Stick Welding Cast Iron Repair with Muggy Weld. Cast iron can be tricky to repair because it's prone to cracking. Follow along as I repair a broken cast iron exhaust manifold using Muggy Weld with no pre-heat. For this demonstration I used a 2 step process starting with an electrode that can withstand the dirtiest of cast irons followed by a cap that has excellent crack resistance properties. Although I believe a good pre-heat and a slow cool down will give you the best chance for success, i wanted to see how this rod would respond in a worst case scenario such as cold welding. It handled the thermal stresses excellent without any signs of cracking. This would be a huge bonus for parts too big to get a good pre-heat / cool down or for parts that are not cost effective to be removed.
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Broken Stud Removal in Exhaust Manifold
We have an exhaust manifold from a 64 Oldsmobile that has two broken and seized up studs that need to be removed, and also one hole that needs brazed up.
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.
The welders at PDX TIG Welding in Portland, Oregon employed a mild steel plate to weld to the cast iron engine block.
After removing the coating from the 77 rods by dropping them in a bucket for a few minutes, 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, it is advised to bring the cast iron to a bright red, then add the rod just before the cast puddles.