AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:Hard to tell from pic, looks like someone applied epoxy? I think thats why some think its al. Tried a magnet?PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:How in the world do you crack cast iron? Are those tabs on the block itself?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:Well I made that post 4 years ago at 19 and stupid. Now i'm back to join the welding community. I picked up an Everlast 185 inverter tig for my first machine. To update the original post:I got rid of the car and bought another one.Last edited by kracka; 12-03-2015 at 12:02 AM.