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What's your Advice

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Pete

03-15-2001 15:56:56




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I'm not sure what approach to take on this job: I have a small cast iron air pump that runs off a tractor's PTO who's cylinder is cracked from top to bottom on one side. The grey cast iron is 1/4" thick and the crack runs for 7". The crack seperates the pieces by about the thickness of a piece of paper. I can work on the outside of the cylinder, but would have trouble doing any work on the inside of it. I can think of three ways to fix it that are probably within my limited skill level. I could:
1) Braze weld the crack with my torch, although I'm not sure exactly what the best rod or procedure is.
2) I could use my wire feed welder (without gas) if that would work, or 3) Forget welding the crack and instead wrap a steel band or two around the outside of the cylinder to draw it back together again.(perhaps use some type of gasket sealer to make it air tight) I don't have any way to fix the bore of the cylinder if I mess it up with my welding so that's making me think about the last option. What do you think?

Pete

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Jerry B

03-16-2001 08:21:38




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 Re: What's your Advice in reply to Pete, 03-15-2001 15:56:56  
Sleeve it just like you would an engine.

A machine shop should have no problem finding a sleeve to fit. It fact the bore of the compressor may already be a standard bore diameter for a popular engine.
This shouldn't cost a fortune.



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wrenchman

03-16-2001 01:00:27




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 Re: What's your Advice in reply to Pete, 03-15-2001 15:56:56  
if you go the band route,and have room.you could have 2 or 3 rings made up about 1/8in. thick & 1/2 to 3/4in.wide with the inside dia.about 20 or 30thousandths small,and heat them to expand enough to slip over cylinder.when cool they will contract and should pull crack shut with enough pressure to seal it.just a thought.:-)



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Tom

03-15-2001 16:27:28




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 Re: What's your Advice in reply to Pete, 03-15-2001 15:56:56  
I like your clamping idea. However since you can clamp it there must not be any fins or other irregularities on the outside. How about making another cylinder? From iron pipe, steel, or a chunk of cast iron purchaced from McMaster-Carr or a company like that? As for welding, maybe it could be carefully stick welded with nickle rods made for cast iron. I good preheat, slow cooling, and only welding a 1/2" or so at a time, peening the weld between welding, and being carefull to not burn through. Oh, Veeing out the crack some before welding too, but not enough to risk a burn through. Just my thoughts on the project.

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Joe Voytilla

03-15-2001 16:16:48




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 Re: What's your Advice in reply to Pete, 03-15-2001 15:56:56  
Pete: I have repaired many cast iron parts, some of which were actual machine elements, such as you have. But first I would like to ask a couple of questions for you to consider. What is the frequency of use? Is this air compressor only used once in a while? If so your suggestion to clamp it together might be the smartest. I would try this first without adding any sealant. Any sealant you add now will impact being able to weld it latter. If that doesn't work, you may also never reach the operating pressure you want, then consider brazing. I know of no mig or stick wire that works on true cast iron. It blows like you wouldn't beleive. WHen it comes to brazing the best choice would be a silver bearing alloy, although expensive. Below that a regular phosphorous/copper allow. Use lots of flux, apply the heat from inside the cylinder and apply the brazing alloy from the outside, this will draw the braze into the joint. Heating the entire casting to 1,000 or so will help speed the process, if you have that capability. One problem you will most likely have is distortion, the cylinder should be honed round after completing the repair, then you will need oversized rings. Damn soulds like you might well look for another pump. I suggest trying your clamp idea first.

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