I haven't welded with aluminum bronze yet, definitely need to do that! I have to give you a lot of credit. Yes, the tips and tricks are good, but your real advantage are those crystal clear arc shots. Best of any I have seen, including the ones taken with those $5,000 welding cameras. See you next week!
Thank you Jody for your helpful videos. I retired from an airline and this type of repair work was not common. My new job is at an Electric motor repair shop, where I am getting accustomed to welding cast iron and cast aluminum. I used your method to replace a broken off lug, on a motor end bell. Turned out great. Thank you.
Jody, I'd like to thank you. I've got a cast iron gear with a broken tooth that needs fixing...this video came at a good time. Without you, I would not have been able to learn how to weld. I have most of your CD's and I'll be getting more soon. I made a welding table last summer through the eyes of a machinist and made videos of it and I'll be posting it soon.
You learn something new every day ! And this isolation is providing me with so much very useful information ! I tig weld every day whether alloy or ferrous but have never attempted to weld cast with the tig and now you've given me the process , thank you very much !
I was thinking the same thing until I found out that aluminum bronze filler wire is in the $35/lb. range! The piece would definitely have to be a pricey item to justify the repair cost! Great to know about it though, because I’ve seen numerous times when a client wanted something repaired regardless of the price!
Talk about surfacing. I remeber in welding school I was like when am I going to surgace with TIG. Great application demonstration. Thank you for all your amazing content knowledge Jody!!!
I'm sure it's not cost-effective for this particular job, but a great demo for this TYPE of job. For example, I've got a Carraro steering knuckle on a CASE 4WD tractor that needs some build-up in a seal area. It would cost about $2000 to replace it, but if I could build it up and machine it, that would keep me going for another few decades. Keith Fenner did a good demo on an almost identical repair, using traditional torch brazing, but it's good to have alternatives, and TIG looks a lot more controlled.
Hi Jody, Thanks again for the video and all you do! One thing. I would not leave the top of the weld rough like you did, this leaves the bolt sitting on small contact areas that can cause stress cracks. Better to grind it flush so the bolt sits flat over as wide an area as possible. Rob
We used to have a huge vise in the shop of our business, it was probably 100 years old, smooth as glass, my Dad had bought it at an auction of a railroad round house back in the early 50's. I should have kept it but let the auctioneers sell it after I closed it down and retired. Heck I wish I would have been able to keep the whole shop, but I just couldn't afford to do it.
Jodie ur a beast dude, I’ve seen a lot of good welders but I’ve never seen someone who can do what u do. Hopefully one day I’ll know just half of what u do
Always look forward to your videos on cast repair. I've been using Ni99 with some success, mostly on engine components that have to heat cycle a lot. I was told the expansion rate is closer to cast to help. But how nicely this aluminum bronze flowed makes me want to give it a try. Would love if you could do a video comparing and contrasting different filler metals or different techniques for cast and when one would be more appropriate.
About the craziest thing I welded cast iron was an old above -ground water well pump that had been frozen and broken into pieces. I did not use silicon bronze but rather nickel stick welds and pieced it together like a puzzle , welded it together on one side to get the shape then ground into the cracks and welded back and forth till it was all solid welded. Pre-heating it every time. It took a lot of lunch breaks at my job but I got it welded up air tight.
Hey Jody, Thanks for all the great info on TIG brazing! I have tried using SiBz dc, and AlBz ac on a few cast iron repairs with excellent results. There is also a third alloy available called Nickel-Aluminum-Bronze. This alloy has about the same melting temp as AlBz, but it has a substantially greater tensile strength. Have you ever used this or do you know anything about it? I would be interested in seeing a side-by-side comparison on this as well, and you are the man to do it! Thanks for all the great videos, you have really "upped" my welding game.
I fixed one of my old vises which had a good 3inch long crack with 2.5mm 304 SS stick welding rods, and the vise has never cracked on me again. I think that 304 + 309 SS works well on cast iron which does not heat cycle.
Wow great tip. I've never tried to weld cast iron but I know the day will come eventually. Need to get out the powertig and do some practicing. I love these videos.
Awesome video. Great tips I’ve for years done a lot of aluminum Have never done stainless or any steel I’ve tried brazing once but this will really help me learn Thank you Larry
Hey Jody always enjoy your videos there great and you explain a lot about what your doing. I really love the tig finger too it's helped me out a lot. I wanted to ask for one request I would like to see a video of tig welding schedule 10 stainless steel pipe got a test on that coming up soon. Thanks
Nice example of what can be done. I would love you to show repairing fins on a cast iron motorcycle barrel if possible, I could really do with some tips on that.. I have one I have been working on but the material is so thin, even tig welding (or brazing, whatever folks prefer to call it) with silicon bronze I'm getting cracking. May get some ali bronze and try that now.Thanks Jody.
