Section 12 - Welding Consumables - Cast Iron Electrodes
Section 12 - Welding Consumables - Cast Iron Electrodes
Section 12 - Welding Consumables - Cast Iron Electrodes
Welding Consumables
Cast Iron
Cast Iron 1
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2 Afrox Product Reference Manual - Welding Consumables - Cast Iron
Cast irons, like steels, are essentially alloys of iron and carbon, Perlitic Malleable Cast Iron
but whereas the carbon content of steel is limited to a maximum
of 2%, cast irons generally contain more than 2% carbon. If full graphitisation is prevented and a controlled amount of
carbon remains in the iron during cooling, finely distributed iron
To facilitate a better understanding of these materials, they carbide plates nucleate in the iron at lower temperatures. This
can be divided into five groups, based on composition and can be achieved by alloying with manganese, or by replacing the
metallurgical structure: white cast iron, malleable cast iron, grey second-stage anneal by a quench (usually in air or oil).
cast iron, ductile cast iron and alloy cast iron.
It is used in applications where abrasion resistance is important Due to the presence of iron carbide in the microstructure, the
and ductility not required, such as liners for cement mixers, ball strength and hardness of these castings are increased over those
mills, certain types of drawing dies and extrusion nozzles. of ferritic malleable cast iron.
At room temperature, the microstructure therefore consists of The strength of grey cast iron depends almost entirely on the
temper carbon nodules in a ferrite matrix, generally known matrix in which these graphite flakes are embedded. Slow
as ferritic malleable cast iron. The compact nodules of temper cooling rates and high carbon and silicon contents promote full
carbon do not break up the continuity of the tough ferritic matrix, graphitisation, and the majority of the carbon dissolved in the
resulting in high strength and improved ductility. The graphite iron at high temperatures is deposited as graphite on the existing
nodules also serve to lubricate cutting tools, which accounts for flakes during cooling. The structure then consists of graphite
the very high machinability of malleable cast iron. flakes in a ferrite matrix, referred to as ferritic grey cast iron.
If graphitisation of the carbon dissolved in the iron at high
temperatures is prevented during cooling, iron carbide
precipitates out and the matrix is perlitic (referred to as perlitic
grey cast iron). Ferritic grey cast iron is normally soft and weak.
Ductile Iron
Microstructure of ferritic malleable cast iron (x200) Ductile cast iron, also known as nodular iron or spheroidal
graphite (SG) iron, is very similar in composition to grey cast iron,
Ferritic malleable cast iron has been widely used for automotive, but the free graphite in these alloys precipitates from the melt
agricultural and railroad equipment; expansion joints and railing as spherical particles rather than flakes. This is accomplished
castings on bridges; chain-hoist assemblies; industrial casters; through the addition of small amounts of magnesium or cerium
12 pipe fittings; and many applications in general hardware. to the ladle just before casting. The spherical graphite particles
do not disrupt the continuity of the matrix to the same extent
Afrox Product Reference Manual - Welding Consumables - Cast Iron 3
as graphite flakes, resulting in higher strength and toughness repaired. Fabrication errors, such as inaccurate machining and
Welding Consumables
compared with grey cast iron of similar composition. misaligned holes, can also be weld repaired.
Due to the widely differing weldability of the various classes of
cast iron, welding procedures must be suited to the type of cast
iron to be welded.
materials. Perlitic ductile iron produces a larger amount of Electrodes should be dried to minimise hydrogen damage and
Welding Consumables
martensite in the HAZ than ferritic ductile iron and is generally porosity. If machinability or optimum joint properties are desired,
more susceptible to cracking. castings should be annealed immediately after welding.
MMA, using nickel-iron electrodes, is the most common welding
technique for welding ductile iron. Most castings do not require
preheating, but preheats of up to 315°C are used on large
components.
