Weldingof castircn

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'1.1General '1.2Greycasl iron 1,3 Whitecast iron 1.4 Ductilecastiron 1.5 Compacted graphjte cast iron (Cc_iron) cast iron 1,6 Malleable cast iron 1.7 Alloyed

1 What is cast iron?

Somecommonapplications

5.1 FoundrydIecls 5.2 Rpairs 5,2.1 General 5.2.2 Cracks (light stress) 5.2.3 Frsctures (hlgh stress) 5.2.4 Holloweddamages 5.2.5 Burntcastings 5.2.6 Thinsections

2 Factorsaffectingweldability
2.1 General 2.2 CoolingsAesss 2.3 lrregularshap 2.4 HAZsnd Iusionline 2.5 Carbon pick-up from base nE*al 2.6 Otl impregnalion of lhe cast ron

6 Consumables
6.1 Gensral 6-2 lron basedsleclrodes 6.3 Nickelbasedelectrocles 6.4 Copper based lctrodes

3 How to confol these factors

3.1 Cooling slres9es 3.2 lrrogular shapes 3.3 HAZandtusionline 3.4 Carbonpick-upfrom basemetal ol cast iton 3.5 Oilimpregnation

Weldingprocedures

4.1 Cleaning 4.2 JointPreparation 4.3 Preheating 4.3.t Preheatingmethods levels 4,3.2 Preheating 4,4 welding 4.4.1 Gneral 4.4.2 Buttering layers 4,4.3 Singlelayerwelds 4.4.4 Mlltilayerwelds 4.5 Postweld heat treatrnent 4.6 Cooling

I What is cast iron?

1I GENEBAL Byaloying pureironwithcarbontheme ting pointcan be lowered from 1534C (purelron)to1147 C (4.3% C).Ths reducton is lsed indlsiria y to prodlce cast iron-Cast iron iherefore,has a high carbonconient (betweef 2 and 5olo)whichconsiderably afiecis iis weldab liiy.lf additionioih s phosphorusand sulphurcontent are usuallyhigherthantorordnarysteel,wh chfurtheraffectsihe weldabilty. Pure ron,alloyedprimarlyw th2 5%carbonshows owduciillty, low hardnessand low strength,and s on thewholeavery briitle maierlal.To improvethesepropedies(andto renderthe irof add tlonalpropertes ike heai-, corfosion-and wear resistance), cast ironsare oftef aloyed and/or heai treated.Thenumerous amountofalloys so createdmay forconveniencebe divded into groups. iheiollowing Greycast iron Malleable cast ron Ductilecasi ron

1.6 MALLEABLE CAST IRON [/alleable castirons areproduced byheattreatmeni of white cast ironstorenderihemmoreducti greyirons.Theyhavelower ethan carbon andsilicon conteni thangrey rons, io secLrre whte kon so difcaton.The microsiructure conssls ofaggregated, somewhai irregular nodules ofgraphite distrbuted n a mairix ol pearl lerrite, ie ortempered martensite. L,lechan cal properiies aresimilar to duci e iron. Wdd ng oi malleable ironmayprod uce a ihinwhlteironzonein ihe weldandihe podion ol lhe HM adjaceniiolhe weld meta.Th s ls notserous n manyapplicapartsproduced lions.However, io be welded areoftenrender,ad excelleft wedabiliiy by a decarburizing heattreatment. 1,7 ALLOYED CAST IRON Alloying properties eementsare added io improve lke heat, corrosonandwearresistance andio increase sirength. "n crosilal'(heai (corrosion Examples are"Ni resist" resistance), " ' (hig resistance), and meehanite h iensle). These ironsshowa weldabi ty similario ductie irons. However, onespecal typeoi alloyed ironis "N hard", whjch s more kea while ronandthereforeto be considered as non

1,2 GREYGAST IRON Grcycast ron isthe mostcommontype of cast iron(aro!nd 70 % ofa lcasl ironsare grey).Themicrostruciure consisisol graphite f akesdist buled n a matrixof ferite, peff ite o. boih The graphitepossesses zero strength.and thereforeruprurew alwaysappear in this phase.and sincegraphiteis grey.the fracturesurfacewill ook gre)lThereby ihe n a,.ie.Greynon ! sually c o n t an s u p i o 4 a : o C a . d u o i o 3 i : S i . l i i sm a d e b y s l o w cooing otihe casting.Some old r_!ps may coniain considerabe amo!nts oi sulphura.d phosphorus.which can makewelding dlfiiculi Ho\lever o. moderncasilngsihis is seldomthe case, and weldingis mosi ofien e..poyed wilhoutcomp ications,

