How to Weld Cast Iron

How to Weld Cast Iron

Titanium, ceramic, and stainless steel-coated skillets are popular substitutes for cast-iron skillets today. As a result, cast iron has declined in popularity, but its decline hasn’t been as severe as some have believed.  It is estimated that the market for cast-iron cookware will reach US$3,303 million in 2019, up from US$2,537 million in 2017. If you are a beginner and don’t enough know then we will guide you on How To Weld Cast Iron.

Additionally, Transparency Market Research estimates that the global Iron and Steel Casting market will surpass US$202 billion by 2026. There are still many applications for cast iron, such as cookware, worldwide today. First, you decide to weld cast iron, and you need to know how to do it properly.

How to Weld Cast Iron

Cast iron parts will save you both time and money if they are welded in the right way, even though there are several challenges to overcome. For example, cast iron can crack or damage when not welded properly. Now the question arises that how do you weld cast iron.

In many cases, a seasoned and professional welding technician must weld cast iron properly. It is particularly true when critical parts are involved. In addition, this guide will explain how to weld cast iron effectively to use them whenever you have a cast iron project.

The Applications of Cast Iron and Its Benefits as a Welding Metal

The cast iron industry has a wide range of uses. Here are a few examples:

  • Preparing water
  • Fittings for pipes
  • The cast-iron pipe
  • Utensils, pots, and pans
  • Equipment used in agriculture
  • Vehicle engine blocks, manifolds, and heads
  • A machine tool such as a cover, bracket, or base.

In addition to the uses listed above, cast iron metal is used in many other applications. For example, construction machinery and other applications with a high weight requirement are common uses for this technique. Do you know the benefits of cast iron? Here are some ways to use it. There are several advantages to cast iron weld metals:

  • Many desirable characteristics, including rigidity, robustness, thermal conductivity, and humidity control
  • With sand casting, it is possible to shape the object
  • Low-cost material
  • The melting point of steel is lower. Learn how to weld cast iron after you realize how difficult it is to do the
  • Greater fluid than steel

Why Welding Cast Iron Can be Problematic

It’s crucial to learn how to weld cast iron once you realize how difficult the task is because cast iron is usually only 50% successful to weld. This means you’re likely to have damaged or cracked cast iron when you’re done welding. What is the cause of this issue? It is because cast iron is made up of a variety of materials. It is therefore tricky to determine precisely how strong metal is.

A cast-iron piece also can have a hard time withstand how much heat before it cracks. In most cases, the high carbon content in cast iron is the primary cause of these three problems. During welding, carbon may transfer from the welding metal to the metal being weld or adjacent to the welding metal. As a result, the weld joint can become brittle or hard, which can cause post-weld cracks.

The Different Techniques/Methods for Welding Cast Iron

You can weld cast iron in other ways as well. The following discussion does not discuss different types of welding but precisely how it is done on cast iron. Several welding methods are also available, such as gas welding, arc/stick welding, MIG welding, and TIG welding. We will briefly explain each in the following paragraphs.

1. Gas Welding

Gas welding is much slower than arc welding for melting cast iron, as the heating process takes a much longer time. Additionally, this technique uses a flame that is lower in temperature than an arc. As a result, cast iron parts welded using gas welding techniques don’t suffer from carbon migration. Nevertheless, special gas welding rods need to be used for the process. This technique only has one drawback: significant components require a substantial amount of heat to weld. Thus, gas welding for cast iron is more labor-intensive than other welding methods.

2. Arc/Stick Welding

A more effective way to weld cast iron is by using arc or stick welding with the correct welding rods. Electrodes are available for all kinds of tasks. Electrodes are readily available, and the procedure is very straightforward. You can weld the cast iron easily by using any Best TIG welder under the 1500 price range. 

It is important to note that cast iron welding rods contain a special flux with a high graphite content. These special graphites are responsible for the chemical binding of carbon in cast iron. Therefore, the weld metal will not migrate into the heat affect zone in this way. In general, there are three types of cast iron welding rods: Pure Nickel, Ferro Nickel, and Ferro-Magnetic.

Ferro-Nickel rods are typically made from 47 percent nickel and 53 percent steel. Ferro-Nickel rods offer a superior alternative to pure nickel when welding cast iron to steel. Conversely, Pure Nickel is better for those who prefer softer weld deposits. For welding cast iron with an arc/stick technique, we recommend Ferro-Nickel, unless there’s a specific requirement for using Pure Nickel.