Typical Applications for the Filler Metal Castings that have been in service are often saturated with oil or
Types Used for Welding Cast Iron grease. Exposure to high temperatures during the weld thermal
cycle can cause dissociation of these hydrocarbon compounds,
resulting in the formation of porosity in the weld. For this reason,
Filler Type Typical Application any surface oil or grease must be removed prior to welding,
Cast Iron Oxy-acetylene and arc welding of grey, ductile and using solvents or steam cleaning. The surface skin of the casting,
blackheart malleable irons where good colour match which may contain burned-in sand or other impurities from the
is required. Different consumables give either a flake mould, should also be removed. Castings that have been in
or a nodular graphite structure. service for extended periods of time may also require degassing
Ni Joining and repair of grey irons and for surfacing high by heating the casting uniformly to about 370°C for 30 minutes,
dilution welds in stronger grades. Produces a soft or for a shorter time to almost red heat (approximately 540°C),
peenable deposit. Special electrode coverings are using an oxy-fuel gas torch or circulating air furnace.
available to help repair deep cavities and blow holes.
If localised degassing is preferred, the weld area can be heated by
NiFe Joining and repair of ductile, blackheart malleable
depositing a weld pass, which usually becomes very porous, and
and higher strength grey irons. Also used to join cast
iron to dissimilar metals and for welding austenitic then removing it by grinding. This welding and grinding operation
irons. Can also be used on irons with high sulphur and is repeated until the weld metal is sound. The weld may then be
phosphorus levels. completed as specified in the welding procedure. Castings that
have been impregnated with a plastic or glass sealer should not
Ni FeMn Similar applications to NiFe fillers, but a stronger,
more crack resistant deposit is produced. be repair welded, because the sealer may inhibit fusion or produce
excessive porosity in the weld.
NiCu Used when a soft peenable deposit with good colour
match is required on grey, nodular and blackheart It is also important that the outer surface of the casting and any
malleable irons. Also useful for welding castings of ground surfaces be wiped with mineral spirits, such as acetone,
unknown type and composition. to remove residual surface graphite prior to welding. Residual
CuSn Mostly used for its good sliding and anti-seizing graphite inhibits wetting and prevents complete joining and
properties (i.e. for surfacing applications, particularly fusion. When wetting difficulties are encountered, the following
on grey irons). cleaning methods can be used:
Cu Al Similar applications to CuSn, but with poorer surfacing
properties, yet higher strength. Electrochemical cleaning in a molten salt bath operating at
a temperature of 455–510°C in a steel tank. By passing direct
Cu Mn Ni Al Similar application to Cu Al fillers, but used where
current through the bath, a surface essentially free of graphite,
higher strength is required.
sand, silicon, oxides and other contaminants can be produced.
Abrasive blasting with steel shot is suitable for preparing
Practical Considerations the surfaces of ductile and malleable cast iron, but should
not be used for grey cast iron.
Base Metal Preparation Searing the surfaces to be welded with an oxidising
flame or heating the casting to about 900°C in a strongly
Proper preparation of a casting prior to welding is very decarburising atmosphere, may be suitable in some
important. All traces of the defect must be removed from the applications.
casting, usually by chipping, grinding, arc gouging or flame
gouging. Dye-penetrant inspection is recommended to ensure Before any cleaning procedures are used in production, wetting
complete removal of all defects. Thorough cleaning of the joint tests should be conducted, using the proposed filler metal and
faces and adjacent material prior to welding is essential to welding procedure. The filler metal should be applied to a clean,
12 ensure successful repair welding and to prevent porosity and
wetting difficulties.
flat surface and then examined visually. If the surface is not
uniformly wetted, it has not been cleaned sufficiently.
Afrox Product Reference Manual - Welding Consumables - Cast Iron 5
Welding Consumables
Grooving Joint Face
Improved weld performance can be achieved by application of
several special techniques. These include:
Joint design modifications
Groove face grooving
Studding
Peening
Special deposition sequences and electrode manipulation.