Mightiflier Man cards were repealed years ago due counterfeiting and of course fraudulent misrepresentation.Such cards were recently replaced with a pair of prosthetic balls.
Thanks for the great videos, I haven't welded/tig brazed any cast iron, but I would like to, and after seeing you're vids I feel like I could get a handle on it without pulling out too much of my hair. Nice product placement on the DiResta ice pick, too.
...I've got a 1956 P&H 300 amp AC/DC TIG welder.,......they are pretty bullet-proof....old, big and heavy...all copper windings...self-contained water pump for 300 amp torch.....I went on the e-bay and found a few for $300-$500......a steal at that price...but they ARE big and heavy....and any problems, you better be an electronics engineer....! They Need 100 amps at 240 volts (or 50 amps at 480).....still....quite a good deal of you can fix minor stuff yourself..... P&H doesn't make welders anymore, but STILL makes some of the biggest electric Mining shovels for loading those 250 TON trucks.....top quality stuff....then, and now....
Started with $775 acdc 225amp tig welder...worked with it for a year, made money, bought and $1500 tig welder, 6 months later I bought Jody's welder lol Miller Dynasty 280, got it half price for $2900 on Ebay....just saying, if u want it, today, u can do it! Maybe not 20 years ago(wouldve been maybe $7500 to start up)
Diego Martinez the settings were just normal such as 19 volts and 400 wire speed. I have done several cast repairs and they are still good. it does make a difference how good the cast is. some cast is really dirty and it is better if the break is simple. stress will become a factor if the break is complex.
Just caught this today. Amazing man. You are a great teacher. I never would have thought of building up that much. It’s probably stronger than the cast original! You da man.
hey Jody if this job wasn't for a friend would it even be a feasible repair? With shop time and material vs vise replacement does it really pencil out for the customer?
It depends on several things, such as Jody's point about heat cycles in the particular application. For this cast iron, if you can hit it from both sides, and pre-heat, stick welding with a high nickel rod gets it done in most applications.
I probably would have turned the job down if it weren't for a friend. But it was kinda fun. I think the cost of the vise was around 150 dollars. This job would have taken me about an hour if I wasnt filming it. But there are other methods that are quicker like stick. But I have lots of aluminum bronze rod I have had really good results with it so I went with it.
Jody, I've been tig welding for years, but I have a problem with my foot pedal every time I listen to bluegrass music! Hep me! Hep me! I cain't stop my leg! By the way, Burr King is made in my town in the Ozarks. Good little machine. Keep the videos coming . They are great.
That is one of the coolest things I have ever seen! Thanks tons Jody! I have had tons of poor or less than poor results using silicon bronze. I usually just end up throwing the whole piece out and getting a new one on the end. :-)
Great video! It is really interesting to see exactly how to use alumbronze to repair cast iron and it looks so cool too! Thanks for a solid repair and an awesome video to watch also, your the man!!
thanks JD. It was a lot of fun. And lots of opinions expressed here on better ways to do it too so maybe everyone learns something new from all the comments
Thank you for all the comments and suggestions. I did some research remembering Keith Fenner doing this same job 2 years ago. Went back and watched his series My Pinion To Racks Addendum To Dedendum" Part Seven answered my question in the comment section where a viewer asked the same question about tig brazing a ductile cast iron gear. Keith Fenner's answer and reason for using oxy/acetylene and procedure was- he does not tig braze this type of job because it can melt the base material and cause unsuccessful bond and build up. He undercuts the repair area, pre heats to 550 degrees F oxy/acet. braze it using a general purpose low fuming LFBB bronze alloy rod and #2 high heat brazing flux then covers and lets the part cool slowly as he showed in his video. I feel this is proven sound advise for my gear tooth repair which I am going to follow. I am also going to try the tig method on a scrap cast iron gear just to see the results I get and do some destructive testing just to satisfy my curiosity.
love it... I need to build up the very corners of the moving jaw on a big old vise and this is the advise I was looking for. now it's time to get some of that aluminium bronze. :)
I beg your pardon, I write through the Google translator. iron stew through the buffer layer. Buffer materials may be steel, copper, and nickel (nickel best). in your method of copper as a buffer, then you can continue surfacing of steel :) personally usually I use nickel. with respect to the master of his craft from a colleague @ykt_master 🍻
Buzzwords! He dint print nothing! It IS Additive Manufacturing if you like, that has buzz appeal. Nobody will really care because it's an artisanal process, no apps, no stinking CAD.
