Cast Iron Welding Repair Experiment Using Copper Wound Stainless Filler Wire
HTML-код
- Опубликовано: 28 авг 2024
- Cast Iron Welding Repair Experiment Using Copper Wound Stainless Filler Wire. Today we test if wrapping a piece of stainless wire with copper works as a good filler metal to repair broken cast iron. This is a DIY how to repair cast iron welding project for entertainment and education. DISCLAIMER: NEVER REPAIR BROKEN CAST IRON COOKWARE. IT'S TOO DANGEROUS AND NOT WORTH THE RISK. I'm only using cookware in this example because it's undisputed that cast iron cookware is made of cast iron.
Welding Helmet yeswelder.com/...
TIG Welder yeswelder.com/...
Welding Apparel brandonlund.my...
Respirator (fits under my hood) amzn.to/2Hss3Vk
TOOLS & GEAR I USE
🔴 www.amazon.com...
🔥 MORE WELDING AND FABRICATION VIDEOS HERE:
• Welding Projects
🔥 LEARN TO WELD AND FABRICATION VIDEOS HERE:
• Learn to WELD- Beginne...
🔥 Buy YesWelders HERE: yeswelder.com/...
Use Coupon Code: yeswelder.com/...
⇨ SUBSCRIBE: / brandonlund
💲 EVOLUTION TOOLS - Use Coupon BLUND5 at checkout
aspireiq.go2clo...
UK BUYERS can also use promocode BLUND5
💲 FRONIUS WELDERS - Save big when you purchase Fronius Welders using the exclusive links below.
Fronius Welder Buy online bit.ly/2X5Q4tF
Where to buy bit.ly/3dbVmt2
TransTig 210 bit.ly/2ZDxElI
Specs and features bit.ly/2ZDxElI
TransTig 170 product page bit.ly/2ZK9XIq
Free Fazor promo page bit.ly/3cckZsu
💲 EMPIRE ABRASIVES - Use Promo Code LUND and new customers get 10% off their order www.empireabra...
🔥 Links to some of the cool tools you see me using 🔥
Center Punch amzn.to/33994ua
Metal Scribe amzn.to/3idI4y6
Relton Option 1 Cutting Fluid amzn.to/3cM3vFh
Irwin Chamfer Bits amzn.to/2Sa6Ft6
My Safety Glasses (12 pack) amzn.to/2H6tdZf
Amp Bluetooth Noise Canceling Hearing Protection amzn.to/34cZciv
Chipping Hammer (the best): amzn.to/2zs3Lqg
5/8" x 1" Shoulder Bolt (EBay)
12" F- Clamps (Harbor Freight)
Graff Black Diamond Cutting Disc amzn.to/2ELiSRU
APlus Lift Pneumatic Lift Table amzn.to/30cTaiu
Plasma Cutter: amzn.to/2ZsuLQL
Welding Clamps amzn.to/33KyayS
Stick Welding Gloves: amzn.to/2L1fxOX
MIG Pliers: amzn.to/2MJ1jnQ
Metal Marker: amzn.to/2MJzImj
Respirator (fits under my hood) amzn.to/2Hss3Vk
Drill America Drill Bits: amzn.to/2RjXk2i
Metal Thickness Gage amzn.to/32Dtn2O
Welding Blanket amzn.to/31jUjo4
Transfer Punches amzn.to/32MmpH9
Portable Band Saw: amzn.to/2Hs8Mna
1/2" Impact tool: amzn.to/2X7oYC9
4 1/2" Grinder amzn.to/32HFhZe
Cordless Circular Saw: amzn.to/33adAsP
1/4" Impact amzn.to/2DcBf0S
SAVE on the Boots I wear Where I get my Boots rockroosterfoo...
Any commission earned from the above affiliate links goes directly towards helping to support the channel.
FOLLOW ME (for behind the scenes stuff)!
⇨ Instagram: / lunddiybuilds
⇨ Facebook: / lunddiybuilds
⇨ Twitter: / lunddiybuilds
For Business Inquiries: LundDIYBuilds@gmail.com
Disclaimer: These videos are intended for entertainment purposes only and as such, you should not attempt to do any of the things you see me doing. Always read and follow the manufacturer’s safety guidelines before handling tools. Seek professional advice and training before using any tools or equipment. Never operate any tool without wearing the proper personal protective equipment. Final warning, Do not attempt to do any of the things you see me doing!