2 Factors affecting weldability

2.1 GENERAL Whiieironand"Ni-hard'Liypes, because oliheirexteme brittlegenera ness, lycrackwhenattempts aremadetoweldihem. Troube mayalso byexperienced whenweldirgwhite-heart malleabe castiron, dueio porostycaused by gasheidin this typeof ror. Othergrades y of casiironarebeing successfu provided procedLrre welded every day, thecorrect is empioyed. Successfulwe d ngofcastironis manlydependlng on nrinnrz ng the nf uence ofthe following: - Cooling stresses rregular shape oiihe casting Hardening of theHAZ Carborplck-upfrom thebasemetai Oil mpregnation of castiron 2.2 COOLTNG STRESSES Theweldmeialwllcontract upor cooing.Thiscontraclion is largerihan ihe corresponding contraction ofthe casi senerally ron.Duetoihe resu briiileness ol casiiron,the t ngconiraciionai inthewed meia ilcrackingisto stresses mustbeaccomodated

1.3 WHITE CASTIRON White cast iron is evaluated on hardness/wear resistance and mostryusediorsuchpurposes.llis of s niilalcomposition to grey iron,butwith a owersillconconieni.Sometimest isa soalloyed wiih carbidesiabilizers such as C[ Mo and V The m crostructure c o r . i s l s o ' c d l b d F sd s t i b ' r e di r a - E , 1 e r s i . i .o r p e a r r . r.atrx.The carbidesare hard and br tt e, and renderthe Iraciure surfacea whiiislrcolour. Thereby the nar.e. li s made by rapid 'chills".lt coolingwilh s to be consideredas non wedable, aithoughsuccessf! wed surfacingshavebeenachievedon crlsherrolls us ng OKAutrod 12.51.The hardnesswas rendered the m ld steelwed metalthroughcarbon pick up from ihe white iron.Tojoinwhile non, however, weldingis noi recommended.

1.4 DUCTILECASTIRON Ductilecasti.on havesim ar composilion to greyiron,bLriusl]ally h gherpuriiy.Theadd t on ofsma amountsof magnes um brjngs thegraphiteinto fornrng spheroids, |]nilormyclispersed throughout the structure!nsteadolfakes ikeingrey ron.Thiswill,nihe propeftiessimilar anneaeclsiate, renderdLrctile ron mechanical to mild sieel-Welding istherefore seldomdiJliculi w th theseirons_ Howeve[ the voent heaiireair.eni nvoved n weding, iogeihef w ih ihe d uiionfronrthe casi ron,stillca ls for ihe lse oi special o r.trod6. ard cd.eJL p"1r19otr'leprc.Fou,".

2.3 IRBEGULARSHAPE lron castingsare usuallydeslgnedfor rlgity. Theyare seldom of uniformih ckness,and genera ythey are of niricaleshape wlth r a p i dc h a n g e s ofsecilon.Thus th , e yw i l l n o ir e a d i ya d j u s t themsevesto localconlracton, and d Lre to their ow d uclil ty,new iracturesare lableto occur.(SG iron,dueto its good ductilily,is noi so sersilive in ihis respect).

1.5 COMPACTED GBAPHTTE (CGtRON) CASTTBON Compactedgraphltecastiron(CG-iron) may be considered asan :ntermediaie belweenduci e and greylron. lt s producedby addingcontrolled amountsol magnesi!m,t ianiumand cer Lrnr to a cornposition similallo greyiron.Weldng should be pedormed

2.4 HAZAND FUSIONLINE The heal afiectedzone oflhe cast iron adiacentto the weld, w ll be hardeneddur ng weldingdue to the high carbon conteni. The hardness oflhe non nreltedpad oflhe HAZ s ma nty dependingon cooling rate,and the width mainiyon apptiedheai

The portionofthe HAZc osesi to thefuson llne w lconta n p d ri a l l y m e l . - . dc l e r a . - l _ " n i r o q f J L I L e o lt i ' T o ' l e c v e 1 . Jsla'rilo a r o c o r s r s ( :o l c n i ' ' J r e o - m a r l er s i l e c Lomple. which surroundspai(ialy primarycarb de, and lederburite d ssolvednod! es orflakesofgraph te.Thispo,lion isihe hardesl The extentand h ardnessof this zone s ma nly dependng on a p p l F . lp e d . . e - o e ' r - i r e ., l e a t , l p L l a ' r d . o o l1 0 r d t ' d - r " o peaktemperaiur ef a i r y e q u a l n M M A is w e l d i n gS . incethe wil ofconsumabe choice,the p.opeJlies weldlng,regardless also herema nly dependon heat input and cooling rate.