Hi Jody, great video, appreciate the videovideo's you do, I've been in the trade a long time but still enjoy learning new ways of welding different materials.
Hey Jody, another great video and commentary, I love it when you walk us through the process. I need to fill some holes in a radial arm drill table I am currently restoring so this method with TIG/Al/Bronze would be ok? Any hints how to tackle it ie should I concentrate on one area or spread the work out. The table is 640x900mm and holes all over it. I love the use of the Pyrex cups and use them all the time myself now as it seems to help my visibility of the torch too so thanks for putting me on to them. Cheers, Gordon, AUS
Hey Jody I really enjoy your videos I find them very informative. I was reading a blog on your website about starting a business I was wondering any chance we can see a video demonstrating some of the points in that video (ex. Welding desks, shopping carts, mailboxes) thanks
Well I have enjoyed watching your how to videos, I have learned a lot. I have a question that I think you will be able to give me the best answer. I have a very old metal lathe that my Grandfather used for many year. I have it now and have been using it for at least 50 years. Now somehow I over stressed the tool post holder which is also part of the compound cross feed. My question is what is the best method and material to get this back together with the highest strength?
Never used Aluminium bronze on cast iron. I have repaired and built up some Victorian cast iron ram pumps 140 years old using 100% pure copper at the suggestion of of my local welding materials supplier.
I saw a video where the cast iron was welded with Silicon Bronze on AC with little cleaning action. I sort of thought that filler was about always to be used on DC. ?? Great video with lots of good tips - as usual :-)
thanks. I don't recall seeing a video on welding cast iron to steel. if you have one can you point me to it, basically looking to weld a gooseneck cast coupler. use your info and did buy an Everlast 160 tig, works great. looking to utilize my buzz box more, heard I can do cast with it as well. thanks again.
About the flap disc rather than the welding. I got some ceramic 24 grit sanding discs a few years ago. They're better than a grinding disc on everything.
Hey Jody, do you ever sand blast things to prep metal? I fixed a vice recently and as usual, i did a quick clean up with a bead blast. And after seeing this, i will be trying a bronze braze as you instructed here. I used ER312 filler metal, and it worked good, but i could feel how hard the weld became because of the available carbon in the casting. Thank you
I use alumabronz allot to overlay crane hooks for paper mills so they don't gaul the bearing surface of the paper roll shafts, but we use a MIG spray transfer process.
Thanks for the video not had any experience with alum-bronze welding but will get some rods and find something to weld... totally enjoy the videos and helps in brushing up on things not done in years or as in this video never... good insight and useful information. Thumbs UP!
Hey Jody, Interesting video. Do you think that filler rod would work well on injection molded aluminum? I work in a shop build up a surface made up of injection molded aluminum so it can be machined back to spec. The stuff is a real pia to tig- air pockets etc...
I've tried the silicon bronze rod on a vice repair. it was difficult to drill, had to heat treat to soften it. I'll try the aluminium bronze next. I`m not a pro but learning.
I have been on the fence about welding my Wilton bullet vise that has a nice big chip on the shelf under the jaws i was thinking of silicone bronze i don’t have an ac tig welder no aluminum for me
Very good video and content. My question to you is I also have a cast iron gear with a broken off tooth like another viewer mentioned. The gear is on my South Bend lathe for the back gear. Do you think I should try tig brazing it as you did on your vice repair or do you think I would be better to fully preheat the gear and oxy/acetylene braze it and let it cool very slowly before machining or using a file to shape a new tooth ? It is a critical application with stresses on the gear when using back gear for threading. Your opinion would be greatly appreciated. Thanks Ed K. Cleve. Oh.
I would say do what you are most comfortable with and have success with. I do think tig brazing would most likely work as well but a preheat and postheat would still be a good idea
Thanks for your reply. I think I will get a scrap cast iron gear of the same material, break some teeth out and practice both ways before doing the repair on the one for the lathe. I learn from every one of your videos, Thank you.
Eddie Kawecki I'll put my two cents in, I've repaired my share of engine, transmission and rear end parts over the years and found some cast iron and aluminum to be very bad castings and have soaked up oils like a sponge. Besides the pre and post heat procedures cleanliness is very important, sometimes a simple cleaning is all that's needed but sometimes I've had to heat the metal to 150℉ or more for an hour and you can watch the oils seep out. Older castings seem to be a tighter grain and not much of a problem. Just something to watch for, you hate to be almost finished and see crap floating out of your new repair. Good luck
How much rod is needed for such a repair?? I recently repaired a cast vice from a saw which had been repaired many times in the past using wrong techniques and materials. I used nickel welding rods and it works pretty good!
