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Welding down inside a hole without slag: CAST IRON ??

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Truck

03-24-2000 16:49:56

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I posted a while back about rebuilding some drawbar holes on my Cub final drives. These holes are 5/8 11 threaded, and maybe 1.25 inch deep. I managed to repair them successfully but need some advice on how to avoid slag occlusions the next time. I heated the bare casting up over a propane space heater, and welded with the machineable nickel rod after hogging the holes out to all shiny cast. I would weld a bit, then chip, then weld, then chip, but I still ended up with quite a few spots of slag, which worked wonders on drill bits.. I have been spoiled by my MIG welder and haven't chipped slag in like forever..I tried to make the last part of each bead the center of the hole, which did leave slag pockets where the drilling started, but still there are a few minor spots in the threads. Any suggestions for the next time I decide to save one of these $200 plus castings?

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03-26-2000 10:49:50

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Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Truck, 03-24-2000 16:49:56

I would be tempted to weld in a steel plug,and re drilling and tapping.

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03-25-2000 18:04:10

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Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Truck, 03-24-2000 16:49:56

Maybe I'm missing something but couldn't you use a Heli-Coil thread repair or another brand?

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truck

03-25-2000 20:00:08

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Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to al, 03-25-2000 18:04:10

The holes were way too far gone for an insert, already oversized once, then broken. Two holes had half the boss broken off. You bet I used a helicoil elsewhere on the machine where the cast hadn't been egged out too much! Saved myself a good half a day on the two holes!

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03-26-2000 19:38:28

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Re: Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to truck, 03-25-2000 20:00:08

There is also threaded stitch pins that can be used to repair a crack or fill the hole in. I'm a welder and don't like to weld cast if you don't have to. The heating and cooling can make mess out of it.
Al

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Tom from Ontario

03-25-2000 17:22:09

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Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Truck, 03-24-2000 16:49:56

Truck: This is really tough to do if you have to run nearly vertical. I wonder if you could practice on something else, like a piece of normal steel by jacking the power way up, keep the arc short and increase your speed to see if you get a hot enough puddle but get past it to let the slag float. Normal power for a 1/8 rod on a flat seam is 125 for something like 3/8 plate, so down around 75 to 80 is very hard to keep adecent arc going. If you've got a MIG, maybe that product the other gent mentioned might be worth a try. Good Luck. Tom

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Tom from Ontario

03-24-2000 18:38:58

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Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Truck, 03-24-2000 16:49:56

Tough to avoid all slag, but try to minimize by increasing your lead angle, slow travel speed right down and very important, keep your arc length as short as possible. What you are trying to do is keep the slag molten until it floats up at the back of your arc and the short arc will minimize flaring. It sounds like you're doing pretty good otherwise. Don't get the rod real hot. Tom

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Pete

03-25-2000 10:15:45

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Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Tom from Ontario, 03-24-2000 18:38:58

If you have been spoiled by your mig welder, why not use a cast mig wire. I guess you were not aware, Certanium makes the only cast mig wire on the market. It is also a straight wire, not a flux cored. It is Certanium 889M and it is beyond compare

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Steve U.S. Alloys

03-27-2000 05:38:51

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Re: Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Pete, 03-25-2000 10:15:45

Hi Pete,
That name Certanium caught my attention. U.S. Alloys also has a machinable cast iron wire that can be had on either a 5# or 25# spool. It is less expensive and satisfaction is guaranteed. It is called #925. 1-800-325-1568
Steve

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Bill in Mich

03-25-2000 22:51:24

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Re: Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Pete, 03-25-2000 10:15:45

Tom, Could you please tell us how to get a hold of Certanum Company? I have a turbo housing on my A-C that is cast iron and this stuff sounds really good. What do you use for shielding gas? Many thanks, Bill

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Pete

04-01-2000 11:06:56

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Re: Re: Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Bill in Mich, 03-25-2000 22:51:24

Certanium can be reached @ 1 800 458 3222

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truck

03-25-2000 20:03:06

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Re: Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Pete, 03-25-2000 10:15:45

Who, Me? unaware? Nah! Hey did that Ford guy ever get out of the White house? Seriously, what gas does this magic stuff use? And does it require preheat? Can you get it in .030" diameter? Thanks for the update!

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Pete

04-01-2000 11:23:02

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Re: Re: Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to truck, 03-25-2000 20:03:06

Certanium 889M requires 98% argon 2% oxygen, and comes in .035, .045, and 1/16 diameters. If the metal is less than 1" in thickness preheating is not necessary, but it should be welded in a back step skip fashion. IF you contact your local representative they will be able to show you the product and the best procedure for application.

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truck

03-24-2000 19:09:11

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Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Tom from Ontario, 03-24-2000 18:38:58

It is real hard to angle the rod at all in the bottom of the hole.. Any angle tended to make the rod flash to the sides of the hole where it went in. I ended up going almost completely vertical.

The short arc length sonds good.. would I need to go higher or lower on amperage to keep it short as possible? I was running 75-100 with 1/8 rod, which seemed a little high to me. Any lower and I couldn't control the arc well enough to keep it going. Keep in mind that all my arc welding experience was in trade school in the early 80's and I've had a MIG welder ever since.. Lots of relearning to do. ( I used my Miller Thunderbolt gas power welder on the Cub parts.)

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Steve U.S. Alloys

03-27-2000 15:01:45

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Re: Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to truck, 03-24-2000 19:09:11

There are SMAW electrodes for cast iron that do not side arc. They are made for applications in recessed areas. Mine is #923 if you are ever interested. You can view it on our site at Link

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Dusty

03-26-2000 07:09:21

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Re: Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to truck, 03-24-2000 19:09:11

How about using the powder spray with acetylene torch by US Alloys?

Dusty MI

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Steve U.S. Alloys

03-27-2000 15:29:19

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Re: Re: Re: Re: Welding down inside a hole without slag: CAST IRON ?? in reply to Dusty, 03-26-2000 07:09:21

Hi Dusty,
Thank you for your referral. It is greatly appreciated. Steve

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