Cast iron welding 101 - Can it be done" the easy way" ?!?

This is the wire I used
d3vypigyjoqnv3...
This is the welding machine I used
usaweld.com/co...
The torch I used
amzn.to/3urHM09

[@ThisOldTony]

nice work and great fix!

[@jays_metalworks9399]

Expensive wire tho

[@ZILAwelds]

Thanks Toni!

[@ZILAwelds]

@@jays_metalworks9399 but worth it if you need it …. That part i fixed is new almost 4 grand …. And i “only” used a few hundred to fix it ….

[@aktik6000]

Another great video about cast iron welding this evening (This Old Tony got one too 😄) It's nice to see how the pros do their stuff 💪 Thank you Peter!

[@ZILAwelds]

Thank you, i watched his video !!! Only difference he did the drilling, tapping and machining at the beginning …… lol

[@FreeRV]

Hi 👋 Peter! I thankful to learn about seven hundred a pound Jupiter wire and preheating technique! Make it so much easier than normally! Big thumbs up 👍 Great 👍 welding job and upload. Thank you for sharing. Keep growing and sharing!!👍

[@TimWelds]

Nice repair, Peter! That certainly beats stick repair rods followed by the old peen and pray. 😉

[@ZILAwelds]

Thanks Tim, yeah - sometimes even an old dog learns a new trick ... LOL. I would have never guessed it works so well myself ...

[@BMGProjects]

I always look to you for the specialty electrodes, wire, processes and other than mild steel welding.

[@matthewackerson7861]

I cringed at the price of the wire at first but I can see how this is the ticket saves a huge amount of time and money.

[@ZILAwelds]

Mg289 wire is also WELL over $100 per lbs …. This stuff here is sooooo much better, no slag, no excessive prep or clean up …. It saved HOURS!

[@rickolson9011]

Very impressive!

[@ZILAwelds]

The wire ?! I agree …. I was blown away ! I was used to the old school way and whenever i did a short cut things cracked …. This stuff here …. My reaction as i was welding was genuine … first time using this stiff…. Like i said: if they would have had it when i was a kid …. I think i could have made a lot if $$$ fixing a bunch of stuff

[@jackpatteeuw9244]

Most shops would do it the "old school". Pre-heat, tig braze, slow cool. Amazingly small amount of pre-heat ! Much faster. I am a bit surprised you did not gouge out the small cracks and re-weld.

[@ZILAwelds]

the small parts were just too small .. they look big on the screen but if you use my thumb for size reference .... there was nothing left .... and yes - I "old schooled" it for 20 years .... this saved me at lest 2 maybe close to 3 hrs and no handling of excessive hot parts .. etc ... and there is nothing wrong with old school .... this is just faster and most likely better ... more "fail safe" (if you would take the same care as old school) so this definitely give the less experienced welder a fighting chance and the guy who only does cast iron a couple times a year "the edge" over others ...

[@billarroo1]

I've only done cast iron with NI 55, or Oxy/acetylene brazing, but because I peen All beads and only do 3/4" bead at a time, I've had really good luck, even 3 years later there still holding up, now I'll try your new method, Thanks

[@DavidR8]

Fantastic work!

[@dark30welderwelding11]

Thanks for sharing your knowledge. Appreciate it

[@halledwardb]

Cool! Guess it all depends on the value of the repaired part. Weld look great!

[@ZILAwelds]

Yes - typically you only want to fix stuff that is “worth it” occasionally someone asks me about fixing a cast iron pan even en expensive one for upwards of 100 dollar …. And when they hear that my repair exceeds the value of a new one they are mad at me…. I say : go ahead, shoot the messenger … i mean even nickel stick rods go upwards of $70 per lbs !!! And mg289 wire for well over 100 i think about $130 per lbs…. And all the time of pre heating and post heating and fitting and doing …. You spend HOURS real easy …. This job here was over 5 almost 6 when it was all said and done Looks easy in a 15 min video 😂

[@halledwardb]

@@ZILAwelds Yeah. Especially if I put it on 1.5x. Lol

[@ZILAwelds]

@@halledwardb dont weld the cast iron too fast😳 it will crack !!!!