For gray cast iron nickel based electrodes or filler wire are using, if job is for big clients... My question is can we do mpi or pt test on welded joints? Nickel based.. So
Tig Brazing, is not welding, when people are learning, it is a good idea to us the words that correspond with what your doing! You better than anybody knows what the difference between welding and brazing is!!
Hi great video. I have a question what in your oppinion is best way to fix (add material) to chipped anvil. I have tig and mma welder available. many thanks for your support.
Amazing work Jody. I have a related question, I'm TIG brazing silicon bronze for artistic purposes. No joining of metals just filling voids for aesthetics. Would you recommend AC or DC? Base metal is clean AR500. I'm assuming you went AC because of the cast iron, just curious what you would recommend for a similar build-up project.
Have you published the video about the vise repair? I don't see it in your list. Maybe I just overlooked it? I just picked up a heavy duty vise for free from a service tech at the dealership where I work. The fool was throwing it out because the jaws are beat up and rounded. Well if you had the replaceable jaws in there it would have held up just fine! I can true up the cast iron jaws on my mill and make new jaw inserts in a matter of minutes. But after running it through the parts washer I found a small crack at the back of the main casting. I could probably ignore it and be fine but I want to try to repair it. All the videos I'm finding on repairing cast iron this thin section parts, or this one where you used the filler metal to replace part of the casting. I need to figure out how to properly prepare that crack for brazing while not opening it so much that I can no longer braze it. Or do I just need to stuff it full of base metal shims and then braze it after I grind it open to clean it up? Thanks for any guidance!
How well does it bond the filler for strength. In a case you have to add a piece of material thats missing like a small bar stock for build up are there are concerns?
The use of carbon steel instead of the damaged part is very simple, first use brass wire (copper-zinc alloy) flame brazing brass in carbon steel and cast iron two parts, and then carbon steel and cast iron brazing together, and finally need to slowly cool the internal The pressure will not be too much, the power will be much better! Video internal pressure accumulation, strength will be weakened.
About 25 years ago I TIG welded a cast Iron sides on a Johnson Horizontal Saw, with a SS filler. Still working as I use the saw every day.
I haven't welded with aluminum bronze yet, definitely need to do that! I have to give you a lot of credit. Yes, the tips and tricks are good, but your real advantage are those crystal clear arc shots. Best of any I have seen, including the ones taken with those $5,000 welding cameras. See you next week!
Thank you Jody for your helpful videos. I retired from an airline and this type of repair work was not common. My new job is at an Electric motor repair shop, where I am getting accustomed to welding cast iron and cast aluminum. I used your method to replace a broken off lug, on a motor end bell. Turned out great. Thank you.
Jody, I'd like to thank you. I've got a cast iron gear with a broken tooth that needs fixing...this video came at a good time.
Without you, I would not have been able to learn how to weld. I have most of your CD's and I'll be getting more soon. I made a welding table last summer through the eyes of a machinist and made videos of it and I'll be posting it soon.
Time flies but I come back to your videos Jody again and again considering it as best lessons for welders! Thanks a lot for your videos!
You learn something new every day ! And this isolation is providing me with so much very useful information ! I tig weld every day whether alloy or ferrous but have never attempted to weld cast with the tig and now you've given me the process , thank you very much !
I was thinking the same thing until I found out that aluminum bronze filler wire is in the $35/lb. range! The piece would definitely have to be a pricey item to justify the repair cost! Great to know about it though, because I’ve seen numerous times when a client wanted something repaired regardless of the price!
Talk about surfacing. I remeber in welding school I was like when am I going to surgace with TIG. Great application demonstration. Thank you for all your amazing content knowledge Jody!!!
I have a vise on my work table that I broke and welded with 7018, and hammered between each pass. Still working well after almost 30 years.
I'm sure it's not cost-effective for this particular job, but a great demo for this TYPE of job. For example, I've got a Carraro steering knuckle on a CASE 4WD tractor that needs some build-up in a seal area. It would cost about $2000 to replace it, but if I could build it up and machine it, that would keep me going for another few decades. Keith Fenner did a good demo on an almost identical repair, using traditional torch brazing, but it's good to have alternatives, and TIG looks a lot more controlled.
Hi Jody,
Thanks again for the video and all you do!
One thing. I would not leave the top of the weld rough like you did, this leaves the bolt sitting on small contact areas that can cause stress cracks. Better to grind it flush so the bolt sits flat over as wide an area as possible.
