All position, fully machinable cast iron electrode for repairing and “cold welding” of thin sections of cast iron
High nickel core wire generates a quiet steady arc that is extremely easy to handle even with low open circuit AC voltages; starting and restriking without sticking to the work piece has never been so easy
Weld deposit is soft and can be milled, drilled, tapped or machined yet has strength greater than the base metal and the color will match that of cast iron
Excellent for build-up and welding of gray, malleable, and ductile cast iron to itself or for joining these cast iron types to mild and carbon steel, stainless steel, copper alloys and to copper-nickel Monel® alloys
Common applications include engine blocks, gear housings, machine bases, defective castings, filling holes, and building up worn or missing sections which will have to be machined
Instructions: Bevel thick sections or use Chamfer Rod to form a “U” shaped groove. Drill or use Cut Rod to create stop holes at each end of the part to be welded in order to prevent the spread of cracking during welding. Clean the work area as thoroughly as possible. Preheating is not required; however, it is useful in relieving stresses and to increase machineability of the weld deposit in parts greater than ½” thick. 200°F is an acceptable preheat temperature. Using AC or DC+ (reverse polarity), hold the electrode 15° off vertical tilted into the direction of travel. Maintain a short arc length of about 1/8”. Use stringer beads or narrow weave beads in order to prevent excessive heat build-up. Holding the arc over the molten weld metal, follow the pool but do not let the arc get ahead of the pool. Weld only one to four inches at a time, depending on the thickness of the part. If the part is ¼” thick, use a 1” bead, ¼” to ½” thick use a 2” bead, ½” and thicker, use a 3” to 4” bead. Extinguish the arc by whipping it back over the deposited metal. Peen the weld deposit with a chipping hammer to remove any slag and to relieve weld metal stress and prevent cracking. Restrike the arc on previously deposited weld metal and not on the base metal. Do not let the part become too hot during welding and remove slag often. Always choose an electrode diameter that is small enough to permit at least two passes. Gradual cooling of the deposit is strongly recommended.