[@mrgreenswelding2853]

Nice work Pete.

[@ZILAwelds]

Thanks

[@Theboywiththedrone]

Every time I like your beautiful videos 🙋👍👍+FV

[@ZILAwelds]

thanks

[@eugeneanderson7984]

From a 40 year Master Cat Man. Nice work hold your head hi.

[@ZILAwelds]

Thank you ! And thanks for watching

[@89Ayten]

Believe it or not, because of its very high nickel content, 316 stainless wire works very well for welding cast iron.

[@ZILAwelds]

312 stainless work SOOO much better than 316 .....

[@nchannel687]

really good job❤️

[@DirtyBikerbits]

I'm honestly surprised by how much weld you laid down on the back side in a single pass, I thought you'd had to do less than 1 inch beads then peen between passes to limit hear input. If that works/holds up and is legit them it's an absolute game changer. Is it nickel wire? It sounds a bit like silicon bronze wire I've run before, not the worst arc stability but not the best either.

[@ZILAwelds]

yes - I am surprised too .. normally I weld 1/4" ... 3/8" might break already unless it is preheated like a maniac !!!! YES it is holding up and yes it is a game changer ! this part is in use now for almost 2 month ! typically a cast iron repair gone wrong shows its ugly face in the first day or 2 ... it is a "largely nickel based" wire.... so silicon bronze or aluminum bronze .... and no, I dont know exactly what is in it ... that is "their" "secret sauce" they won't reveal that .... but the main ingredient is nickel....

[@DirtyBikerbits]

@@ZILAwelds good shit mate, cast iron is a pita at the best of times.

[@tubeonline629]

I wonder how well it can be controlled on a vertical piece, something that couldn't be turned to a flat position?

[@ZILAwelds]

Not sure, the spec sheet said out of position and it felt really good as if it would run good out of position ….

[@tome2sound]

How did the wire feeder screws rust at 1:32 ??

[@ZILAwelds]

Severe abuse …. Using machine in the rain, not drying it, not keeping things dry,clean and lubed …. Its steel with a black oxide coating just like miller … the stuff inside my 12 vs rusts too

[@Fix_It_Again_Tony]

What alloy is this wire? Is it NiFeMn like Royal 44-30? The datasheet doesn't say.

[@ZILAwelds]

I dont know exactly. That is their “secret sauce”. All i know it works really well!

[@matthewisaac6895]

Peter have you ever tried Crown Alloys Royal 44-30? I haven't but people seem to rate it too.

[@ZILAwelds]

I have not tried that myself, whats have tried is generic NI55 and NI 99 stick and tig as well as MG289 stick and mig (this is a cored wire), affordable alloys cool cast, lawson products coronation ??? cant remember the exact number but its made by MG and some different Rockmount Products (in the past I have used a lot of Rockmount Jupiter A and AAA stick, this was the first time that I used their mig wire. that being said their stick rods work really well but this wire is REALLY knocking it out of the park ....

[@skeetersaurus6249]

It would be VERY hard to justify $180 a pound for MIG wire to fix cast iron. Most professional welders who do weld cast iron (with any experience) will recommend SMAW with 7018 rods (properly stored)...keep in mind, the hardest part of welding cast iron, is keeping the carbon out of the weld zone...which is what causes the cracking to happen. A recent introduction into 'cast iron SMAW' is using 'cast iron coated rods', a predominantly-nickel content rod with a high-carbon cast outer. Likewise, a 'graphite coating' rod could potentially shield the weld zone some...but just like gas 'brazing' or 'muggyweld fixes', I'm VERY dubious when you're not creating an actual metal pool to accomplish a weld. Personally, I'll take the 7018 path, and keep the heat zone controlled (with appropriate pre-heat). Some have even used 6010/6011 and 6013's...but due to the pre-heat area requirements, combined with high possibility of warping, you really just can't beat SMAW with 7018.

