george md, I for one would be very interested in reading about your technique for welding cast iron with a torch! I can probably count on one hand how many times I've had to repair cast iron. Now cast steel I've done numerous repairs on pile driving equipment. For years the company would buy a rod by Welco, called Super Missile Weld. Basically just a more expensive 312 stainless steel. Later we just started using 7018. Now this was on cast steel, not cast iron.
I think this was posted by member Cast Weld on Welding Web forum. If I remember correctly he repairs cast iron for a living.
I do a lot of cast iron repairs with 100% success so far. Last year, after several months of research, I found information on a couple websites & mostly in an old Lincoln Welding book. The process is called "Cold Welding Cast Iron With MIG". I practiced several weeks on broken cast iron parts & broken/cracked manifolds my bro' gave me to get my technique down pat. It has worked with superb results.
I use MIG, 309/309L .030 wire, 98/2(AR/CO2) @15cfh & generally in the 80A range. You can use any gas with a mix of no more than 5% CO2 (ex:95/5). The 309 wire has a carbon content of .01 & works best. The idea is to keep the temperature cool by running short beads <1" & allowing the joint to cool before continuing. After running the short bead, you can take your glove off & lay your hand on the metal & will feel only warm to the touch. Since your pieces are not large, I would suggest shorter 1/2" beads & allow each weld to cool back to room temp before continuing.
On Tractorbynet forum there is a member there who goes by yomax4, he does a lot of cast iron repair with Spray Powder Torch.
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