TFS: Cast Iron Weld Repair with Aluminum Bronze
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- เผยแพร่เมื่อ 27 ก.ย. 2024
- Just a quick vid on TIG brazing cast iron with aluminum bronze. If you need more detail like we usually do - say so. We just might get deeper into the subject....
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Justin as a welder of over 50 years I want to say you are a very good explainer of what you are doing and what to do. IMO you would make a great instructor.
PS - I'm still watching - LOL
His name is Justin lmao
@@jeremymatthews5169 Changed - thanks.
Jason?
@@colebz420 I had wrote Jason first by mistake but Xzempt corrected me so I edited my comment and fixed it.
Weld looks perfectly functional. Plus props for not being afraid to post a rough one.
*braze
Best channel on welding, explains things very well for newbies like me. I am going through restoration process of an old valve resurfacing machine Kwik-Way model P from 1930ies era, its all made from cast iron and there are several delicate pieces broken, also several cracks in oil collector pan etc.. Will try TIG braze it back to life. Thanks for the educational videos.
I have yet to get Aluminum Bronze to flow how I like it, thanks for the demo. I have a customer that brings me 3 or 4 toyota 22R pick up turbo manifolds a year that all crack in the same location. For those I do the same prep with much more pre-heat and use Nickel 99 stick rod with the flux cleaned off with a wire wheel and TIG it on AC just the same. When finished they look surprisingly good, similar to TIGed steel and they never come back.
Thank you again for the great content.
Very educational. The exhaust manifold on my 4cyl Tacoma cracked 20 years ago and I had the local ag welding shop try to fix it rather than buying a new one. I think they braised it, but can't remember after all these years. It lasted about 25 miles before cracking again. After a brand new manifold also cracked, I replaced it with a stainless header that also boosted my torque a little.
Normally I use dc for this, next time I will try the ac settings, thanks.
For me dipping my rod in borax powder makes the bronze flow even better and makes the dirt flow on top of instead of in the bronze.
I love your voice on the voice over! Subscribed, and now I'm going on a trip through the old video
Good explanation on how and why this technique works so well. While it works well on old and dirty cast, it works even better on new and clean material. With the right conditions, it can have a bright polished gold look.
Very informative video!...I've done a fair amount of Silicon Bronze but knew nothing about Aluminum Bronze. BTW It never occurred to me to ding you because the repair "didn't look good"..Thanks for another great vid!
Thank you again!!! Thanks for all the explanations of the whys for your decisions on this weld. Awesome!!
People say I'm verbose sometimes. But at least when I explain something I leave them without understanding. Good job taking the time to explain.
Great explanation of this technique.
Good video! I have used silicon bronze for this type of repair as well.
I weld and braze with alu bronze pretty often, and have found that it works best for me at about 80% EN, a little more than you were using. And the A2 alloy works better than the other alloy. (Just trying to help)
Yes, I get the bevel. Everyone says to preheat cast iron, but I never do. I heat it as I go. I use pure argon and slow down the wire feed speed so I can "ball" it and dip it. Works great with aluminum bronze and silicon bronze as well. Never had one break near the weld. Ever. Argon or helium only( if you're rich) and slow heat up. Also, it wets so well, I never clean up, lol.
I did a little bit of bronze brazing when I was down in Mississippi at the Seabee training center down there. It’s definitely a wild thing to use and try to get used to.
Great !!... I have done it with a stick welder about 100 times.... I am going to do my next block or manifold this way and see what I get. Thanks for the great video.
Well explained , Well Done ! Push/ scrub rod into weld pool and try to keep arc on the wire / weld puddle . Similar to gas brazing, flux will also help.
I've made similar repairs on cast iron but used a bit of a different method to prepare, before grinding along the crack drill a series of 3/16 holes along the crack without breaking through, now after grinding you will have a much larger clean purchase to put the bronze in place, not only does it provide more adhesion but also gives a greater amount of bronze joint width to give a less rigid seam reducing the chance of another crack developing.
Great review, but need to stipulate the need for Argon. thanks again!