[@ZILAwelds]

Well, there is always "that guy" who can weld earthing on the planet with 7018 .... LOL. and y9ou seem to be more talented or luckier than me when it comes to welding everything with 7018 .... either I am not as good or not as lucky - glad it works for you !

[@gillihansmobilewelding]

​@@ZILAwelds Haha, maybe it's because you're an actual welder.

[@jeremycable51]

Did I see a crack in the broken piece when you flipped it over?

[@ZILAwelds]

You some some void similar to undercut. Which in this application is not a big deal

[@jeremycable51]

@@ZILAwelds just was curious looked to be holding very well cast iron always turns out to be a pain in the ass this makes it look like cake

[@AshleyMckendree]

Was this for a carpet cleaning truckmount?

[@ZILAwelds]

No like a sewer cleaning truck / suction excavator

[@Jonathan-bf6nh]

Respirator might be a good investment

[@ZILAwelds]

Well, having one is part of the battle, wearing one is a different story

[@Jonathan-bf6nh]

@@ZILAwelds I hear that. Great welding video's, I have really enjoyed them. Keep them coming.

[@vandalsgarage]

Exactly. That's probably nickel alloy wire. Nickel oxide fumes are a known carcinogen. I'd check the safety sheet.

[@kamranehsan]

Hi there, does anybody know the exact composition of this material..

[@ZILAwelds]

No. These castings, they are pretty much always an “educated guess” …. THAT is what makes it interesting…. To lay a beat of weld on fresh material is not too hard …. But to “correctly identify the material…. And then chose the correct repair procedure …. that is a different level…. And in case you meant this high priced specialty filler…. Of course not. The chemical composition is proprietary so that you have to buy their stuff and no china man will copy it and sell it for cheap….

[@kamranehsan]

Thanks for ur reply. Although, the company must have the main ingredients of there material..

[@kamranehsan]

Likewise orlikon do mention there main ingredients for there all materials..

[@ZILAwelds]

@@kamranehsan this is what the company provides d3vypigyjoqnv3.cloudfront.net/app/uploads/2020/06/Rockmount_Jupiter-MIG_Mig-Wires-GMAW_Product-Information.pdf?t=1592507735 rockmountwelding.com/products/jupiter-mig-wire/ that is all they have to do by law ... as fas as the blower casting ? no clue who is even the manufacture ..... it was on a Vector suction truck but I have no clue who the blower manufacture is or what it is made from ..... it is a popular thing for aluminum boats manufactures to tell people what they used for their boats .... maybe even for aluminum semi truck trailers you can find some information here and there ... high end skid steer or excavator implements will also tell you .... everyone else keeps trade secrets .... and if its cast - they only write :cast not even cast steel, cast iron or anything else ....

[@ZILAwelds]

@@kamranehsan I remember when I used to live in Europe oerlikon gave good info ....

[@paulbernett1581]

You gona leave all those Dill Baryes ?

[@kenbudd3]

Did you use argon

[@ZILAwelds]

75% argon 25% co2 as per wire specs

[@mohammedtroy4296]

chucke2009 trained you well

[@ZILAwelds]

🤣😂

[@mohammedtroy4296]

@@ZILAwelds try tig welding using the same wire remember tig uses dc negative so 75% of the heat on base metal the cast iron wiil be heated while welding

[@dragonweldingfabricationll8080]

That's a lot faster and cleaner than stick.

[@ZILAwelds]

damn right Kevin ! and a lot less screwing around with excessive pre and post heating and handling a hot part all the time ... it shaves off at least 2 maybe 3 hrs !!!!

[@dragonweldingfabricationll8080]

@@ZILAwelds Send me the product info. Just text it to me when you can. Thanks.

[@mrgreenswelding2853]

Some times welding needs to be dressed. Even at my work some times we dress things not much but some times.

[@beemerkon]

Dude you have no idea "I'm watching " no you really have no idea you don't know what a pain it is normally. I bet that helper can give you a answer to every question you ask

[@okiedoke6373]

You don't know how much pain-in-the-ass this is normally if they only understood that they would understand exactly why that wires so expensive hastelloy and 309 you run into your own problems then high-quality cast rod is 20 $30 to stick anyway