3. MIG welding

It is often used to weld cast iron, but MIG welding is not an excellent choice for this application. There is only a reasonable reason for using this technique for repeating applications for which procedures can be created. The following tips will help you weld cast iron effectively if you choose this method:

  • If you are using a MIG welding process, you should use specialty nickel wire. If you prefer stainless steel, it is quite costly. A cheaper alternative is to go with concrete.
  • An 80/20 rule usually works best in most situations. How does this make sense? Argon and carbon dioxide make up 80% of the mixture. If you are afraid that rust will eventually form on cast iron, you should avoid using this method
  • The use of studding can ensure a strong weld. Depending on the nature of the job, the answer will vary.

6. Manual Metal Arc Welding (MMA)

When the correct welding rod is used, this type of welding is also called shielded metal arc welding (SMAW), is often described as the best method for joining cast iron together. In addition to the application, the required color match and the degree of post-weld machining will determine the choice of the electrode. You can also weld Aluminum material easily using the Best Aluminum TIG welder.

In manual metal arc welding, nickel-chrome and iron-chrome electrodes are the most common types. The iron electrode will produce welding metal that contains a high level of martensite. In addition, a lower strength weld metal is another factor that can assist in reducing preheating and HAZ cracking in nickel electrode welds. Whenever possible, the melting of the parent material should be minimized. Therefore, keeping the dilution to a minimum will minimize the effects. 

4. TIG Welding

The most common reason that people elect not to weld cast iron with TIG is similar to that of MIG. What does this mean? Using this method, TIG is a process known for its open-arc design, carbon migration cannot be minimized because this process is an open-arc technique.

Also, it is an expensive process. The positive aspects of TIG welding include its capability to produce a robust and clean weld in cast iron. In addition, if you use the right setting wire and gas, you can use cold weld with TIG welding.

Having learned more about the different techniques, you now have the knowledge required to determine which is the best method to use. However, regardless of how you weld cast iron, you need to follow a few basic steps. In the following section, we discuss these steps in more detail

The Key Steps in Welding Cast Iron

It is imperative to get to know what steps are involved in welding cast iron effectively before you attempt to weld it on your own. A DIY cast iron welding project involves four steps. This procedure will allow you to produce an extremely durable cast iron weld if you follow it in the proper order.

1. Identify the Alloy

They are made up of a high amount of carbon, which gives them their hardness. Cast irons belong to the family of iron-carbon alloys. The cast iron metal is hard but loses ductility. As a result, it is much more malleable than wrought iron or steel. Miller Maxstar 150 STL is also effective to the weld cast iron.

The purpose of welding is to heat and cool the metal. As a result, the metal expands and contracts during the process.  Since cast iron cracks instead of deforming or stretching when stressed or heated, welding cast iron is challenging. Nevertheless, some alloys can help improve this situation. You have two options to choose from.

Grey Cast Iron

This cast iron alloy is the most common and is more ductile than white cast iron. The carbon on grey cast iron during manufacturing progresses into graphite flakes, which evolve into either a ferrite crystal structure or a pearlite crystal structure. Welders may encounter problems with this cast iron ally because graphite flakes can enter the weld pool and embrittle the metal while welding.

White Cast Iron

You can also choose white cast iron as an alternative. Grey cast iron loses its carbon as iron carbide and is thus transformed into graphite. This type of cast iron keeps the carbon as iron carbide without oxidizing it. There are no joints in the microstructure, so the cementite is hard and brittle. However, white cast iron typically has a poor weldability rating.

Ductile (Nodular) Iron

Grey iron is composed of the same components as ductile iron, but grey iron contains more impurities. The matrix of ductile iron contains graphite spheroids instead of the graphite flakes found in grey iron. The spheres of graphite spread across a ferrite area within the rest of the matrix.

Malleable Iron

Compared with white iron, malleable iron contains significantly less carbon than white iron. With that heat treatment, it generally generates a ferrite or pearlite structure with nodular graphite and has better flexibility than white ferrous iron.

Checking the original specification will allow you to determine the type of iron you are working with. Additionally, you can identify the alloy you are working with by performing a chemical or metallographic analysis. For example, grey cast iron will demonstrate a grey color along a crack, while white cast iron will display a whiter color due to the cementite it contains. It is nevertheless more weldable than ductile iron, which also exhibits whiter fractures.

2. Clean the Casting

Whether you’ve chosen a cast alloy for welding or not, you need to prepare all castings properly before welding. It is equally important to remove all surfaces from the casting so that welding can be performed. By doing so, the weld area of the casting will be thoroughly cleaned.

It is necessary to apply heat quickly and carefully to the welding area to ensure optimum welding performance for a short time period. It will prevent any trapped gas from entering the weld area of base metal. In some cases, you may want to rest a weld pass on the cast-iron surface to check for its preparedness. IMPERFECTION on metal will lead to porous surfaces. You need to repeat this process several times to remove the porosity.