Rob
We used to have a huge vise in the shop of our business, it was probably 100 years old, smooth as glass, my Dad had bought it at an auction of a railroad round house back in the early 50's. I should have kept it but let the auctioneers sell it after I closed it down and retired. Heck I wish I would have been able to keep the whole shop, but I just couldn't afford to do it.
Jodie ur a beast dude, I’ve seen a lot of good welders but I’ve never seen someone who can do what u do. Hopefully one day I’ll know just half of what u do
Always look forward to your videos on cast repair. I've been using Ni99 with some success, mostly on engine components that have to heat cycle a lot. I was told the expansion rate is closer to cast to help. But how nicely this aluminum bronze flowed makes me want to give it a try. Would love if you could do a video comparing and contrasting different filler metals or different techniques for cast and when one would be more appropriate.
Ditto. Ni99Ti is the go-to choice for anything I fix that will heat cycle. :)
About the craziest thing I welded cast iron was an old above -ground water well pump that had been frozen and broken into pieces. I did not use silicon bronze but rather nickel stick welds and pieced it together like a puzzle , welded it together on one side to get the shape then ground into the cracks and welded back and forth till it was all solid welded. Pre-heating it every time. It took a lot of lunch breaks at my job but I got it welded up air tight.
Very satisfying to watch these repair videos sir. I look forward to the other vice repairs.
Thanks again for yet another great video, Jody. Can't wait to see the repair on that vise!
Nice repair, I've never used alum bronze on cast iron before but I've got some stuff in the garage to try it on, thanks for sharing.
Hey Jody,
Thanks for all the great info on TIG brazing! I have tried using SiBz dc, and AlBz ac on a few cast iron repairs with excellent results. There is also a third alloy available called Nickel-Aluminum-Bronze. This alloy has about the same melting temp as AlBz, but it has a substantially greater tensile strength. Have you ever used this or do you know anything about it? I would be interested in seeing a side-by-side comparison on this as well, and you are the man to do it! Thanks for all the great videos, you have really "upped" my welding game.
I fixed one of my old vises which had a good 3inch long crack with 2.5mm 304 SS stick welding rods, and the vise has never cracked on me again. I think that 304 + 309 SS works well on cast iron which does not heat cycle.
HOLY COW! Those alu/bronze rods are something like $400 buck per 5 kg down here in Oz. That's a freaking lot of rod in that weld!!!
Wow great tip. I've never tried to weld cast iron but I know the day will come eventually. Need to get out the powertig and do some practicing. I love these videos.
Awesome video. Great tips I’ve for years done a lot of aluminum Have never done stainless or any steel I’ve tried brazing once but this will really help me learn Thank you
Larry
I picked up a tig finger at my local Norco welding and I love it!
Burned
Hey Jody always enjoy your videos there great and you explain a lot about what your doing. I really love the tig finger too it's helped me out a lot. I wanted to ask for one request I would like to see a video of tig welding schedule 10 stainless steel pipe got a test on that coming up soon. Thanks
Nice example of what can be done. I would love you to show repairing fins on a cast iron motorcycle barrel if possible, I could really do with some tips on that.. I have one I have been working on but the material is so thin, even tig welding (or brazing, whatever folks prefer to call it) with silicon bronze I'm getting cracking. May get some ali bronze and try that now.Thanks Jody.
I do not understand why 25 peple gave "do not like".( people are jealous and spiteful ) Its professional work .Thanks for this video.
That explains why the mini vise I repaired with er70s2 failed so quickly, new welder here...
Well this was a surprise. I was expecting a video on how to weld a broken heart.
Now you gotta surrender your man card.
Mightiflier
Man cards were repealed years ago due counterfeiting and of course fraudulent misrepresentation.Such cards were recently replaced with a pair of prosthetic balls.
Dang, missed that!
It'll only work if you have heart colored welder ;p
I thought it was going to be how to weld the crack of dawn!
Thanks for the great videos, I haven't welded/tig brazed any cast iron, but I would like to, and after seeing you're vids I feel like I could get a handle on it without pulling out too much of my hair.
Nice product placement on the DiResta ice pick, too.
What's up Jody...you'll be at a million subscribers soon
I follow this channel just in case someday i can afford a tig welder.
...I've got a 1956 P&H 300 amp AC/DC TIG welder.,......they are pretty bullet-proof....old, big and heavy...all copper windings...self-contained water pump for 300 amp torch.....I went on the e-bay and found a few for $300-$500......a steal at that price...but they ARE big and heavy....and any problems, you better be an electronics engineer....! They Need 100 amps at 240 volts (or 50 amps at 480).....still....quite a good deal of you can fix minor stuff yourself..... P&H doesn't make welders anymore, but STILL makes some of the biggest electric Mining shovels for loading those 250 TON trucks.....top quality stuff....then, and now....