Thanks again Brandon, they can’t say you didn’t try it. I spent many a day with 3 welders who were trying everything they had heard or seen on welding or cutting cast iron ash lines in a power plant. I’ll say this for them, they never gave up trying until they died. They were a great bunch of guys. Stay safe and keep having fun. Fred. 🙏🏻🙏🏻👍🏻👍🏻👏🏻👏🏻✋🏻✋🏻
Thats awesome Fred. I actually had a guy tell me today that cast iron cant be welded and that he had 20 years in the trade. I guess once you start entertaining a "cant do" attitude then you are half way to failure. How were you guys repairing them Fred? Oxy Brazing with cast rods? Were they pressure lines?
They were trying both ways. That was almost 60 years ago. The ash lines had to be rolled after so many hours and hopefully replaced before they started leaking or bursted. I was there for 6 months and was laid off but changed fields. Got my eyesight back in the bad eye and decided to try welding a few years ago. My wife says I am very trying whatever that means ! 🤗😁🤣
Very interesting. On a side note your wife must know mine because mine says the same about me....😏 lol
That's very interesting. I wonder how that would work on nodular or ductile iron. Thanks again for the video and this experiment.
Great suggestion!
I saw a comment about the content of information in your videos I've always been impressed with the way you don't just put a video out there you take the time to teach and explain what you're doing
You are the professor of DIY keep on keepin on
Awww man I truely appreciate that! These types of videos do take me a considerable amount of time researching whereas a lot of these processes and procedures arent well documented. I appreciaiate that @Scott June
I'm impressed how smooth that stainless and copper welds @Brandon Lund
@Antonio Claudio Michael I'm going to dig a little deeper into this combination because it flowed like butter. I was actually surprised it failed. It could be because if other repairs so I might try this again on a new pan. I was really hoping it was going to work.
@@BrandonLund this on a new pan would be a great video I did see how well it flowed and that was impressive to me
I've welded cast iron. I did it by heating it with a blow torch and then just kept it hot with the torch, then I slowly decreased the time heat was on it, then buried it in sand with a towel over the top. Worked great...heat then re-heat. It almost seems your weld was good with copper, but your cool-down was way too fast. I'd love to see that again, but you heat and re-heat.
@Hip Airbrush what you described is typically how I weld cast also. As far as the cool down, I did it in this video the same as I did in the 3 prior repairs hoping to keep the results consistent. One other viewer mentioned try 309 because of the dissimular filler. I hadn't really thought about it that way. I'm also wondering if the past 3 repairs on this could have really messed up the grain structure. I really want this to work because the metals flowed like butter. I'm going to try this again but with a new pan and heat more as you suggested. Even if it's not identical to the previous repairs I feel like this is a good filler metal once I get it figured out.
@@BrandonLund I'd love to see that. I saw exactly what you meant with the weld how it penetrated nicely. I think hitting it with the blow torch a few times to keep it hot would help it not crack. I'm now wondering also, if you couldn't use a nickel rod and wrap copper around that.
I like that idea!
Most stainless steel has a meaningful amount of nickel in it already. Around 10 or 11%. Nickel will bond well where other metals will not. If you buy a diamond coated abrasive tool, nickel is what they use to "glue" the diamond to the substrate.
@solarguy I learn something every day. Very interesting. Thank you for sharing. 👍
Need more post flow when tig welding. 5 seconds min regardless of material. I usually use 10 seconds. Unless its aluminum. Then u can get by with a lower post flow. 20 cfh was good tho.
I will give that a try. I usually set 7 for everything and 10 for aluminum although I'm confindent thats not why this failed. It very well could be that i put too much heat into it. I plan to try this experiemnt again using a new pan because several others cant be completely wrong. I'm amazed how well it flowed
The more i think about it maybe the filler rod isn't the problem but the process isn't really ideal being the weld didnt fail it cracked next to the bead being tig is slower and introducing so much heat netting more expansion and contracting vs quick tacks with stick or mig, maybe with tig if you had a way to have a propane or map gas torch running on the backside keeping it hot while your welding would help ,good stuff Brandon
@jimcaf57 I think the filler rod is going to work I just have to work on my execution. I think whereas the pan had been repaired 3 other times in that series that the grain structure has probably weakened. Im going to try this again but with a new pan, continued heat with a torch as you mentioned and maybe less amperage by using a smaller diameter copper wire. I might try 309 wire but I'm not 100% convinced yet that the wire was the issue like you and I both agree on
One of the things I really enjoy about your posts is the quantity of information that you provide. I am so learning about welding and what you give is very helpful. Question: If you were to have welded over the known craca, both front and back after heating the pan again, would it have made a difference??? Also, if you had used a MAP gas torch to heat the metal so it didn't cool between welding passes, would that have prevented the cracking??? Also, if you had put the pan back in the oven or sand immediately, would that have helped??? Great job!!!