50 mm
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Afrox Product Reference Manual - Welding Consumables - Cast Iron 7
Cast Irons
Welding Consumables
Type MMAW FCAW Gas Welding Gas Brazing
Grey Cast Iron Afrox Ferroloid 1 Filmax FN55 Super Silicon Fluxobronze M15
Afrox Ferroloid 2 Filmax Ni-1 Afrox M15 Bronze
Afrox Ferroloid 3 Afrox Nickel Bronze DB
Afrox Ferreloid 4
Afrox Transcast 55
SG and Nodular Cast Iron Afrox Ferroloid 1 Filmax FN55 Super Silicon Fluxobronze M15
Afrox Ferroloid 2 Filmax Ni-1 Afrox M15 Bronze
Afrox Ferroloid 3 Afrox Nickel Bronze DB
Afrox Ferreloid 4
Afrox Transcast 55
White Cast Iron (Chilled NR NR NR NR
Iron)
Malleable Cast Iron Afrox Ferroloid 1 Filmax FN55 Super Silicon Fluxobronze M15
Afrox Ferroloid 2 Filmax Ni-1 Afrox M15 Bronze
Afrox Ferroloid 3 Afrox Nickel Bronze DB
Afrox Ferreloid 4
Afrox Transcast 55
NOTES
1 Use Afrox Transcast 55 for joining, build-up and crack repairs.
2 Use Ferroloid 4 for cosmetic repairs.
NR = Not Recommended
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8 Afrox Product Reference Manual - Welding Consumables - Cast Iron
Afrox Ferroloid 1
Applications
This electrode is suitable for the repair of all commercially
available irons such as grey, blackheart malleable and nodular
spheroidal graphite irons, with or without preheating.
Classifications
AWS A5.15 ENiCu-B (carbon content modified)
EN ISO 1071 ENiCu-B (nearest)
Packing Data
(DC+ AC 70 OCV min)
Diameter Electrode Length Current Pack Mass Item Number
(mm) (mm) (A) (kg)
3,15 350 65 - 95 5,0 W075803
4,0 350 100 - 130 5,0 W075804
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Afrox Product Reference Manual - Welding Consumables - Cast Iron 9
Afrox Ferroloid 2
Welding Consumables
Afrox Ferroloid 2 is an all-position, basic coated electrode for the
strength welding of cast iron and for joining mild steel to cast iron.
The electrode uses a mild steel core wire and deposits a steel weld
metal, which tends to rust. A good colour match between the weld
and casting should not be expected.
Applications
Afrox Ferroloid 2 is used mainly for the repair of grey, i.e. failed
iron castings and defective components with and without the
application of a preheat. In both cases, the weld metal and heat
affected zone are unmachinable after welding and finishing can
only be achieved by grinding.
Classifications
AWS A5.15 ESt
EN ISO 1071 ESt (nearest)
Packing Data
(DC+ AC 70 OCV min)
Diameter Electrode Length Current Pack Mass Item Number
(mm) (mm) (A) (kg)
3,15 350 70 - 105 5,0 W075813
4,0 350 90 - 120 5,0 W075814
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Afrox Ferroloid 3
Welding Consumables
Applications
This electrode has been specifically designed for the strength
welding of high duty cast iron, such as meehanite, malleable and
spheroidal graphite or nodular irons. It is ideal for welding thick
sections of different types of cast irons to each other or to steel.
It can be used to weld high-phosphorous castings and to join
thin sections of gray cast iron to themselves or to other ferrous
materials. Although preheating is recommended, the electrode
can be used where no preheat has been applied.