3.2 IRREGULARSHAPES partsoithe casting dueio in associated Toavod cracking caused byweldng, t is oftenusefuto contraci onalstresses pariby preheat siressesnginorderiobaancethese expandihis prehealrng. namedndireci Th s lypeoi preheat ng is commonLy as agenerarule, ofthis preheating, FlgI shows theapplication

2,5 CARBON PICK-UP FROM BASE METAL will calse caton pick-up n ihe Thedilltion wilh base rlralerial weLdnreia conteni oi cause lncreased weld meta . t w ll a so su phur and phosphorusii s!ch are presentin the casl ron
FS1 Doired lnesshoweifecl I . o p r e h e a ts u s e d

OFTHE CASTIRON 2.6 OIL IMPREGNATION ihereby Oilmay be absorbed n graphileand micropores, peneiraiingdeep into the casi iron.Dur ng weding, thiso w evaporaleand causeporosityin ihe weld meta.

3 How io controlthese factors

3I COOLINGSTRESSES Using conect welding parameters. We d wth shortstringerbeads,low amperageand planthe bead The smallerthe volumeto cool, the smallerthe coolingstresses. to long ones. Consequently, shofi beadsare preierred Weavng wl I resuli n argerpats of the weld io cool,thereby c . d i r g c o o 1 0 s l e s s e sS . r r r o p rb " d d s d r eL t e e ' o ' e o e _ layers, welding,subsequentayersw I heatpfevioLrs In multilayer iherebyreleasng some of lhe stressesbuit |]p dur ng wed ng oi ihln Toiurther o w e r t h eh e a ti n p u i , l np a r t i c !a r w h e nw e l d i n g secions, t has been provedusefu ioweld in thevertica down p o s t o n . T hs s p o s s i b l e u s n g i h e O K S e l e c t r o d9 e2 . 5 8 . Using consumablesthat provides a ductile weld metal Resd ualstresslevels nwed meta areusuallyntlrereg on oi ts y, to owerthe res d ua stresslevelsor y eld stress.Consequent io coolingstresses, weld metalw th low y e d slressarepreierred s u c hw i i h h i g hy e d s t r e s s . Performing preheating wilh increasTheyieldstressolanymaier a generaiydecreases y, ii the conlraciionalsiresses lngremperalure. Consequent nthewed o r g i n a in g l r o mw e l d i n g c o u l db e f u l y a c c o m o d a i e d than room iemperature, the melaiai a highertemperature res dualstresslevelwo!ld be lower.Consequentlypreheating may lowerthe nf uenceofcoolifg siresses. Peening Peenng w ntroducecompressvestressesin iheweld meta insteadofthe iensileslressesftroduced duringihe weding operatlon. This s the mosi uselulmethodto avo d crack ng in casi

whenlsing ih s proc3,r L:: r ls belterlo heai a largeareaio a low temperaiurethan1oh:ai 2 s-a Larea to a high ter.peraiure. ii However. a high oca pr:h:a: in the o ni w sl I be necessary, asofi machineab elved is reor r3ci. When weldingan ntncatecasrii-oco lia n ng rap d changesoi generalpreheaiis nh g o - , cb e o a i n t an e da t a section,lhe jusl uder red hear.Where:f:s s .loi poss ble.many temperature ag.nera creheatto black repairscan be madesaiisfactorilywrh h e a t w i r t - a , o .p ar e h p d i or,l e j o i r i . A p . . l e . o - ' o - t d b e i n o i h e a ii o b u i l d c a r r e do u t s l o w l y l oa l o w a ! n i f o r md l s i r i b uo re or up in ihe casting.Genera prehealng up to a remperaiu furnace around600"Cmay be car ed olt in a suitabe mprovised u s n g g a sh e a U n g orcharcoa. F naly, the more lntricaietheshape.theqreaterlhe needior evenlyappliedpreheatlng. 3.3 HAZAND FUSIONLINE The hardnessof the HAZmaybe oweredby p.eheatng. However, to reacha substantialha.dnessreductio.. rr^ecastingwould to around 500 C needio be preheated The hardness ofthe part y rerneied zone c ose io tire ius on line b v r e d L 9 t l p t m d ' L o e c r t e _0 e d t - r e ma) belowered (e.9. using oly amperager. d!fing weLding 3.4 CABBON PICK-UP FROM BASE METAL Carbonpick-upfrom base mefa w Lawaysoccurin cast iron there s lwo waysoi m nimizing the effectsoi we ding.In princ paL. n c o m bn a i i o n w t h s l o wc o o l i n g , l o 1 u s i n gh i g hp r e h e a l i n g avo d ihe detrimentaeflecis of the carbon pick-up-Th s is esseniialwhef using Fe based consurlrables. po ic 2 Using consumableswherelhecarb nk u p s n o t d e t r m e n ial.This s bytarthe most used method,and the consumables are mostlyoi N 'based type. OFCASTIBON 3.5 OIL IMPREGNATION Whenoilhas penetrated deep intolhecast iron, t s imposs blelo removeby anydegreasng agent,s nce this willaiiect only ihe Insteadthe oilhas lo be burnt off by comparablylong heat treatmentsal temperaiures around500'c. Norma heat ng time a p p l i c a i i o n s is hl s n o t p o s sb e , a n d f o r s u c h ,g a u g i n g On nrany mayprovldeasu tab e enoughso uiion. w th OK Selecirode 21.03 Should porosty st Llocc![ the best way to producesound we ds y removetlre we d meial by grlndingand rewed t s to repeated until no porosityoccurs.