@Jim MacSuga thanks man! You make some great points. I'm actually concerned that whereas I have repaired this part 3 other times that It could have to do with the change in grain structure. I could of drilled a small hole at each end of the crack and rewelded it but then that would have changed the result compared to how I welded the other 3 times. Map gas is great to use between passes but whereas I went from welding to peining to welding again the part never had enough time to cool. As far as putting it in sand or the oven, once I was done it went in the sand immediately. An oven is even better if you can lower the temp by 25 degrees every hours or so it will greatly help with that rapid cooling effect.
Thanks!!!; That mwk s sense.. going to weld a cast iron motor housing and that will help!!!
@@jimmacsuga2592 good luck buddy!
It's good to see the old cast iron pan back again!
Lol I agree @Neddy L
I'm curious about the results of this test as it pertains to the pan itself. Is it really a valid test, seeing as how you have already welded that handle back on so many times prior? I would have to imagine the iron was already so muddled up as far as grain structure from the previous tests. Wouldn't it be more accurate to use a pan that had broken, but not re-welded yet? Just thinking that could be a factor in the failure, as the area at the toe of the weld is constantly being "assaulted" by rapid heating cycles each time it was repaired...hmmmm 🤔🤔🤔
@Steven watkins I think what you are saying probably has a bigger impact than what I originally thought. I feel like those filler metals flowed so nicely that it would have to work. One other commenter suggested 309 which I never really gave a thought thinking I was welding cast to cast. But 309 might be good for the dissimular properties of the copper. I think this will work but I have to get the process dialed in. I think what your saying will help, The grain structure has to be pretty brittle from the previous repairs and maybe 309 wire then a strict post cool down. Even if the procedure isn't the same as the 3 prior repairs, I really want this to work and I feel like it will with some more experimenting. A new pan, a new number for the original breaking strength and then test it using these fillers. I feel like the results would be simular to a nickle repair. Fingers crossed! Thanks again buddy. I agree 100%
@@BrandonLund I love all of the experiments you do, it helps us all learn together! I can't wait for future tests and results!!!!
New a old timer good at welding cast. He welded cold. Example like yours he would weld maybe 1\4 inch pean it then let cool to room temp then repeat till done. Always nickel rod appropriate size for thickness. Like he said to me weld a little wait a lot
Jeff Rose he is spot on! I have done a lot of cold welding. Although i get a lot of grief from the folks saying i'm doing it wrong, it is a well established and documented proven method.
Alright alright alright let's go Brandon finally Friday
@Scott June right on brother!
I'd like to see if there are other applications to stainless + copper mixed or perhaps other copper mixes???? Also, Have you done any welding with any tool steels at all? I have a batch of A2 Air hardening tool steel tig rods that I have barely touched, but had some success with repairing an old fashioned BMC no 9 locking wrench which had a section of really worn down jaw. Anyways I enjoy the videos, looking forward to the next one!
@John Lane I'm planning to do some more experimenting with that combination because it flowed beautifuly. Im sure there are other applications where this could be used including maybe a new cast iron test with virgin cast. I've never tried tool steel
Very interesting good Experiment and Testing Video On stainless and copper mix rod as always @Brandon Lund
Thanks man I appreciate it!
@@BrandonLund anytime brother
Peening relieves stress.normalizing
Is a heat treatment
@Brian Patrick Exactly 👌
i have a very thin cast iron kettle....i have taken it everywhere in my country to fix it but it doesn't work. Wish I was near You
A lot of people wont fix it.
Interesting video young man!
@Jon Dingle thanks man!