Classifications
AWS A5.15 ENiFe-CI
EN ISO 1071 ENiFe-2 (nearest)
Packing Data
(DC+ AC 70 OCV min)
Diameter Electrode Length Current Pack Mass Item Number
(mm) (mm) (A) (kg)
2,5 350 70 - 90 5,0 W075822
3,15 350 90 - 120 5,0 W075823
4,0 350 120 - 140 5,0 W075824
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Afrox Product Reference Manual - Welding Consumables - Cast Iron 11
Afrox Ferroloid 4
Welding Consumables
Afrox Ferroloid 4 is a nickel cored electrode designed to produce
machinable welds in cast iron, without any preheat. When used
in the recommended manner, the fusion zone is extremely narrow
with hard areas of heat affected iron at a minimum. Welds are free
from cracks and porosity, and exhibit mechanical properties ad-
equate for cast iron. The colour match of the deposit approximates
that of cast iron.
Applications
This electrode has been specifically designed for the rectification
and repair of all commercial grades of cast iron, where machining,
after welding, is to be carried out. Preheating and post weld heat
treatment is not required in many applications where the location
of the defect or shape of design is such that high stresses are not
developed. Control of heat input is essential, particularly avoiding
local heat build-up.
Classifications
AWS A5.15 ENi-CI
EN ISO 1071 ENi-Cl (nearest)
Packing Data
(DC+ AC 70 OCV min)
Diameter Electrode Length Current Pack Mass Item Number
(mm) (mm) (A) (kg)
2,5 350 40 - 90 1,0 W072832
2,5 350 40 - 90 5,0 W075832
3,15 350 60 - 105 1,0 W072833
3,15 350 60 - 105 5,0 W075833
4,0 350 90 - 135 5,0 W075834
5,0 350 150 - 190 5,0 W075835
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Afrox Transcast 55
Welding Consumables
Applications
This electrode has been specifically developed for strength
welding of high duty cast irons such as alloyed cast iron,
meehanite, and malleable and nodular irons. It is ideal for welding
various types of cast irons to each other or to steel.
It may also be used to weld high phosphorous castings and to join
sections of grey iron to same or to ferrous materials. Although
preheating is recommended, the consumable can be used without
preheating the parent material.
Classifications
AWS A5.15 ENiFe-CI
EN ISO 1071 ENiFe-2 (nearest)
Packing Data
(DC+ AC 70 OCV min)
Diameter Electrode Length Current Pack Mass Item Number
(mm) (mm) (A) (kg)
3,15 350 80 - 125 Sleeve (2 electrodes) W072933
3,15 350 80 - 125 1,0 W072934
3,15 350 80 - 125 5,0 W075933
4,0 350 90 - 150 5,0 W075934
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Afrox Product Reference Manual - Welding Consumables - Cast Iron 13
Welding Consumables
Afrox Filmax Ni-1
Afrox TIG Ni-1
Afrox Ni-1 solid wires for TIG and MIG welding are designed to Applications
give a low carbon pure nickel deposit with the addition of tita-
nium for refinement and de-oxidation. They are used for joining Applications include tanks and vessels, process pipework
pure nickel to itself, for buffer layers, and for cladding joint faces and heat exchangers, in chemical plant for salt production,
and flanges. The solid wire is also useful for welding cast iron to chlorination and evaporation of caustic soda. Also used for
give a soft low strength deposit. Afrox Filmax Ni-1 is also excel- handling corrosive alkalis and halides. Repair and rebuilding of
lent for metal spraying. standard grades of grey cast irons and malleable cast irons.
Materials to be Welded
ASTM-ASME BS DIN Proprietary alloys
UNS N02200 NA11 2.4066 Nickel 200 and 201 (Special Metals)
UNS N02201 NA12 2.4068 Nickel 99.6 and 99.2 (VDM) 2.4061
Classifications
AWS A5.15 ENi-CI
EN 18274 Ni 2061 (NiTi3)
Packing Data
(DC+ AC 70 OCV min)
Diameter Pack Mass Item Number Diameter Pack Mass Consumable Item Number
(mm) (kg) (mm) (kg) Length (mm)
1,0 15,0 W077672 1,6 5,0 1 000 W077667
1,2 15,0 W077673 2,0 5,0 1 000 W077668
1,6 15,0 W077674 2,4 5,0 1 000 W077669
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Applications
Typical components are machine bases, pump bodies, engine
blocks, gears and transmission housings.
