TFS: Cast Iron Weld Repair with Aluminum Bronze

Just a quick vid on TIG brazing cast iron with aluminum bronze. If you need more detail like we usually do - say so. We just might get deeper into the subject....
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[@denniswhite166]

Justin as a welder of over 50 years I want to say you are a very good explainer of what you are doing and what to do. IMO you would make a great instructor.

[@denniswhite166]

PS - I'm still watching - LOL

[@jeremymatthews5169]

His name is Justin lmao

[@denniswhite166]

@@jeremymatthews5169 Changed - thanks.

[@colebz420]

Jason?

[@denniswhite166]

@@colebz420 I had wrote Jason first by mistake but Xzempt corrected me so I edited my comment and fixed it.

[@dustinwolfe9591]

Weld looks perfectly functional. Plus props for not being afraid to post a rough one.

[@dustinwolfe9591]

*braze

[@NilsJakobson]

Best channel on welding, explains things very well for newbies like me. I am going through restoration process of an old valve resurfacing machine Kwik-Way model P from 1930ies era, its all made from cast iron and there are several delicate pieces broken, also several cracks in oil collector pan etc.. Will try TIG braze it back to life. Thanks for the educational videos.

[@FCP32]

Thank you. You do a great job explaining the process. I took a welding class and you explained things better than my instructor. I am grateful that you share your knowledge and experience. Thank you!!

[@rudyrayaaw5138]

I have yet to get Aluminum Bronze to flow how I like it, thanks for the demo. I have a customer that brings me 3 or 4 toyota 22R pick up turbo manifolds a year that all crack in the same location. For those I do the same prep with much more pre-heat and use Nickel 99 stick rod with the flux cleaned off with a wire wheel and TIG it on AC just the same. When finished they look surprisingly good, similar to TIGed steel and they never come back. Thank you again for the great content.

[@razorworks9942]

Hey young man, like someone else posted, I've got a few years and knowledge behind me in this trade, and I appreciate your approach and attitude towards this one. After 45+ years under my belt, I learned something from you! Aluminum VS. Bronze.... Thank you for sharing, I too think you would make a very good instructor! Cheers, Razor!

[@FixItYerself]

Thanks. First exhaust repair I've seen done on KZbin that looks like it will last. Such a pro

[@erniehenshaw4066]

Nice Job and instruction Justin. Bravo.

[@ORflycaster]

Very educational. The exhaust manifold on my 4cyl Tacoma cracked 20 years ago and I had the local ag welding shop try to fix it rather than buying a new one. I think they braised it, but can't remember after all these years. It lasted about 25 miles before cracking again. After a brand new manifold also cracked, I replaced it with a stainless header that also boosted my torque a little.

[@classicrestoration]

Good explanation on how and why this technique works so well. While it works well on old and dirty cast, it works even better on new and clean material. With the right conditions, it can have a bright polished gold look.

[@hashemmi24]

I love your voice on the voice over! Subscribed, and now I'm going on a trip through the old video

[@Turbo44mag]

I Love the way you groove the crack, an old school deep weld that will hold to more surface area.

[@JimbosGarage]

Nice work Justin, I am going to have to try aluminum bronze, I have only used silicon bronze.

[@TheFabricatorSeries]

Gibe it a go! I like it more than silicon bronze at the end of the day. The "gold" is 10x more lustrous (and it's a bit stronger).

[@DCweldingAndArt]

Yep, gna have to get a pound of that stuff. Also thinking about trading my Everlast 210EXT out for that HTP 221. Good idea? (I want a better, more controllable AC arc, and spot timer) seems that HTP gets better reviews than the everlast 350ext, already got basic Dynasty 280 for high amps

[@smederijstruik]

Normally I use dc for this, next time I will try the ac settings, thanks. For me dipping my rod in borax powder makes the bronze flow even better and makes the dirt flow on top of instead of in the bronze.

[@Titantramp4u]

Very informative video!...I've done a fair amount of Silicon Bronze but knew nothing about Aluminum Bronze. BTW It never occurred to me to ding you because the repair "didn't look good"..Thanks for another great vid!