MORE WELDING AND FABRICATION VIDEOS HERE:ruclips.net/p/PLfbf78fMz9Vol0uX2-GNc6mLi75zpqb5f
LEARN HOW TO WELD VIDEOS HERE:ruclips.net/video/ADa1I319GJ0/видео.html
4 1/2" Grinder amzn.to/32HFhZe
Tig Welder yeswelder.com/products/tig250p-acdc?ref=BRANDONLUND
Hood yeswelder.com/products/auto-darkening-welding-helmet-eh-302c-cb?ref=BRANDONLUND
A recap for a blast from the past. Considering that you can buy nickel TIG rods in half pound increments from eBay, and one pound mig wire, I don’t see why anyone would want to play around with combinations not meant for this. And if that’s a problem, the old standby if bronze brazing is fine if the strength isn’t as important, or the part is thick.
But that pan is pretty thin, so it’s weak anyway.
It's all in good fun @Mel Gross. A lot of these suggestions I get often come from far off places of the world that don't have the same luxuries that you and I have like ebay and Amazon. Heck, I still get comments from people saying cast can't be welded so I'm always open to learning new methods especially when I get real odd ones like in this video.
The penitration is impressive on the stainless and copper
Man it ran so nice! I'm going to try this again very soon with a new pan.
Wonder how TIG (AC) with Aluminum Bronze filler would hold up, I have use that combo a few times for cosmetic fixes.
Great vid!
@Main Street Machine Works That's a great suggestion! Thank you! I bet it would work well.
Good video. I missed if you said whether or not you have an oxy acetylene. If you do you get a better heat treat from that.
I need one of those helmets. Lol
@Earl Cavenaugh I have a complete oxy acy setup but tank is empty at the moment. I havent been using it much since I got the plasma but it's occasions like this that it would be handy. On smaller parts I use Map gas to maintain the temp after the preheat
I'd like to see how a new pan - the exact same size - would sustain that much weigh (and more ) on its handle... as a comparison. My guess is that your repair's good enough... Thanks for the vid.
@R Belang I'm curious also. I'm going to repeat this test again with a new pan and maybe with 309 filler instead of the 308
Put the 2 wires in vice and other end put in a drill to spin wires together
That works pretty slick! 👍
Brandon I noticed that you cooled your weld every time you made a pass with your welding gas perhaps that’s the problem?
@Robert Dominiczak I'm not sure...because it's a odd coMbination it's hard to tell. I did another video using a different filler and kept the heat on it. The results were much better. ruclips.net/video/njcL2eVR5FQ/видео.html
I understand that but copper cools down quicker? Which makes it shrink quicker. Look into shrink rates on different metals?
Thats correct Robert. I'm very farmular with metal shinrikage. Because of it's thermal properties I often use copper as a backer to prevent blow out on thin metals which is also why I decided to keep constant heat on the link I attached hoping that the thermal stress in between heat and cool cycles would be less. Copper is on the far end of the spectrum as compared to stainless which is why I said it's really just a guess of why it may or may not work because both materials are very different. One article quoted the thermal conductivity of copper as being 20 times that of stainless which is why I think this is not a great combination as a filler metal. Both metals have very different heating and cooling rates and therefore they are both going to expand and contract at very different rates. Although the second video was not a failure, there are far better filler metals out there but thats why we do these experiments so we can all share and learn and with every video I make doing these odd combinations, i'm always learning new things.
The kreeking is the cast iron going thru a thermal shock
Ever weld cast iron onto mild steel? I'm curious because I see these cast iron caps for square tube fence posts. Not sure they NEED to be welded down, but I would rather weld them down so nobody steels them.
@Aaron the Amateur if they are Grey cast it should be no problem.
I have a 12 hour rechargeable bicycle handle mounted LED head light I got from Amazon mounted to the right side of my helmet. I don't ever have to run light's at night and almost never turn on all my over head light's. 👈🤓👍
LED lights are a huge plus when trying to see throught the hood!! @Mike K
Another quality video with quality content! Thanks for the time and thought put into this!
@blackout thanks man I appreciate it! 👊🙏
Try silicon bronze mig wire.
@Bryan Smith thank you for that suggestion! and I will be doing this. I've had good luck with Silicon tig but never tried mig 👍
That's how we learn.
Right on man! @MT Pocket Builds
Very interesting test Brandon 👌. I'm researching the Yeswelder brand and I'm like this 🤏 close to jumping on the Mig205DS Machine.
