Another broken casting....

[yorkiepap]

Hey guys,
Here's another broken casting that came in that was caused by another woman driver on her cell phone yadda...yadda...yadda instead of paying attention. This is a base/pedestal for a cast mailbox that is threaded at the top for the mailbox to be screwed down in place. Fortunately for my customer, the woman did stop to inform him of the damage & offered to pay for the repair. I finished it today & the customer was pleased with the outcome.

I've been doing all casting repairs with the Cold Welding Cast w/MIG process that has resulted in 100% success so far. I used .030, 309L, 98/2(AR-CO2), at 80A for this job. The customer had both pieces lightly ground clean to get a good look at the break so all I had to do was wire wheel the metal clean & put a .045 bevel on both pieces. The break fit together quite nicely & I did a very small tack on opposite sides to hold. Then I ran a 1" bead on opposite sides. The casting was only luke warm to my bare hands after welding. I allowed to cool for 15 min. & did another (2) 1" beads, again on opposite sides & repeated this process with 15 min. intervals. The casting never got more than luke warm to the touch & NO TINKLING of the casting so I knew it was solid with no cracks. Hope this may help someone. Here's the pics.

Denny

[Monte55]

nice job man

[aametalmaster]

Nice work...Bob

[Zrexxer]

so all I had to do was wire wheel the metal clean & put a .045 bevel on both pieces.

Now that's a small bevel!

[yorkiepap]

Hey Zrexxer,
Yes, that would seem small, although, with a .045 bevel on each piece, the .090 "V" provides a really good start of the .030 wire & puddles quite nicely to flow into the joint. It has worked nicely on other applications as well. Sometimes, minimal works best.

Denny

[Zrexxer]

Ahh I wondered about that... I thought you might have done something like I tend to do, like thinking 45º and typing .045.

[B_C]

Wow another light pole guy.....hahahaha I repair the city's broken light poles all the time myself....BUT theirs are aluminum.......

[boykjo]

I have a 1998 murray riding mower and the front axle assembly is cast and it broke in two and also has a crack about 4" long from the bottom to the top. I havent figured out what process (Stick, tig or braze) I am going to use to repair it being it will be under heavy stress.

heres a pic of what it looks like

http://www.quickieparts.com/murray-p...-assembly.html

It sits in my house whispering to me "I want to be fixed" and I keep putting it off.

I"ll post the prep and repair with some pics when I get the urge to tackle it.

[B_C]

I have good results with Ni Rod Nickel 99 (Tig ) On cast iron. If it's cast steel just weld it with you mig or stick I guess.... I'm not a stick welder so maybe someone else can add to that....Good luck ...

[boykjo]

Its definitely cast.

I never tigged cast iron. Will it create a puddle on the cast and add the ni rod nickle as filler like regular tigging or will it melt the nickel to the cast iron and fill as in soldering?