4 Weldingprocedures
4I CLEANING p orto welding. Casiironitself,s of Allsurfaces musibecleaned to lurther weaken the suchlowstrngth thatit is unnecessary jolntby omitting welded ihis importantprecaution. Oil,grease, eic. degreased chemically, otherwise Surfaces sha be thorouqhly porosily willresult. gears f ihe cast ronhaslongbenin coniactwithoil,(like holdlng oil), iheol maybe immersed in oilorgearboxes wayol car absorbed byihe graphite or micropores.This penevaie deepintothecasting.To rcmove suchoil,which oiherwisewillevaporateduringwelding, chemica degreasing Insiead thecasiing musibe heatedioburnoul is notenough. js doneat temperatures for theoil.This around 400-500'C

- Dirt,castskin,paint,etc. llbelongsto normalwedingprocedlretoremovecontamin thenickel based tionsliketheseprioriowelding. However, consumables normally used forthe welding of castironare moresensitiveto iromth s thanrnrld contarnination steel ii isenough cleaning. Generally So,besurctomakeaihorough areawithin 20 mmfromihe weld. to cleanlhe 4.2 JOII'ITPBEPARATION - Jointangles shou ld bewiderihan formildsteel, around 80 90 - Allsharp ofi,to minir.ize heatconcen edgesmlslberounded

- Generally io v-lonis.Th s is thepr me u-grooves areprefeffed withother reason whygaug ng ls so beneficialin comparison possible, methods forprepalring casiironjoints. is notalways andforsuch li is obviousthatthis provides - Cracks mustbefulyopened to a lowaccessability. However, gauging applications, w th OKSelectrode2l.03 often leave 2--3nrmontherootsideioalloweasyltting. Use ofihe oil.In a suitable enough soluuon, by localburnoul 21.03 iorjo ni preparation on allcracksnt OKSeleclrode addition io ihis,gauging wi lprovide ihe nrost suilablejo - Cavities lrkeblow holes, andcleaned. etc.mustbe opened coniiguraiion

in Castlron Jointpreparation

60-75.

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4.3 PREHEATING 4.3.1 Preheatingmethods A thoughasat siactoryjointcanbe ach evedw thout preheating, the riskof crackingdueto ihe rigidityor ack of duciil ty especallv reducedby preheatng. n comp caled shapesis considerably ,lgs' Tlere arF tlree -ethods o'apply,ng preheatIo tl-e casl Local preheating,to retardthe raie of coo ng oi ihe weld joinistressesand General ireheating, to releaseinterna locked_up to retardcool ng ofthewe d, ftheiemperaiure s ralsedtoabove in ductilty occurs,which increases 450"C,a sLighimprovement jn This allowsfor some the iemperature. flrrlher increase wih tendencres reducesthe d stortional siressadlustmeniand grealLy weldedaswellas i n t h e j o i n tb e i n g a n d t h e r i s ko f c r a c k i n g ofthe wed deposiiand heal affecied reducingthe hardness Indirect prehearing,which is oftenvaluabe, ifused with cauno. lorexpandlng an assoclatedpart oilhe casiing n orderio stressescausedbyweld ng ba ance contraclionaL 4.3.2 Preheatinglevels All eves ofpreheat ng is usuallybeneficja. Noweverthere may eves . onre'key_ g b e a p o i n t n e s i a b l i s h i ns - Ambienltemperature l e n t i e m p e r a t u r er w n gi h a t l h e c a s in g i s o f a tl e a s t a . n b Secur on its surtace no air rno siurewill condensate secLrfethai