Justin..have used this material on lots of cast iron...anzing how strong it is if done correctly....thanks for sharing this great tech to the world...best regards...Paul
great video I have some welding experience but mostly stick and gas so learning all the time. Three suggestions for the repair unrelated to the brazing directly, 1 if you have an ultrasonic cleaner in the shop it will get your crack cleaner, 2 I noticed you preheated the general crack area with the propane a more thorough preheat and a post heat will help reduce re occurrence, 3 while you have the burr out clean all the casting dags off as this will also help stresses travel through the casting and reduce the chance of more cracking, probably irrelevant because I see a set of custom headers in its future, or an ls3 cheers for the great video and explanations
I can't wait to see what you have in mind for the truck!
I still enjoy welding cast with the old torch and brazing rod
Used some today repairing jaws to an adjustable wrench! I’m impressed with how strong it actually.
Justin your a great Teacher. Have you ever Tried Half argon & half Helium. Talk about a Wet & flowing Puddle. the extra heat is amazing. It also works Very well on all Copper.
Sweet video Justin! I was wondering the difference in bronzes! Thanks man 👊
I had 3 of those trucks. A 90 2.4 with a home brew supercharger, a Carby 87 2.0 and a Carby 88 long bed D-50. Miss em.
Good video , I had a 1995 mighty Max , fun little truck to drive , miss it but it spun a bearing and didn't have time to fix it so had to get rid of it .
Pretty neat stuff just did a cast iron manifold! I will have to try out aluminum bronze!
Once again thank you for taking the time to show us looks very good
Another premium video !!! - Light-bulb moment for me Thanks HUGE!!!
This is going on a manifold. What is the typical operating temperature of this? The service temperature of brazing alloys is under 500F. Copper and copper-zinc filler metals are generally used on ferrous metals. They can also be used on many nonferrous metals. The upper service temperature for these alloys is 400°F (200°C)
Real world situations, I dig it. And I like the mighty max. Time for a 4g swap video lol
Fighting Fire with Fire is an Aussie move. 👍👍
one of the things i did not see what is the argon flow setting?
and well done!
Really well done - THANKS!
EDIT from below -- Is aluminum bronze good for cast iron to under 1/4 inch thick steel?
Great instructions following the Key Rule: You have anticipated and answered ALL of the inevitable questions, VERY well. Thanks again - you saved me a bunch of time.
Easy to follow lesson and presenting reasons why you did what you did. Question about the finishing the braze. I guess if one were doing it for "show" it should be ground down, cleaned up, etc. But if it was wholly for repair could you have left it as finished after the 1st pass braze. Or should a 2nd pass be made to blend it in more?
I brazed Manifold one time and found out the hard way that it does not work, and that I did with a torch, I’m just wondering if the bronze part of your filler rod presented any issues?
If I have the chance I’m going to try it for my self, it does look very promising, thanks for the information.
Thank you for demystifying this - great video.
Tig brazing and mig brazing - the argon takes the place of the flux that you need when you oxy fuel braze.
That would have been good info to add I reckon. Hopefully I'll remember if I revisit the topic (credit to you of course)
@@TheFabricatorSeries yep Pete know his stuff too. If you dont follow him you should.
@@mrgreenswelding2853 Where would one find him ?
@@barryhorne7052 click on Zila above that Peter Zila's channel.
I've only oxy-acetylene brazed, with flux - while you don't need it for preventing oxidation reactions, wouldn't the use of flux aid the cleaning/floating out action on remaining contaminants in the crack?
Can you do a stainless steel to cast iron tig video? I've been seeing guys weld v-bands to the hot side of turbos for external waste gates.
Thanks.
Hey Justin, quick question for a newbie TIG welder. Can you bond steel to cast iron, such as a steel manifold bolt to the manifold? Thanks for any help you can give!
Love it great welding can’t wait to see what you do with the project. Keep up the great work
Ithiz goud edeya your the best
Nice work Justin, I am going to have to try aluminum bronze, I have only used silicon bronze.
Gibe it a go! I like it more than silicon bronze at the end of the day. The "gold" is 10x more lustrous (and it's a bit stronger).
