Tig welding to cast iron

[Pete.]

I have two of these end housings on my grinder. The machine was a very early model and they made the housings top edges too low, so oil that is supposed to be contained and allowed to drain away internally spills over the edge. Looks like the factory fitted these two brass strips to raise the edge (this is a 1940's machine so fit and finish weren't top of the agenda as well as materials being in short supply). The strips still leak so I want to do something more permanent.

Basically I want to bend up a strip of steel or stainless and tig-weld it to the top edge of the casting to raise the edge by about 6-7mm. What are your thoughts on this? Another option is to re-make both the end housings from aluminium block.

 

[Chris Stevens]

Tig brazing will work perfectly. Only downside is the rods are quite costly, but you will find them very useful.

 

[Pete.]

But not welding? Someone has welded one of the handles and made a nice job of it.

 

[Wallace]

How about using Sikaflex or an Epoxy glue?

 

[Shox Dr]

I've used Sif No8 in the past, works a treat.

I'd tack it, and seal with mastic

 

[Pete.]

well, after giving it some thought I've decided to build up the edge with weld and if that doesn't work I'll make new ends. I'm going to use 309L and run a stack of runs to gain about 6mm in height.

 

[Screwdriver]

If you do weld it remember those welds are going to be glass hard so if they are messy, you'll have to grind them off with a stone.

 

[Tinbasherdan]

Some cast is better to weld than others. I did an eccentric cam for the valve gear on an ancient stationary engine, and it was like welding Swiss cheese, full of air bubbles

 

[Pete.]

First one done. Don't think I'll bother cleaning it up except for the gasket face.

 

[Richard.]

First one done. Don't think I'll bother cleaning it up except for the gasket face.

View attachment 77043

Might crack. Stainless filler isn't a good choice for cast iron. Had I read this sooner I would of suggested a Ni/Fe filler for cast iron. I would of sent you a few too. I still will if you want to do any more. You'll certainly need them if that 1st one cracks.

 

[Pete.]

Yes it has a tiny crack at each end where the first weld went on. Din't crack until a later pass though. I ried to go fast and keep the heat input down. Ican live with how it has come out since it's only holding back a shallow puddle of oil and the paint will stop it seeping.

 

[Richard.]

Yes it has a tiny crack at each end where the first weld went on. Din't crack until a later pass though. I ried to go fast and keep the heat input down. Ican live with how it has come out since it's only holding back a shallow puddle of oil and the paint will stop it seeping.

Ok well if it runs let me know and I'll send you a couple ni50 rods to repair it with.

 

[Windy Miller]

I have some Tig brazing rods if you need any Pete...

 

[TechnicAl]

I was going to say........if its cast iron welding should be the last resort..........but it was done

Who knows what you get when you use 309...........possibly fully austenitic with all that carbon but probably a bit mixed.....fully austenitic also suffers from cracking........Id choose mild steel before 309 but the Ni or NiFe are the best.

Personally I think TIG is the worst process as its too hot unless you preheat and then your hands are too close to the hot casting.........but it looks OK so what do I know

 

[Chris Stevens]

B

I was going to say........if its cast iron welding should be the last resort..........but it was done

Who knows what you get when you use 309...........possibly fully austenitic with all that carbon but probably a bit mixed.....fully austenitic also suffers from cracking........Id choose mild steel before 309 but the Ni or NiFe are the best.

Personally I think TIG is the worst process as its too hot unless you preheat and then your hands are too close to the hot casting.........but it looks OK so what do I know

Seemed to me TIG brazing some steel strips on would have worked perfectly, and I would guess cracking at some stage is very likely, which would kind of defeat the purpose of modifying the part in the first place?

 

[Pete.]

All advice gladly received. Well the job is now done and fitted. On the second one I put large blobs on the ends first and they haven't cracked but the run of weld did in a couple of places. I just washed over them with the torch - there's no need for strength here it's just raising a lip to hold back the oil pond whilst it drained.

The resulting weld filed quite easily where I had to add some relief for the table.

 

[Pete.]

Video of grinder running:

Jones & Shipman 540 grinder

 

[Maker]

Video of grinder running:

Jones & Shipman 540 grinder

That is awesome, I didn't know they were automatic. You wouldn't happen to have any pictures of the mechanism inside?

 

[ronan]

Doesn't look like a 540 to me, it must be an early version. Wasn't the design american ? Given to J&S for the war effort or something like that.

 

[sardine]

The iron oxide dust that builds up on a grinder makes good Thermite, mixed with fine aluminium powder.

Carry on.