We all do
alexander love llll,llggl. G,m?,.c,gmgjcvgk
Started with $775 acdc 225amp tig welder...worked with it for a year, made money, bought and $1500 tig welder, 6 months later I bought Jody's welder lol Miller Dynasty 280, got it half price for $2900 on Ebay....just saying, if u want it, today, u can do it! Maybe not 20 years ago(wouldve been maybe $7500 to start up)
I have had great success with gmaw 035 solid wire. just the put piece back on as normal. it works because it doesn't shrink much
Robert M What setting were you using?
Diego Martinez the settings were just normal such as 19 volts and 400 wire speed. I have done several cast repairs and they are still good. it does make a difference how good the cast is. some cast is really dirty and it is better if the break is simple. stress will become a factor if the break is complex.
Just caught this today.
Amazing man. You are a great teacher. I never would have thought of building up that much.
It’s probably stronger than the cast original!
You da man.
you just have to make sure there is no porosity or inclusions
hey Jody if this job wasn't for a friend would it even be a feasible repair? With shop time and material vs vise replacement does it really pencil out for the customer?
Twenty minutes with a grinder and SMAW super missile rod would have done it.
Dumb question but you're saying for thick cast iron stick welding is the way to go?
It depends on several things, such as Jody's point about heat cycles in the particular application. For this cast iron, if you can hit it from both sides, and pre-heat, stick welding with a high nickel rod gets it done in most applications.
I probably would have turned the job down if it weren't for a friend. But it was kinda fun.
I think the cost of the vise was around 150 dollars. This job would have taken me about an hour if I wasnt filming it. But there are other methods that are quicker like stick. But I have lots of aluminum bronze rod I have had really good results with it so I went with it.
Well the tips and tricks are always appreciated, thanks for the video AND the reply
Jody, I've been tig welding for years, but I have a problem with my foot pedal every time I listen to bluegrass music! Hep me! Hep me! I cain't stop my leg! By the way, Burr King is made in my town in the Ozarks. Good little machine. Keep the videos coming . They are great.
That is one of the coolest things I have ever seen! Thanks tons Jody! I have had tons of poor or less than poor results using silicon bronze. I usually just end up throwing the whole piece out and getting a new one on the end. :-)
Great video! It is really interesting to see exactly how to use alumbronze to repair cast iron and it looks so cool too! Thanks for a solid repair and an awesome video to watch also, your the man!!
thanks JD. It was a lot of fun. And lots of opinions expressed here on better ways to do it too so maybe everyone learns something new from all the comments
Great video as usual. 👍🏻 I ran mag drills a lot at my last job, I love those things.
Thank you for all the comments and suggestions. I did some research remembering Keith Fenner doing this same job 2 years ago. Went back and watched his series My Pinion To Racks Addendum To Dedendum" Part Seven answered my question in the comment section where a viewer asked the same question about tig brazing a ductile cast iron gear. Keith Fenner's answer and reason for using oxy/acetylene and procedure was- he does not tig braze this type of job because it can melt the base material and cause unsuccessful bond and build up. He undercuts the repair area, pre heats to 550 degrees F oxy/acet. braze it using a general purpose low fuming LFBB bronze alloy rod and #2 high heat brazing flux then covers and lets the part cool slowly as he showed in his video. I feel this is proven sound advise for my gear tooth repair which I am going to follow. I am also going to try the tig method on a scrap cast iron gear just to see the results I get and do some destructive testing just to satisfy my curiosity.
love it... I need to build up the very corners of the moving jaw on a big old vise and this is the advise I was looking for. now it's time to get some of that aluminium bronze. :)
I beg your pardon, I write through the Google translator.
iron stew through the buffer layer. Buffer materials may be steel, copper, and nickel (nickel best). in your method of copper as a buffer, then you can continue surfacing of steel :)
personally usually I use nickel. with respect to the master of his craft from a colleague @ykt_master 🍻
Answered one of my questions, I'd miss this video somehow. Thanks for the wealth of knowledge you provide.
so basically you manually 3D printed a new leg for it.
that's quite cool.
Buzzwords! He dint print nothing! It IS Additive Manufacturing if you like, that has buzz appeal. Nobody will really care because it's an artisanal process, no apps, no stinking CAD.
@@leonardpearlman4017 glad to hear this artis doesn't stink
Hi Jody, great video, appreciate the videovideo's you do, I've been in the trade a long time but still enjoy learning new ways of welding different materials.
awesome can't wait to see the repair on that simplex I recently did one on a similar vise but I'm curious to see how it comes out! Rock on brother!