Yep, gna have to get a pound of that stuff. Also thinking about trading my Everlast 210EXT out for that HTP 221. Good idea? (I want a better, more controllable AC arc, and spot timer) seems that HTP gets better reviews than the everlast 350ext, already got basic Dynasty 280 for high amps
Liked for the brazing, followed for the FIGHT FIRE WITH FIRE wisdom hahaha
Big project without name? It's got to be "Mitsubig'a'project"..haha. Thanks for good advice about al.bronze.
Thanks bro...for explaining that really helped me out a lot
Nice job👍🏾
It's beautiful!
Cool stuff ....l have to weld a flywheel/ pulley.... Thick Cast iron part does not get hot ....l have silicon bronze in the workshop.... Or should l buy Alum Bronze???
Precision Panel Craft.
Thank you for explaining why you used aluminum-bronze over silicone-bronze. That said-isn’t it possible to use AC with silicone bronze or is there a reason that would be taboo?
Wondering if this will be a good technique for repairing a vise with a missing jaw shelf. Material needed to attach to create missing piece.
What are the (dis)advantages of stick welding for this project? I hear stick welding is often preferred for cast iron.
Hi I’ve never been taught how to weld professionally my dad just turned me loose when I was young I’ve welded cast with a gas torch and silicone bronze and had it stick well do you ever fix any cast with the gas torch and if u do I was wondering if you had a video on it so I might learn proper thank you for your time and everything
If the manifold had a hole in it, say the size of a silver dollar, would you fill the hole by running beads around the perimeter until the hole was filled, or could you use a piece of mild steel to fill the hole, and then use the aluminum bronze to secure it? And, in your opinion, would either of these choices be a long term successful repair?
Very cool. Thanks for sharing!
Thank you for saying silicon bronze in the video. The whole time I was watching I was trying to think of that name. my brain was going magnesium bronze no, titanium bronze no, those probably don't exist but I was just trying to think of it. Do you think this stuff is good enough to attach steel pipes to a cast iron exhaust manifold that will be used for a turbo ? I know its strong enough but will a turbo manifold get hot enough to melt it. I guess i could just look up the melting points and then guestimate how hot the exhaust should get.
Everytime i try tig brazing i have mini explosions happen. With or without gas, heat parent equal to filler or focusing on filler doesnt matter what i try. Ive tried the type with white flux and bare type. What am i doing wrong?
Nice vid but minor nit. This is a demonstration of braze welding which is not the same as brazing. You applied the arc directly to the filler metal. If you brazed you would heat the target and the filler metal would melt on contact and flow in via capillary action. It is not possible to braze with an arc because you need to generate large heated area.
Thanks! Great video!
Did u ever finish the project out of this truck??
Great vid thanks for posting!
Two thumbs up great job explaining
First of all, love the videos. You have taught me quite a bit about welding and I appreciate it greatly. My question, would it be a bad idea to drill a few more small holes at angles to essentially give the brazing rod more places to bite into and hold onto the cast iron, or is that completely unnecessary? I'd suppose if this had a turbo it might be more important for it to have a stronger hold on the base metal. Just a question that popped into my head while watching this. Looking forward to more videos of your mighty max! I'm the same way with the OBS Fords... Although after working on one for a while, I completely understand some folks hate for Ford lol. They just had very little clerical skills, or common decency with their building methodology 😅. Thanks again!
Edit: just noticed this is two years old LMAO whoops! You've already taken this apart and are building a tube chassis 🤣
How has it held up?
great vid, but could you show how to weld cast iron? i have been told that it can be done by pre heating the cast iron, then using mig process with er70 s6 in very short stretches no longer than one inch at a time then pern the crap out of it, wait for part to cool then repeat i have not welded cast iron only read about it, so i an interested.
Can you use silicone bronze
Just out of curiosity, when the cast iron heats up under normal conditions when the crack would start flexing wouldn't the bronze break free from the cast iron?
Where can I buy these aluminium bronze rods? Brand name?
Does anyone know why there is lot of white smoke when tig brazing?
I was waiting for the fire! Lol!!
Nice job too!
Heres a question, can all cast iron be brazed, had one that kicked my ass and nothing would melt onto it and stick.
It was an old fireplace grate probably from the early 1900’s, all it did was make big porous bubbles of black like carbon and any filler I had tried just beaded up and rolled off.