ductile buliering moreaffectthe Toallowforcoo ngssiressesto (Oicoursethe HAZ basemateria. ihebr tt e HAZofihe ayerihan lrom each cooling stresses affected by base meialwill be ofthe and the area outovera arger weldbead,buitheyw I be spread hardphases ofthe HAZwllbe annealed) on: is employed Buttering Prmarily on rg d wed ng proced!res welds,to a ow lor l-"ss Multilayer is nrainlydueiotheiolowng: runs.This thefill

a0-100"c
Preheatng io aro! nd 80 100'Cwill securethat al wet surlaces w Lldry therebyno hydrogenconiribulionfronrair hum dity - 200-250'c on ducu e iron to to aro!nd 200-250'C is Lrsed Preheating prevenlmadenslteformation n ihe HAZ.li is noi necessarvto preheaitheseironsto highertemperaiures Sometimesit nrav t g ntheregionof300 s,n c e p r e h e an e v e nb e d a n g e r o u s 500'C may promoteplec p tat on of proeuiectod cemenite, which consderably owerstheirducti ty Up to 500'C is Lrsed at alltemperatureevelsuplo Indirectpreheating 500'C.The h ghe[ ihe beiier,provded boih heaiingand - 500-600"c 500 600"Cis used on grey and CG iron to achievelowest possiblehardness n the HAZ. - The contractonaLsiresses i'ori Ine coolingweld rneta in subsequentbeads wil be accomodatedin the butieringlayer, ! thereby oweringlhe st.ess eve and ihe risk oicfack ng. - The heai from subsequenr beadsw Llanneathe HAZ in the sness eve in previousbeads and owerthe cast iron, - No dillt on from thecasl ron wl occ|]r,dLretoihe insulatrng buiiering ayer. Welds between cast non and othermetals ike sieel,copper to securegood wed bond. alloysor nickela Loys. Rebuilding largersurface defects, resut ng rrom over mach ning,casungoperationsor mechanicaforces,eic The idea here s io irame ihe defecl, us ng short stringerbeads can fo lowed by immediaiepeening.Theresl oi ihe rebuildning procedure weld ng |]s ng a less rgld commenced then be welds perforlned under heavily restrained conditions, e.g. rep acinga holowed damagewlh a milclsieel plate.

Muliiayerwitir bLie..g i-..

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4.4 WELDING As mentionedabovewed ng can be performedwth d fierent ageneralrule,ihe higherlhe preheating evelsoi prheating.As facilitateihe g r d thewelding procedure.To eve , the Loss ons,wew ll herework with th reedifferentier.pera reconimendat (cold welding) Room temperature 250"C(semi-hot weldins) - 500"C(horweldins) Flrrther we needio diflerbetweenthreekinds o1welds: Butterin9 layers Single layer welds

4.4.2 Buttering layers "buttering On someweids lt is often beneficialtouse a boih) ol the su{acesto that one que. means Ln shorttlris techn lor beweldecl,are surfacedpriorto thejoin ng operation The reasonsfor usingthisiechn que may beerthermelalurgrcalor Fig 3A. nrechanical. Metalurgic6l Toavoidlormalion ofbritle phasesin dissLmildwelds 4