It has all the features I think would benefit me over time.
Have a great weekend.
@Gabriel Szekeres I just got one. I'm going to be using it this weekend. If it's any good I will give you a discount link.
just a thought 309 is for dissimilar metals not 308
@jimcaf57 Great point. I know a lot of folks that have welded cast with both 308 and 309. I went with 308 thinking cast to cast but I see what your saying about the dissimular filler. Thats an interesting persepective. Personally I have never really had much sucess with any of the stainless fillers on cast. I think 308 is non machineable so the next test i do I will try 309. I reallly want this to work because the combination of the two metals flowed like butter. Thanks for mentioning that! 👍
I had a friend ask me about welding cast and I chickened out.
I get asked a lot also. I tell them under no circumstances is it guaranteed and the risk they take is I could totally destroy their part and I have them sign a waiver saying they agree to this. I also don't repair any cast iron that I'm told is structural. It can be risky but the truth is that pretty much anyone can repair cast iron with about a 90% success rate. It's that 10% failure that can come back and haunt you.
This trick also works with ordinary mild steel welding rods.
Hmmmmm I never thought to try. I'm curious now! Thanks for sharing! @Ky5
Good one Brandon. Love that you are showing alternative methods. My first boss showed me this one, years ago. Haven't done it since then😂😂😂 I find welding Cast a great fun challenge.
Good one.
(Appealing to your OCD. I see your grinder rack isn't powder coated yet😋😋)
Thanks man! @Basil Keen because I wasn't given much information from the original poster other than use stainless and copper, is what I'm doing here seem like how you were told? Should I be doing anything different? ? Someone suggested i should try 309 because of the dissimular copper / stainless combo. I never thought of it that way. I went with 308 thinking about the cast to cast weld. This filler really ran awesome and I feel like this will work if I refine my procedure. I think a big part is the used pan has probably messed up the grain structure from the previous welds. I'm open for suggestions and I'm hopping I can make this work. Thanks buddy!
EDIT: Just when I thought I had pushed my powdercoating obsession out of the way, you bring it up. THANKS hahaha 🤣🤪🤪🤪
@@BrandonLund Glad to help with your OCD 😂😂😂😂
Pretty sure it was 308 that I used back then. Worth giving 309 a try.
What you did was exactly what my boss showed me back then 👍🏻👍🏻👍🏻
Yah thanks 🤣🤣🤣 it will be another 2 weeks before I stop obsessing lol.
Thanks for your feedback. I thought it seemed logical. Im going to try this again but with a new pan.Thanks buddy! 🙏
@@BrandonLund 😂😂👍🏻
Let's go Brandon! 😜
🤣🤣🤣 hahaha u know it! 😁😁😁
Yeah the options for people with beards are harder to find and usually more expensive. I always have a beard because my wife likes it. I just snug the mask up tight and it seals pretty good. I keep my beard on the shorter side though. A big old beard would defintely be a problem with one of those masks.
Thats exactly my situation @Christopher Salisbury. I keep it short because my wife likes a beard on me and it drives me crazy when it starts getting too shaggy. The mask might not fit perfect but it's catching tons more than if I didn't have it on. Have a great weekend buddy!
I have brazed miles of cast iron. Stronger than the cast.
@Willie Pelzer I just had a guy tell me in another video that cast cant be welded....and he said he had 20 years experience. You better not let him see your comment! 🤣🤣🤣. Brazing has always been the most trusted method, it's these weird filler combos that really interested me.
peening hot metal with no safety eye wear is pretty risky,
2mins 30 in and loving this video already
@Karl Myers thanks man! 🙏
Google "copper contamination cracking"
I'll check it out. Thank you! 👍
I like that helmet that is sweet the sides darken seperate of the main
Woohoo my helmet is on the truck...on the way to my house!! I can't wait to try it out tomorrow.
Right on brother! 🙏
Super nice helmet Antonio. Im very new to using a true color and panoramic View. Its next level.
Gas weld with brass. Who doesn't have a oxy setup. Not a welder.
Gas was actually the very 1st process I learned on but over the years I find myself using it less and less especially once I got a plasma. Oxy Fuel and tig brazing has and proabably will always be the prefered method, it's these oddball combos that really interest me.
This is a big deal for me!
Glad i could help :)