[@chadmoyer1453]

People say I'm verbose sometimes. But at least when I explain something I leave them without understanding. Good job taking the time to explain.

[@chrisfournier6144]

Great explanation of this technique.

[@rjuarez4913]

Thank you again!!! Thanks for all the explanations of the whys for your decisions on this weld. Awesome!!

[@robr4662]

Good video! I have used silicon bronze for this type of repair as well.

[@mWaffen]

Great review, but need to stipulate the need for Argon. thanks again!

[@reneguay1347]

I still enjoy welding cast with the old torch and brazing rod

[@Peter-V_00]

I've made similar repairs on cast iron but used a bit of a different method to prepare, before grinding along the crack drill a series of 3/16 holes along the crack without breaking through, now after grinding you will have a much larger clean purchase to put the bronze in place, not only does it provide more adhesion but also gives a greater amount of bronze joint width to give a less rigid seam reducing the chance of another crack developing.

[@TedCookHVAC]

Great !!... I have done it with a stick welder about 100 times.... I am going to do my next block or manifold this way and see what I get. Thanks for the great video.

[@yewwtooob]

Yes, I get the bevel. Everyone says to preheat cast iron, but I never do. I heat it as I go. I use pure argon and slow down the wire feed speed so I can "ball" it and dip it. Works great with aluminum bronze and silicon bronze as well. Never had one break near the weld. Ever. Argon or helium only( if you're rich) and slow heat up. Also, it wets so well, I never clean up, lol.

[@ypaulbrown]

Justin..have used this material on lots of cast iron...anzing how strong it is if done correctly....thanks for sharing this great tech to the world...best regards...Paul

[@daviddefer445]

Well explained , Well Done ! Push/ scrub rod into weld pool and try to keep arc on the wire / weld puddle . Similar to gas brazing, flux will also help.

[@ryanwolfe911]

This is interesting, I've never thought about using aluminum bronze and a tig. I've always heated my cast in an oven, welded it with a nickle rod and then stuck it back in the oven to cool slowly. I'm gonna have to try this.

[@Turbo44mag]

That is the way I was always told to do it, just and tack.

[@Equiluxe1]

I found that pure copper is best for repairing cast iron, discovered this when I had the job of repairing 150 year old Victorian cast iron ram pumps for a client. The cast was so full of carbon and other inclusions that I was having trouble with both Aluminium and Silicon bronze filler I had some 99.9% pure copper filler from another job so I tried that and it just flowed straight in.

[@hjvisagie]

Will try that also, Tx

[@splinky99]

I weld and braze with alu bronze pretty often, and have found that it works best for me at about 80% EN, a little more than you were using. And the A2 alloy works better than the other alloy. (Just trying to help)

[@dumbdog2924]

I did a little bit of bronze brazing when I was down in Mississippi at the Seabee training center down there. It’s definitely a wild thing to use and try to get used to.

[@gmoose777]

great video I have some welding experience but mostly stick and gas so learning all the time. Three suggestions for the repair unrelated to the brazing directly, 1 if you have an ultrasonic cleaner in the shop it will get your crack cleaner, 2 I noticed you preheated the general crack area with the propane a more thorough preheat and a post heat will help reduce re occurrence, 3 while you have the burr out clean all the casting dags off as this will also help stresses travel through the casting and reduce the chance of more cracking, probably irrelevant because I see a set of custom headers in its future, or an ls3 cheers for the great video and explanations

[@051570orion]

Good video , I had a 1995 mighty Max , fun little truck to drive , miss it but it spun a bearing and didn't have time to fix it so had to get rid of it .

[@dudebro2288]

Used some today repairing jaws to an adjustable wrench! I’m impressed with how strong it actually.

[@ChrisKartes]

Fighting Fire with Fire is an Aussie move. 👍👍

[@paulbernett1581]

Justin your a great Teacher. Have you ever Tried Half argon & half Helium. Talk about a Wet & flowing Puddle. the extra heat is amazing. It also works Very well on all Copper.