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raie,and Preheaiing as mentionedabovewill lowerthe cooLing ihe reductionin therebythehardnessofthe HAZ. However, hardness w llbe marg nalwith a preheatlevelofonly 250"C,and procedure givenin section3l are recommendauons theref ore the Cold welding Thehardnesso ih f e H M w i l l d e p e n d o n t h e c o o l i nrs a i e . T h e o n l y va d also here,ihough somewhatless rigid. - nterpassiemperaiureshal bekeptat250"C. wayto owerih s wiihoutpreheating is to use a higher heai inpui. - Shorrstringerbeadssha Lbe used (no weavingl). N,4axjnr!rn This will, however, implya larserweld poo and iherebyhigher 50 mm. coolirg stresses, which is evenmore deirimerta ihan the HAZ The back-sieptechniq'reshown in fig 4 s preferred. in re at onto cold weLding, bLri Theamperagemay be increased Therefore, do noi lse high heat inputl musi be st lth n gauge elecvodesand moderateamperages io lmitihe Instead i h e H A z z o n es h a l b e a s t h i na s p o s sb L e dangerousarea, and coolingsiressesmust be neuiralized.i is - Peenng shallbe periormed(seeseciion 3l ). ihereforeextremelyimportantlofo low below pfocedurerecom- S l o wc o o l n g i s i m p e r a t v e l - W e l dw ' ' r s h o r ls r n n g F ' b F a d(s 2 3cm.. - Usethin gaugeelectrodesand weld with lowamperage. Hot welding Weldingon DC negatve wilresuli in lowerdiuiion from base because Thispreheaiinglevelismosilyusedforsmallercaslings, weldlngon maieral, and may be benetcal, in particularwhen parls. filculiy nvolved in heaiing arge H oi welding smost ofthed greycast iron with pure nickelelectrodes. preheaiing benelicialongreyand CG kon. On Sc-iron, however, - The intermed iaie temperatu re shallbe kept below 100'C. sho!ld not exceed350'C. - Use hebac(-sleo i e c h ri q L es l _ o w 1 1ligr, The weding may be carriedout asfor normalsteelwelding, ne or ) Famme.lreweos-i3cewirharoJroeoroo,pe ' e c l v wth the exceptionihatpeen ng should be performed. r r o e l l ^ e w F d m e i a l s a l o w e d l o d ahe weldirq.T"e - OKSelecirode92.58should be preferred to OKSelecvode cool, the greatertherisk ol crackingdue to coolingsiresses. wil subsianta y ncreaseihe T h e r e f o r e p e e n i n g s h ob ue ld p e r f o r m e d w h i l e i h e w e l d m e i a l i s 9218, s nce this high preheating dilutroa from base rnaterial, and OK92,58 is the mosttolerant ariothe st lred hot.lt s importantnolto hammerperpendicu of the lhree in ih s respect. wed bead, blt raiherfrom ihe end oiiheweld lowardsthe Slow coo ing s mperativel stariing po ni-Th s sto avoidcauslngcracks bythe peening itse f. operation 4.4.4 Multilayerwelds - Allbeads n phys ca coniaciwith the cast ronshal bewelded fors ngle ayerwedsaccordingtoihe proceduregjven - The last bead musl noi bewelded direcilyio the cast ron, but on iop ofa prevoLrs welded bead. - The best results n multilayer weldlngon casi ron are aways achievedusifg the butteringlechn que (seerig 3).

4.4.3 Singlelayerwelds On s ngle ayerweds, allweld meta is in conlaci with the cast iron.Further, no heatlreaimentofthe HAZ by ihe weldingoJ r gid subsequentbeadswilloccur.Thisca ls for parucularly wedingproceduresand/orpreheaiing.

Semi-hotwelding Thispreheatng leveLis most y usedfortheweldingofducu e kon are givenforthis and thereforethebelow recommendatons

4.5 POSTWELD HEATTREATMENT Themosicommon heat treatment afterweld ng is stress-relief questonedwheiher anneal ng. i hasbeen it w I mprove the propert esof thewed or not,butjtsuses w de yspread, andthe overa experience seems to be good. Tempering to lowerihe hardressofihewe d rnayalso occur.Th s is pad cularly usefuwhenwe dingwiih Fe-based consunrabes. 4.6 COOLTNG (incompariBecause ofihe lowthermal expansion of casilrons, sonwithmostweld metasused), andbecause oltheoften niricale isessenlial inal cast shape of thecastjngs, s ovi/ cooling ronweldng. pace n a coveroisaw Sow cooingmayiake dust,vermiculiie, hot drysandor in iheovenLrsed forthe preheai ng operaton.

5 SomecommonaPPlications
5I FOUNDRYOEFECTS Thesedelectsaremainlycavitiesandblowholes - They mustl rst be openedup and ceaned of d ri ikeirapped - Use OK Selectrode 9218 or92.58iof llthe caviv. 5.2 BEPAIBS 5.21 General bec assedinto two groups,lighily Castircn repairscangeneraLy stressedappLicaions and heavily app cations stressed Wherethe delectve part is understress,lhe repar normarrv thoui consisisof cutting and weding the defectve nraierraLw r.aterialprovd ng add t onaL strengthening Wherethe defectivepart must be capableoltransm tung h gh loads,the repar s often ach evedwiih ihe aid ofmeclranica means,becausethe iensilesirengihofacast ron weld is:s!a \'

