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Hello, in today's episode I will be welding cast iron, a rutile coated electrode with a diameter of 3 mm,

which I additionally wrapped with copper wire with a diameter of one and a half mm,

in order to insert some soft material into the weld.

Thanks to that I hope that I will avoid or minimize stress in the welded material.

The first thing I would always do when welding this type of difficult to weld material would be to heat it,

for example, to a temperature of 200 degrees,

which will allow me to avoid stresses that will cause cracks or microcracks in the welded material.

As you can see, the cast iron that I will be welding during today's test is prepared so that

the place where I will be welding is open gap

and therefore some root should be done.

In this particular situation, I decided to weld the first layer from the top down,

which from my point of view will affect less stress in the welded material

compared to welding from the bottom up.

To be honest, before welding I was afraid that such a situation would happen somehow,

what you can see in the place where there should be a uniform weld, there is just a hole.

I am not sure what is the reason for the improperly made weld,

maybe the copper wire with which I wrapped the electrode,

may have oxidized during welding

or simply this type of material should not be welded from top to bottom.

However, when it comes to welding from the bottom up, I am honestly impressed because it works quite well.

I will add that for the first time I weld this type of material

with an ordinary rutile electrode wrapped with copper wire.

The quality of the weld can only be assessed after the material has cooled down,

which should be cooled slowly.

During the cooling time the material should be hammered

should be extended to remove the stress resulting from the welding process.

The weld is already a little cool so we can assess the visual quality.

To be honest I am impressed when it comes to quality,

taking into account the materials with which I made this connection,

admittedly there are pores or holes on the surface of the weld,

maybe this is the reason for the auxiliary material I used in the form of copper wire,

or just something this was not the case with my welding technique.

Personally, I think cast iron welding using this type of material is noteworthy

and I will definitely try to refine the technique or material selection in the future,

which I will probably publish a video about.

Due to the fact that it is an exhaust manifold, which, as you saw, is also welded in the weld there are holes

I can't leave it as it was made and that is why I have to repair the weld.

In this particular situation, I decided to use the Tig method to repair the weld.

I will try using the current alone without applying the binder to distribute the weld layer

superficially in order to remelt the incompatibility in the weld.

Not ignoring all the steps I mentioned earlier

we perheat the material before welding, hammered this material for sure

and do not overheat the cast iron during welding.

Due to the fact that the Tig I use is with a lift and at the end of welding on cast iron material,

there remains a crater that can be qualified as a crack,

which will certainly lead to further cracks in the materials.

In this situation,

I found a solution to extinguish the arc on the outer plate

thanks to which I will avoid this painful problem during welding.

After complete welding, the material should be hammered thoroughly

to eliminate the stress arising during welding.

Finally, I would try to extend the cooling time, for example by wrapping some insulation material.

Thanks for your attention and see you soon