[@joeolejar]

I had the same kind of crack on a Geo Storm. Grooved and drilled it just as you did. Preheated it on the grill. Tig welded the crack. Lasted some 7 years until a teenager Tboned it.

[@LPMutagen]

I had 3 of those trucks. A 90 2.4 with a home brew supercharger, a Carby 87 2.0 and a Carby 88 long bed D-50. Miss em.

[@lwrdinu]

I can't wait to see what you have in mind for the truck!

[@lewisreid7031]

Fantastic, nae scary . Had Aluminium Bronze rods for a while now but you have helped me understand some of their advantages in a really easy manner.

[@williamh6547]

Great video, thanks for the STRAIGHT FORWARD TRUTH👍👍

[@SteadArcFab_Ministries]

Sweet video Justin! I was wondering the difference in bronzes! Thanks man 👊

[@bobbyboykin7137]

You think like I do, great video and solid repair.

[@joshuasherman3892]

Pretty neat stuff just did a cast iron manifold! I will have to try out aluminum bronze!

[@MullnerFab]

I always watch til the end. Got to make sure I don’t miss anything haha

[@djlinux64]

This is going on a manifold. What is the typical operating temperature of this? The service temperature of brazing alloys is under 500F. Copper and copper-zinc filler metals are generally used on ferrous metals. They can also be used on many nonferrous metals. The upper service temperature for these alloys is 400°F (200°C)

[@1970chevelle396]

Great to see Cast Iron Welding. I've never had good luck with welding cast iron.

[@chrisjones6165]

Lots of ways to skin a cat this cat just takes lots of prep work and steps

[@southjerseysound7340]

This is more brazing than welding,but I've found it's one of the best ways to repair cast iron when you can't use stitch n lock.

[@garytodd5605]

Keep trying you will get there. Get as clean as you can possibly get it. I personally can do a better job with oxy acetaline. Seem to be able to control the heat better. I still use Tig on occasion. I really need to use the Tig more on this type of repair just to improve the Tig skill. Not everyone wants to mess with cast repairs. After welding I put repaired part in a bucket of sand for slower cooling.

[@southjerseysound7340]

@@garytodd5605 good advice and if someone is looking for help brazing I'd recommend Keith Fenner's videos. He is the is the KZbin brazing king and really dialed his camera in to get some great shots. He did a hub repair series that had some great information on it.

[@ignusa749]

one of the things i did not see what is the argon flow setting? and well done!

[@AerialLensVideo]

Really well done - THANKS! EDIT from below -- Is aluminum bronze good for cast iron to under 1/4 inch thick steel? Great instructions following the Key Rule: You have anticipated and answered ALL of the inevitable questions, VERY well. Thanks again - you saved me a bunch of time.

[@petermccuskey1832]

Thank you very informative. Never Al bronze but going to try it

[@johnmathews3027]

Once again thank you for taking the time to show us looks very good

[@gusfoundry9093]

Another premium video !!! - Light-bulb moment for me Thanks HUGE!!!

[@sacrificialrubber779]

I just started TIG welding...like 3 hours worth!😂😂😂👍🏻Love the vids! You helped me make my decision to buy a AHP 200!🤘🏻🤘🏻🤘🏻

[@austinburtch5972]

Real world situations, I dig it. And I like the mighty max. Time for a 4g swap video lol

[@markbreidenbaugh6033]

You should have.... But if you.... You could have..... But I can..... You should have!!!!!!!!! Awesome Job Man thanks for sharing!

[@atiaaatiaa56]

Ithiz goud edeya your the best

[@123suzukisamurai]

Nice. Thanks

[@tomherd4179]

Easy to follow lesson and presenting reasons why you did what you did. Question about the finishing the braze. I guess if one were doing it for "show" it should be ground down, cleaned up, etc. But if it was wholly for repair could you have left it as finished after the 1st pass braze. Or should a 2nd pass be made to blend it in more?