Materials to be Welded
ASTM/UNS BS
A602, A47, A338, A220 2789 – SG irons
6681 – Ductile irons
Classifications
DIN 17745 2.4472
BS 2901Pt5 NA47
Packing Data
(DC+ AC 70 OCV min)
Diameter (mm) Pack Mass (kg) Item Number
1,0 15,0 W077695
1,2 15,0 W077696
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Afrox Product Reference Manual - Welding Consumables - Cast Iron 15
Welding Consumables
Afrox Super Silicon Cast Iron
A general purpose high silicon, square section rod for gas welding,
and rebuilding grey cast irons. The weld deposit is machinable and
gives an excellent colour match with similar corrosion resistance
to the base metal. It is widely used for rebuilding and repairs to
cylinder heads, water pumps, etc.
Brazing/Welding Parameters
Process Oxy-acetylene
Flame Setting Neutral
Flux Cast iron flux (Item Number W001524)
Packing Data
Diameter Electrode Length Pack Mass Item Number
(mm) (mm) (kg)
5,0 500 5,0 W000372
6,0 500 5,0 W000373
10,0 500 5,0 W000374
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16 Afrox Product Reference Manual - Welding Consumables - Cast Iron
Classifications
AWS A5.27 R CuZn-C
Rod Identification
M15 Stamped
Brazing/Welding Parameters
Process Oxy-acetylene
Flame Setting Neutral (depending on base metal)
Flux Use with Afrox M15 Brazing Flux (Item Number W001553)
or Afrox Liquid Flux (Item Number W001555)
Packing Data
(DC+ AC 70 OCV min)
Diameter Electrode Length Pack Mass Item Number
(mm) (mm) (kg)
2,0 750 5,0 W000504
3,2 750 5,0 W000500
5,0 750 5,0 W000501
6,3 750 5,0 W000502
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Afrox Product Reference Manual - Welding Consumables - Cast Iron 17
Welding Consumables
A general purpose flux coated bronze alloy used for bronze
welding and brazing copper, cast iron, steel sheet and for light
assembly work. This low fuming brass rod is fast flowing and
leaves minimal flux residue. The fast flowing nature of the alloy
reduces heat input which causes distortion.
Classifications
AWS A5.27 R CuZn-C
Brazing/Welding Parameters
Process Oxy-acetylene
Flame Setting Neutral
Packing Data
Diameter Electrode Length Pack Mass Item Number
(mm) (mm) (kg)
2,5 450 5,0 W000375
3,2 450 5,0 W000376
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18 Afrox Product Reference Manual - Welding Consumables - Cast Iron
A versatile 10% nickel bronze alloy rod suitable for bronze welding
and brazing of steel, cast iron and copper alloys. Since the weld
deposit work hardens in service, the rod is ideal for building up
worn or broken parts such as gear teeth, bearings, valve seats and
faces. It is widely used for maintenance work.
Brazing/Welding Parameters
Process Oxy-acetylene
Flame Setting Neutral (depending on base metal)
Flux Use with Afrox M15 Brazing Flux (Item Number W001553) or
Afrox Liquid Flux (Item Number W001555)
Packing Data
Diameter Electrode Length Pack Mass Item Number
(mm) (mm) (kg)
1,5 700 5,0 W000520
2,0 700 5,0 W000522
3,2 700 5,0 W000521
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Afrox Product Reference Manual - Welding Consumables - Cast Iron 19
Welding Consumables
Afrox Cast Iron Flux
Packing Data
Container Mass (g) Item Number
500 (jar) W001524
Packing Data
Container Mass (g) Item Number
500 (jar) W001553
Packing Data
Container Mass (l) Item Number
5,0 (container) W001555
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