Repair Engine Block — Sep 27, 2010 This engine block was completely finished machined. The weight of this block is approximately 28,000 lbs. It had a very large sand inclusion on the fire deck. Read Full Case Study
Casting Repair — Nov 15, 2010 The foot broke off this 2,340 lb. casting, which was then sent to Metal Surgery for repair. Read Full Case Study
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Cast Iron Welding

Cast Iron Welding

A thorough evaluation of the iron casting area to be upgraded will determine whether the metal stitching process or the welding process will be utilized.

Considerations will involve:
  • Location of area to be upgraded.
  • Effect of the application of heat on casting dimensions.
  • Ability to preheat.
  • Type of upgrading to be performed (cracking, lack of stock etc.)
  • Economics of metal stitching versus welding.

If the decision is made to weld, and material specifications are not available, a metallurgical analysis will be preformed and proper procedure written. The welding procedure generally used is that listed in American Welding Society’s Standard D11.2-89, “Guide for Cast Iron Welding”. Certified welders will perform the necessary upgrading.

Cast Iron Welding

Preheating is applied with a confined heating area, torches or ceramic heating pads (electrical). Welding modes are SMAW, GMAW, or FCAW (Shielded Metal Arc, Gas Metal Arc, Flux Cored Arc).

When post-heating or stress relieving is required, ceramic heating pads generally are used.

All welds are ground to conform to the base metal contour and are inspected visually and/or using the inspection techniques of liquid penetrant and magnetic particle testing.