3. Pre-Heat

When cast iron is under stress, it becomes susceptible to tracking. Therefore, when welding cast iron, it’s important to keep the heat low to avoid cracks. During the welding process, cast iron goes through three steps. Here are the three steps:

  • Pre-heating
  • Slow cooling
  • Low-heat input

The main reason for controlling heat during welding is to prevent thermal expansion. As metal warms up, it will expand. The metal will not be stressed as long as the entire cast iron piece is heated and expanded at the same rate. The opposite is also true; localizing the heat-affected zone may lead to mental stress building.

Due to localized heating, it can limit expansion. The cooler metal around it controls Heat-affected zones. Moreover, A heat-affected zone’s thermal gradient determines the amount of resulting stress that results. It is possible to stretch steel and other ductile metals so as to reduce stress caused by restraints on their expansion and contraction. Using a portable TIG welder is the best way to weld cast iron

A pre-hearing process reduces the thermal gradient between the heat-affected zone and the casting body. By reducing tensile stress, we are reducing welding-induced damage. High-temperature welding methods generally require a higher preheat temperature. If a pre-heating step is not feasible, then low-temperature welding is the best option to reduce heat input. Alternatively, you can use welding rods or wires with a low melting point.

The cooling rate also impacts the stress-induced at the weld. The rapid cooling process can cause collapse, resulting in brittle welds. On the other hand, low cooling minimizes the stresses associated with contraction and hardening. Pre-heating your cast iron reduces the chances of cracking, while it will still be susceptible to cracking when it is under stress. Cast iron welding requires this step, which demonstrates its importance.

4. Which Welding Rods Can be Used?

In addition to the welding rod choice, there are various ways to weld cast iron, but nickel rods are most preferable.

99% Nickel Rods

The results obtained with these electrodes are superior to other electrodes, despite their higher cost. It is best to use nickel rods with a 99% nickel content for castings. For example, the low or medium phosphorus content. These rods are also machineable. Using pure nickel rods produces a malleable, soft deposit during welding.

55% Nickel Rods

They’re also machinable, making them attractive to those looking for thick section repairs and less expensive than 99% rods. Their lower expansion coefficient means that they cause fewer fusion line cracks than 99% of rods. Ferro-nickel rods can easily weld Iron and steel. You can also use steel rods, which are less expensive than nickel rods but not as effective. 

Steel Rods

Steel rods are the least expensive and best for minor repairs and fillings. However, steel electrode wire produces hard welds, impossible to machine, and requiring extra grinding. Yet, steel rods are more reliable than nickel rods and can match colors better despite these drawbacks.

5. Peening

In the process of cooling and contracting, welds accumulate residual stress, triggering cracking. Applying compressive stress can reduce the possibility of cracking. When a weld bead is soft, the weld bead is subjected to compressive stress by peening. It is recommended to only use peening on welds produced with nickel metallic consumables, as this metal is relatively ductile.

6. Post-Weld Heating

Cast iron is susceptible to cracking due to rapid cooling. Using insulating materials or applying heat periodically can slow down the cooling process. Several methods are used to cool the metal, including placing it in an insulating blanket, putting it into dry sand, or even putting it in a wood-fired oven and letting it cool as the fire burns out.

Frequently Asked Questions

Can you weld cast iron?

There is a degree of difficulty when it comes to welding cast iron. It is most often used for repairing cast iron castings rather than joining cast iron to other parts. If casting defects are discovered after a part has been machined, they can be repaired in the foundry.

Can I weld cast iron with a TIG welder?

The TIG process is also suitable for joining metals of different types. The welding of cast iron is notoriously difficult, but the use of TIG welding is an effective method of joining cast iron pieces. The brittle nature of cast iron makes it prone to cracking and failure during welding.

Can I weld cast iron with a MIG welder?

MIG welding cast iron

Yes, it is possible to weld cast iron with MIG Welder. A MIG welding process using flux-cored electrode wires can be used on cast iron, but the resulting welded joint is not as strong as that of MMA welding.

Which welding is best for cast iron?

shielded metal arc welding and Manual Metal Arc Welding (MMA)

The process is also known as shielded metal arc welding (SMAW), and it is generally considered to be the best method for cast iron welding as long as the welding rods are selected properly.

Can you weld cast iron with a wire feed welder?

Wire-feed welders are an excellent choice when this type of job is involved, and fortunately, they are not hard to use once your know-how.


Finally, we have provided comprehensive information about how to weld cast iron. Welding cast iron requires the right techniques and precautions. In addition, to clean surfaces, pre-and post-weld heating help cast iron to do smooth cooling after welding. The welding and joining experts at TWI have decades of experience working with cast steel. If you have questions or need assistance, you can use the contact form below.


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