[@donnyo65]

Thank you for demystifying this - great video.

[@hjvisagie]

Learned a new skill now

[@thewayidoit8895]

It's beautiful!

[@asmithh2697]

Awesome. If someone has a question, where can they send it? Thanks

[@vidlangers]

Awesome vid man. Can't wait to see what else is in store for the truck😉.

[@MadMaxx570]

Liked for the brazing, followed for the FIGHT FIRE WITH FIRE wisdom hahaha

[@matthewbrown5677]

Cool stuff ....l have to weld a flywheel/ pulley.... Thick Cast iron part does not get hot ....l have silicon bronze in the workshop.... Or should l buy Alum Bronze??? Precision Panel Craft.

[@conradnudd7398]

I brazed Manifold one time and found out the hard way that it does not work, and that I did with a torch, I’m just wondering if the bronze part of your filler rod presented any issues? If I have the chance I’m going to try it for my self, it does look very promising, thanks for the information.

[@OMGTHATSTHEGUY]

Can you do a stainless steel to cast iron tig video? I've been seeing guys weld v-bands to the hot side of turbos for external waste gates. Thanks.

[@lipton6996]

Excellent video

[@MrBryant252005]

Thanks bro...for explaining that really helped me out a lot Nice job👍🏾

[@ZILAwelds]

Tig brazing and mig brazing - the argon takes the place of the flux that you need when you oxy fuel braze.

[@TheFabricatorSeries]

That would have been good info to add I reckon. Hopefully I'll remember if I revisit the topic (credit to you of course)

[@mrgreenswelding2853]

@@TheFabricatorSeries yep Pete know his stuff too. If you dont follow him you should.

[@barryhorne7052]

@@mrgreenswelding2853 Where would one find him ?

[@mrgreenswelding2853]

@@barryhorne7052 click on Zila above that Peter Zila's channel.

[@gordowg1wg145]

I've only oxy-acetylene brazed, with flux - while you don't need it for preventing oxidation reactions, wouldn't the use of flux aid the cleaning/floating out action on remaining contaminants in the crack?

[@djlinux64]

Nice vid but minor nit. This is a demonstration of braze welding which is not the same as brazing. You applied the arc directly to the filler metal. If you brazed you would heat the target and the filler metal would melt on contact and flow in via capillary action. It is not possible to braze with an arc because you need to generate large heated area.

[@mattaluoppal]

Big project without name? It's got to be "Mitsubig'a'project"..haha. Thanks for good advice about al.bronze.

[@stephen271]

Thanks for another great video with great info

[@unclecowboy2003]

Hi I’ve never been taught how to weld professionally my dad just turned me loose when I was young I’ve welded cast with a gas torch and silicone bronze and had it stick well do you ever fix any cast with the gas torch and if u do I was wondering if you had a video on it so I might learn proper thank you for your time and everything

[@justinmanthe3929]

Hey Justin, quick question for a newbie TIG welder. Can you bond steel to cast iron, such as a steel manifold bolt to the manifold? Thanks for any help you can give!

[@JCMakerspace]

Spot on Justin.

[@stephengriffith1605]

Love it great welding can’t wait to see what you do with the project. Keep up the great work

[@dekebell3307]

Very cool. Thanks for sharing!

[@donngrimes6179]

Thank you for explaining why you used aluminum-bronze over silicone-bronze. That said-isn’t it possible to use AC with silicone bronze or is there a reason that would be taboo?

[@davidcraft4909]

Thank you for saying silicon bronze in the video. The whole time I was watching I was trying to think of that name. my brain was going magnesium bronze no, titanium bronze no, those probably don't exist but I was just trying to think of it. Do you think this stuff is good enough to attach steel pipes to a cast iron exhaust manifold that will be used for a turbo ? I know its strong enough but will a turbo manifold get hot enough to melt it. I guess i could just look up the melting points and then guestimate how hot the exhaust should get.