Hey Jody, another great video and commentary, I love it when you walk us through the process. I need to fill some holes in a radial arm drill table I am currently restoring so this method with TIG/Al/Bronze would be ok? Any hints how to tackle it ie should I concentrate on one area or spread the work out. The table is 640x900mm and holes all over it. I love the use of the Pyrex cups and use them all the time myself now as it seems to help my visibility of the torch too so thanks for putting me on to them. Cheers, Gordon, AUS
Hey Jody I really enjoy your videos I find them very informative. I was reading a blog on your website about starting a business I was wondering any chance we can see a video demonstrating some of the points in that video (ex. Welding desks, shopping carts, mailboxes) thanks
Well I have enjoyed watching your how to videos, I have learned a lot. I have a question that I think you will be able to give me the best answer. I have a very old metal lathe that my Grandfather used for many year. I have it now and have been using it for at least 50 years. Now somehow I over stressed the tool post holder which is also part of the compound cross feed. My question is what is the best method and material to get this back together with the highest strength?
great lesson , thanks , and the Tig Finger is great to use around here ....
How do aluminum bronze vs. silicon bronze compare for cast iron, what's the advantage of each?
Which one flows / wets easier?
Aluminum bronze. Looks a mistery to weld ! Definitely trying this out👍🏻🤘🏻
Never used Aluminium bronze on cast iron. I have repaired and built up some Victorian cast iron ram pumps 140 years old using 100% pure copper at the suggestion of of my local welding materials supplier.
I saw a video where the cast iron was welded with Silicon Bronze on AC with little cleaning action. I sort of thought that filler was about always to be used on DC. ??
Great video with lots of good tips - as usual :-)
thanks. I don't recall seeing a video on welding cast iron to steel. if you have one can you point me to it, basically looking to weld a gooseneck cast coupler. use your info and did buy an Everlast 160 tig, works great. looking to utilize my buzz box more, heard I can do cast with it as well.
thanks again.
Welding Art
About the flap disc rather than the welding. I got some ceramic 24 grit sanding discs a few years ago. They're better than a grinding disc on everything.
Hey Jody, do you ever sand blast things to prep metal? I fixed a vice recently and as usual, i did a quick clean up with a bead blast. And after seeing this, i will be trying a bronze braze as you instructed here. I used ER312 filler metal, and it worked good, but i could feel how hard the weld became because of the available carbon in the casting.
Thank you
The bead blast medium can contaminate the material you are welding.
What kind of shielding gas do you use for this process?
I use alumabronz allot to overlay crane hooks for paper mills so they don't gaul the bearing surface of the paper roll shafts, but we use a MIG spray transfer process.
Have a 6" vise just like that snapped the frame while installing ujoints. Was going to dump it but this gives me hope.
Laying that first bead down is called "Buttering the weld".
That's what I called it when I was dating my wife😝, only with her, it was buttering the biscuit lol
Thanks for the video not had any experience with alum-bronze welding but will get some rods and find something to weld... totally enjoy the videos and helps in brushing up on things not done in years or as in this video never... good insight and useful information.
Thumbs UP!
Nice old vintage heavy duty vise at the end there...👍..
Hey Jody, Interesting video. Do you think that filler rod would work well on injection molded aluminum? I work in a shop build up a surface made up of injection molded aluminum so it can be machined back to spec. The stuff is a real pia to tig- air pockets etc...
Is it easier to fill completely like that? I still don't fully understand why you didn't try to fit back the old pieces. -Welding Student
I've tried the silicon bronze rod on a vice repair. it was difficult to drill, had to heat treat to soften it. I'll try the aluminium bronze next. I`m not a pro but learning.
Would be curious to see TIG aluminum with with Muggy super alloy.
Maybe I missed it, but why not braze the broken foot back on instead of all that build-up?
WOULD SILICON BRONZE BE SAFE TO USE FOR A CAST IRON SKILLET. THANKS FOR YOUR TIME.
-BOB
I have been on the fence about welding my Wilton bullet vise that has a nice big chip on the shelf under the jaws i was thinking of silicone bronze i don’t have an ac tig welder no aluminum for me
Very good video and content. My question to you is I also have a cast iron gear with a broken off tooth like another viewer mentioned. The gear is on my South Bend lathe for the back gear. Do you think I should try tig brazing it as you did on your vice repair or do you think I would be better to fully preheat the gear and oxy/acetylene braze it and let it cool very slowly before machining or using a file to shape a new tooth ? It is a critical application with stresses on the gear when using back gear for threading. Your opinion would be greatly appreciated. Thanks Ed K. Cleve. Oh.