5.2.3 Fractures (high stress) !n the FaiLure byfracture is usla ly due to asudden increase ihe work ng load, and the repalrmusibe capableof transmitting oad carriedbythe parts in quesiion.Thiss ofien achievedby nreanswhjch consislsof re nforcinqthelolni wlth mechanical orpreferablyby some form of coverslrapsf xed by boLls, shrinklnqon a iroop or band to carrythe tensileload. which may coverareasin thln sections,such as water Fractures the deiectivearea tackets.are often bes: rapairedby removlng and weLdingn a f;!c s:ee 3a:cn. AnoiherioF ci r-.ca. x-rc^ is o.::si:n: ) successi'r yused. r.c.nran3:c. c..s:s:s ol s:!Cii.8 [lild steel bui nor a tra-vs ^se.e! Lni.:n.':cs ri :n: ir:ci-.. anc we.cedio the s ar. sii-c ces: 'o. ."ior::ie rainl.b ot \reLong Jpr.e o ni ls comrerc,-c. : Ls essenia to iirreadthe studs and screwthem ilrmly in buttwelds rssomewnal inio:ir: oarenimelal.Theus-aofstuds slnceweding nef:crive whe.eiensilestrcssesare involved, brokengear otienservesloloosenthesiuds- Forreinforcing are involved, stldding s a whereshearsiresses ieeih. however: usetu strengiheningdevoe. 5.2,4 Hollowed clamages inthe Ahollowed damagein iron castingsmay be repaired iollow ng way: - Removea ldamaged niaterialfromthe cast iron (preierably bv grindlng). - Roundoff allsharp edges. Gr nd the edges oi ihe cast ron io around45 degrees - Butterthe edges ofthe cast iron w th OK Selecirode92 58 or 9218.

5.2.2 Cracks (lisht stress) It ls essentiaio detemineihe exaci lengih oia crack.Asaie generalrule s to cut oui more maiedala ong hs lengthihan is necessaryloensurethat tire whole ol the crack has been rea LV

The practce ol di ling a smallhole (-3 mm n d ametet accu ratelylocaled at eitherend ofthe crack,to preveni tirom ihe repair!s often employedwth good res!lts. spreadng dLrring ng out and weldingdo noi nvolvemLch work, ii s WherecLrtt oflen advisabeto free one end ofthe crack by cutung outto the edge of the casting.Wherethe crack has alreadyspreadio an edge,weldlngshould slart irornthe i xed end and trave outwaros Thepointatwhichweldingshouldcorimenceincasesotherthan the abovemusi be decidedon the merltsof each repairAtyp caL method o i r e p a i r o f ac r a c k n t h e c e n t r e o f a c a s t i n g i s s h o w n

ls.5.

Alignment of workpiece A surfacesihatshallbe mechanlcay attachedto another in thai pos t on dunng welding sudace,must be fixed accurateLy in crack ngwhen surfacesw Llresult lfnoi, anymisfitbetweenthe mountinglhe repared Part. Oneverycommonexafape ofih s, iscrackedbraceson eLecirical enginehousings(seefig 6).We d ng a brokenbracewthoui properfixingoflen resultsin ihe brace not being in plane When tighien ng the boLlsupon mountingthe engine,a new crack will occur due to the low duct ity of the cast iron 6

]-{--Trrflnl]TllllT/llTfril-

- Cuta mildsteelplatetoftintothebuttercd hollowed section, in heatexpansionbetween Becauseof the greatdifference steelandcastiron,it is betterto usea steelplaiewith abouthalf theihickness otthecast imn-This willalsolowerihe amount of weld metalneeded, therebymakingit easierto limit ihe heai rnput, - Grindthe edgesof th mild steelto around45 degrees.(Leave 2 mm 'oor faceto fucrlrtale fixng ot lhe two suriaces), - Tackweldlhe steelolate in to the cast iron, - Weld withshortsrringr bads usingthe back-siep technique. Placethe beacls one alter the otheras in fig 8. - When peening, hammeriowards ihe weldbeadratherthan perpendjcular to thweldsurface, to avoid crackngtheweld. lf allpieces of broken castironarepossible to usein the repair there isnoneed operation, fora rnildstee replacer. lt isihenalso possibleto weldwithout the buttering layeieven though thisstil willprovide a betierweld.