[@kooldoozer]

Every time I try and TIG braze with aluminum-bronze, I get a little blow out with this green-blue flame which is, I think, the zinc coming out of the alloy. I have no problems TIG brazing with silicon-bronze what so ever. Any idea what I may be doing wrong ?? --Doozer

[@TheMadJoker87]

love the explanation, genius me tried this once on my grandpa`s 55 fordson thames, but used bronze filler meant for gas welding (it has zinc in it i think?) lets just say that didnt go so well...

[@robostyle9773]

Great vid thanks for posting!

[@AndreasR1]

What are the (dis)advantages of stick welding for this project? I hear stick welding is often preferred for cast iron.

[@thomashightower1660]

Thanks! Great video!

[@randallmercer4995]

If the manifold had a hole in it, say the size of a silver dollar, would you fill the hole by running beads around the perimeter until the hole was filled, or could you use a piece of mild steel to fill the hole, and then use the aluminum bronze to secure it? And, in your opinion, would either of these choices be a long term successful repair?

[@j.d.1488]

Wondering if this will be a good technique for repairing a vise with a missing jaw shelf. Material needed to attach to create missing piece.

[@jamescullison2148]

JUST AWESOME!! THANKS FOR SHARING!!

[@thinkingmanhillbilly]

Have you ever done any work with a "Cobra" oxy/act torch? I have seen guys weld aluminum with one they seem to work pretty good, there good for making dry sump oil tanks because it anneals the weld as it goes so they don't crack as bad.

[@richardsolomon8076]

Thanks Justin, gr8 video

[@one4stevo]

Two thumbs up great job explaining

[@Akya2120]

First of all, love the videos. You have taught me quite a bit about welding and I appreciate it greatly. My question, would it be a bad idea to drill a few more small holes at angles to essentially give the brazing rod more places to bite into and hold onto the cast iron, or is that completely unnecessary? I'd suppose if this had a turbo it might be more important for it to have a stronger hold on the base metal. Just a question that popped into my head while watching this. Looking forward to more videos of your mighty max! I'm the same way with the OBS Fords... Although after working on one for a while, I completely understand some folks hate for Ford lol. They just had very little clerical skills, or common decency with their building methodology 😅. Thanks again! Edit: just noticed this is two years old LMAO whoops! You've already taken this apart and are building a tube chassis 🤣

[@ChrisWojnarski]

Thanks for the great video Justin 🍻🙏

[@alasdairdavidgray7316]

Great video, how about building a tube manifold?

[@madcapmagician6018]

great vid, but could you show how to weld cast iron? i have been told that it can be done by pre heating the cast iron, then using mig process with er70 s6 in very short stretches no longer than one inch at a time then pern the crap out of it, wait for part to cool then repeat i have not welded cast iron only read about it, so i an interested.

[@TheOldKid]

Everytime i try tig brazing i have mini explosions happen. With or without gas, heat parent equal to filler or focusing on filler doesnt matter what i try. Ive tried the type with white flux and bare type. What am i doing wrong?

[@paulmorrey733]

Thanks

[@bruced1429]

very good idea for filling that crack. I was wondering if you have ever tried oxy hydrogen brazing? I recently started it because it is very clean ( jewelers use it) it is not as hot as oxy acetylene but produces no impurities but water which evaporates . you can use flux coated rods or pure aluminum. I have not tried your method for cast steel, I just use Arctec cast 90 rods dcen . I may try aluminum bronze now .

[@bruced1429]

@@barryhorne7052 yes oxy Hydrogen is very clean and it seems to clean the area as you move along.

[@Nicknacktheking]

Interesting thanks for the info!

[@rdtaylor8585]

Awesome stuff, I have a cast iron block from a 2005 new Holland tractor ,broke on lower corner ,leaking oil through it,the corner of the baseban supports it,I just paid a hold lot for tractors put 5rs on it and now this,roughly a 5 inch crack that goes off on each end to the base pan.any suggestions ,braze it or JB weld

[@Edcm85]

JUSTIN IS MY HEROOOOOOOOO!!!!!