I would say do what you are most comfortable with and have success with.
I do think tig brazing would most likely work as well but a preheat and postheat would still be a good idea
Thanks for your reply. I think I will get a scrap cast iron gear of the same material, break some teeth out and practice both ways before doing the repair on the one for the lathe. I learn from every one of your videos, Thank you.
Eddie Kawecki I'll put my two cents in, I've repaired my share of engine, transmission and rear end parts over the years and found some cast iron and aluminum to be very bad castings and have soaked up oils like a sponge. Besides the pre and post heat procedures cleanliness is very important, sometimes a simple cleaning is all that's needed but sometimes I've had to heat the metal to 150℉ or more for an hour and you can watch the oils seep out. Older castings seem to be a tighter grain and not much of a problem. Just something to watch for, you hate to be almost finished and see crap floating out of your new repair. Good luck
How much rod is needed for such a repair??
I recently repaired a cast vice from a saw which had been repaired many times in the past using wrong techniques and materials.
I used nickel welding rods and it works pretty good!
and the way we support you is with a Thumbs Up and a BIG THANKS and one day when I get a tig welder I will be happy for you to mail me the finger
very nice repair.
I have never seen anybody change directions when TIG Welding. Can you change directions on Carbon Steel, SS, and aluminum also?
For gray cast iron nickel based electrodes or filler wire are using, if job is for big clients... My question is can we do mpi or pt test on welded joints? Nickel based.. So
...With a good root pass, this might be better than trying to stick that broken off piece back on...?
Tig Brazing, is not welding, when people are learning, it is a good idea to us the words that correspond with what your doing! You better than anybody knows what the difference between welding and brazing is!!
Great video. What filler metal would you use for a cast iron exhaust manifold? And what about cast alum intake?
Hi, did you use a cast iron filler to this job? mvh sverre eriksen, trondheim ,, Norway
Hi great video. I have a question what in your oppinion is best way to fix (add material) to chipped anvil. I have tig and mma welder available. many thanks for your support.
Great video, I love seeing repair work!
Thanks as always, Jody. but I expected you to sweat the two parts together. What would be the problem with this?
Awesome work Jody. Another super helpful video!
This guy can weld wood.
Nice work Jody!
Hey Jody, great video! Just curious if you like to get a buck an in for Tig welding, how much would you charge for a job like this?
I guess the question might be: "How much per CUBIC INCH?".
Amazing work Jody. I have a related question, I'm TIG brazing silicon bronze for artistic purposes. No joining of metals just filling voids for aesthetics. Would you recommend AC or DC? Base metal is clean AR500. I'm assuming you went AC because of the cast iron, just curious what you would recommend for a similar build-up project.
What rod would you recommend for TIG welding a cast iron handle back onto a cast iron pan that will have many heating and cooling cycles?
Have you published the video about the vise repair? I don't see it in your list. Maybe I just overlooked it?
I just picked up a heavy duty vise for free from a service tech at the dealership where I work. The fool was throwing it out because the jaws are beat up and rounded. Well if you had the replaceable jaws in there it would have held up just fine! I can true up the cast iron jaws on my mill and make new jaw inserts in a matter of minutes. But after running it through the parts washer I found a small crack at the back of the main casting. I could probably ignore it and be fine but I want to try to repair it. All the videos I'm finding on repairing cast iron this thin section parts, or this one where you used the filler metal to replace part of the casting. I need to figure out how to properly prepare that crack for brazing while not opening it so much that I can no longer braze it. Or do I just need to stuff it full of base metal shims and then braze it after I grind it open to clean it up?
Thanks for any guidance!
Definitely storing this in the memory bank
Thank you Jody. Another great video.
How well does it bond the filler for strength. In a case you have to add a piece of material thats missing like a small bar stock for build up are there are concerns?
Do you sell t shirts with that Hog welder ? And stickers with that hog welder ? I would love that logo on my welding machine or a hat
Ok, but can you please explain us how many amps you use, what is the gas flow?
Man that's a lot of bead running! I it was me I would have grinded a bevel and welded that ear back on.
What gas did you use?? Excellent work by the way.
Hey Jody,should you use a respirator because of the copper content in the filler.
This is more like brazing than welding, right?
The use of carbon steel instead of the damaged part is very simple, first use brass wire (copper-zinc alloy) flame brazing brass in carbon steel and cast iron two parts, and then carbon steel and cast iron brazing together, and finally need to slowly cool the internal The pressure will not be too much, the power will be much better! Video internal pressure accumulation, strength will be weakened.