I was guessing it was a super high carbon content cast that wasn’t even weldable.
Wire brush is not enough, use a flapper. That will help with the carbon grunge. I agree with looks and sometimes you just have to repair the problem. That's also why they make grinders. Tell the naysayers, pretend you just went out and bought a repaired one. Grind on that!
Thanks for the videos! Have you tried 312 stainless filler for cast ever? I’ve had decent luck on pump casings with it. I do use sib and aluminum bronze as well.
Old vid I know - sorry for going necro. But question is - you mentioned you’re using AC I think ? So since you’re only using the torch for heat could you do this with a DC rig? Thanks.
Justin, Have you tried EZ Weld TIG wire for cast iron?
Interesting thanks for the info!
I'm curious when you when youenclose a bronze mixture in does it cost to go into the grain of the cast iron or does it just float on top the reason why I'm asking is I was wondering if it makes a mechanical Bond or if it just builds in the crack or does anything
Hi Great video.What kind of tungsten did you use? Also was it pointed or balled?
Would aluminum bronze be good for welding (brazing whatever) something like an axle truss to an axle housing? I've seen lots of videos where people just preheat and mig mild steel straight to the casting but im not sure how much I trust their back yard fab. Would there be any advantage from one to the other?
Thanks
Yep still watching! What are you going to do, drop a blown Hemi in the little truck? Ha!
JUSTIN IS MY HEROOOOOOOOO!!!!!
how about a video welding cast iron?
I'm limited to my DC tig machine would aluminum bronze still work?
yes
What about using silver solder?
more expensive !
6.0 ls swap and 7875 turbskie on the mighty max. go go go
As always, great video. What type of tungsten were you using?
try green 3/32
This isn't relevant to this video, but maybe you can help me out with something.
Justin, what is the little pot that you use for holding solar flux!? I've looked using all sorts of search terms, but can't seem to find anything other than closed glue pots for rubber cement.
The pot itself is a 3 inch tube welded to a disc to create a cup. The cup just conveniently fits inside of a silicone reducer I had laying around. It looks fancy, but it's just scraps.
@@TheFabricatorSeries
I thought it might be something like that. Thanks. I'll see what scraps I have around the shop. Always nice making something instead of buying something, anyway.👍
@@cavemanjoe7972 I used the bottom of a Pepsi can for a lot of years before this haha
@@TheFabricatorSeries
Ha! That's great!
Can't do that in the shop I'm in right now, though. No matter how many times I told him, the owner would throw out my pepsi can with my solar flux in it while complaining about garbage. I've been using an old Altoids tin that I spray painted red and threw a random company logo sticker on to make it look like a small tool case so if anybody moves it, they just toss it in the side bin on my tool box.😂
I have done these types of repairs many times using my acetylene torch. I just got a TIG outfit and have wanted to try doing this for a while. Is there any difference in the rods used for oxy fuel brazing and TIG brazing? Also I had always belived that the aluminum bronze is used on cast iron because aluminum is prone to iron pickup. Basically this means that Iron and aluminum bond chemically and to date no process has ever been developed to separate them. Any chance this is a reason for the use of this filler in this situation.
Flux is on oxy fuel brazing rods
@@Sicktrickintuner, well, yes and no. Oxy fuel rods also come uncoated and you heat and dip them into a powdered flux that I believe to be borax. These rods last indefinitely in storage provided they do not corrode. They are only slightly less convenient. My question was about the metallurgical differences. I know that tig welding rods do differ slightly from oxy fuel welding rods and I was hoping that someone could fill me in. I do have a hand full of silicon bronze uncoated gas rods and I was wondering would these work ok with the TIG?
Can you join mild steel to cast iron with this procedure ? { example modify a 200ci Ford intake. }
yes
awesome vids
Could you of used a welding torch instead of a rig torch
FYI if you can weld/braze this is what you do instead of using JB Weld!
It looks good to me.
MIC- FROM MEXICO hello does anyone have an idea how to weld antimony?
Its says Mitsubishi, but it turned out to be a Sonabitchy ! just kidding there good trucks
Where's the Mighty Max project!?
Still watching....