Welding A Diesel Cast Iron Engine Block with Muggy Weld 77 Arc Electrode

This Yanmar diesel cast iron engine threw a push rod through the top, leaving a large hole in the cast-iron block. For this repair, Muggy Weld 77 arc electrode and 2% lanthanated tungsten with 17 lbs argon was used. Most farm tractors would not have survived a cracked block, let alone a hole in the cast block you could put your fist through.
The welders at PDX TIG Welding in Portland, Oregon, employed a mild steel plate to weld to the cast iron engine block. Cut the steel slightly smaller than the hole to use the 77 rod's elongation as a buffer between the cast iron and the mild steel. The same block can be stick welded using the 77 with AC or DC Reverse electrode positive.
After removing the coating from the 77 rods by dropping them in a bucket for a few hours, tack welds were used to secure the steel plate in place before adding 1/2 inch welds throughout the weld area-- making sure to cool for a minute or two between passes.
Peening is always helpful, as well as heating the block, so it doesn't cool too quickly. When TIG welding with the 77 electrodes, it is advised to bring the cast iron to a bright red, then add the rod just before the cast puddles. The 3/32" diameter is most popular when TIG welding cast iron engines. Wood ashes packed over the welded area will help the cast iron cool slowly.
Try the 77 electrodes on injection port cracks on 2002-2004 4020 Branson tractor cylinder heads.
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#heliarccastiron #tigweldtractorengine
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