5.2.5 Burntcastings "Burntcasi Theterm iron"generally describes a casliron,which isoxidized bolhonthesurface aswellaswiihin themaiedal.This oxidation occurs whenthe castng hasbeenexposed to hiqh service temperatures, Depending on thealloying contentt may starlalready at 400'C. Burntcastironis characterised by: 1 A visible oxide-skin forming on ihe surface. Thisoxideconsists of Fer03, Fe304 andFe0. Fer03 holdsmost oxygen andwilltherefore takethe outerplace of thethree. Oxides of alloying components mayof course atsobefoundin thisoxideconrpex. 2 Internal oxidaiion penetratesquicklyinioihematerialaongihegrap Oxygen ilakesForthermodynamica reasons, the result is notonly burning ofgraphileto COandCO,,butalsotheformation of ironoxides.This ironoxidewilform in a zonesurrounding the graphiteflakeslfexcess is sullavailable oxygen andthe wi I beburnt lernperature is righl, thegraphite off.Thegraphite isthenreplaced eitherwiih ironoxideor noi at al,leaving an emptyspace wiihinihe siructure. This process is continuous andwillcontinue untilthe materia is destroyed, Theironoxideis nrore voluminous ihanlrcnwhlchcauses a "swelling" presence willalso of thecasling.The of ironoxides result in an increased hardness, This, iogethrwiih therough anddirtysurface, makes burnt parts castingsvery difiiculttowe d, urlessiheworn ofthesurface areremoved. Therefore, on suchapplications ii is always bestio grindorgaugedownto soundmetalbefore weldng, praciice goodwelds However, hasshownihai reasonable canbe planes achieved in sleelmanufaciuring on riser andmouds, (380-600A). using theOKSelectrode 91.00 withhigh amperages pemitsrhe Thereason seer.stobethatthehighanrperage cutdeepjnlolhecasting, crealing electrodeto a goodbondto Furthei soundmetal. muchofthe impurilies lendto riseto the As an emergency solutioron smaller castings wth burnior procedure conoded surfaces, thefollowing mayhelptocreate a suitable eno!ghbond. - Ceanthesurfacefrom al dusiandlooseattached damaged maierial.This maybedonewiih a stee brushorgrindins. - UseOKSelectrode 9T.58 to strike reDeatedlv overthe surface inthesame wayasstriking a match. This willcause somesteel metalfromiheelectrodetostickonthewornsu ace,providing a better bonddu ng ihe actual welding, - UseOKSeectrode ior theactual welding. 92.58 Experience hasshownthat OKSelectrode94.25 mayprovide successfulweldswhereNi basedelecirodes havefailed. Sohave for insiance exhaust manifolds been successiullv welded on

Fig 7

5.2.6 Thinsections Thinsectionsarefound in manycastings, suchasengine blocks, problem cy inder heads, valves, etc.The main istoavoid appying too muchweldmetalinorderiominimize ihe coolirgstresses. Therewillalso be difficulties n peening, sirceihe hammering in iiseifmavcfackthe weld. Thebesiwayto apply weldrnetais io weldin ihe tustenough position.This verticaldown is possibe, using ihe OKSelecirode 92.58, whlchhasa specialcoating thatpermiis wedingin this Position. peening, Toavoid breaking thecasling during it is better io harnrnerin a45 degree angle iowards thewelded bead,raiher ihanperpendicularto theweldsudace.

Fig 8

6 Consumables
6.1 GENERAL for castironwelding: Elecirodes - Casiironcomposiiion 91-00 OKSeLectrode - oKSelecirode 91.58-Mildsteelcomposiiion - OK Selectrode 9218-Purenickelelecircde - oK Selecirode compositron 92.58 NickeFiron - OKSelectrode co..position 94.25-Coppertin ELECTRODES 6.2 IRONBASED of hughiron for the repair is developed 91.00 OK Selectrode plates andslag botlom ingot moulds, as steel such castings, glving ironcomposiiion pols.lt deposits aweldmetalofcast wi! befairly properiies Theweldmetal rusting similarcoourand preheating without hardwhenwelding orsurface of caviUes is usedlor refiLing 91.58 OKSelectrode it rs andthereiore andbriiiL, metalwillbehard defects.Theweld properties will rusting and forjoining. Colour not recommended goodbonding on be simiartocastiron.lt is alsousedto secure and doorsiormartin manifolds, iron, suchas exhausi burntcast

ELECiRODES BASED 6.3 NICKEL Theweld of allcasiirons. forwelding 9218isusd OKSelectrode is recommended machineable.lt andveryeasily meialisduciiie machinear'le general repair andwhere for refilling ot caviiies, 150 HB lt hardnessesaround cast ironwith on weldsarereouired so formultilayer in more thantwo layers, mustnotbewelded andOKSelectrode forthefillruns 92.58 useOKSelecirode welds, g2lSforihecap runs.ltis notrecommended on highsulphuror rons. highphosphorus li is irons. wedingofallcast is usedforcold OKSelectrode92.58 lt strength. higher ironbecauseofiis forductlle oarticula v useful welds arerequredon cast whenmachineable is recommended to iolerant 250HB lt is more around hardnesses ironswith phosphorusihan 92.18 OKSelectrode withsulphurand diluiion ELECTRODES 6.4 COPPER BASED of copper for thewelding 94.25isorimarilvused OKSelectrode goodresults maybe hasshownthat experience alloys. Howeve( on some irons. high sulphurcasi ectrodeon usingthise achleved heLplulon burntcasliron,when it hasalsoproved occaslons l^ave failedl l^en aclira orliiy' rol asqood eleclrooes t\i based 9218. asfor OKSelecirode