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How to Arc Weld a Cast Iron Exhaust Manifold

Testimonials

Mike,

These pics come from a new aerospace test facility that they are constructing at the University of Notre Dame. The SSF-6 is working great.

 

aluminum welding and metal repair

I am attempting to make all of these fittings air tight as they are used for pressure measurements. We can¹t have any leaks. I had very little warpage of my base metal and I think this is really going to work out very well.

 

metal fabrication and repair with muggyweld

Thank you,

 

David Hipskind
Turbomachinery Technician
The University of Notre Dame
Institute for Flow Physics and Control (FLOWPAC)
The Hessert Laboratory for Aerospace Research

 

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En Espanol

Second repair on Cummins exhaust manifold. Mike used a 130 amp mini welder to make the repair, to demonstrate a worst case scenario for using our electrodes.

 

A cast iron exhaust manifold from a Cummins diesel truck was headed for the junk pile because the shop did not have a cast iron welding rod to repair it. At a cost of $400 to replace, our 77 and 72 rods were an inexpensive alternative.

 

We did not preheat the part and experienced no re-cracking when the weld had air-cooled.

 

TIPS:

 

Always weld no more than 2 inches at a time and let cool for 2 minutes between passes. For some cast irons you may only want to weld an inch or less and let cool 1 minute between passes.

 

Low and slow is the key to a sound weld with cast iron.

 

77 and 72 Electrode Products

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Exhaust Manifold Repair Kit 3/32"
Exhaust Manifold Repair Kit 3/32"

Kit Includes: 3 rods 77 electrode 3 rods 72 electrode ..

Exhaust Manifold Repair Kit 1/8"
Exhaust Manifold Repair Kit 1/8"

Kit Includes: 2 rods 77 electrode 2 rods 72 electrode ..

Exhaust Manifold Repair Kit 5/32"
Exhaust Manifold Repair Kit 5/32"

Kit Includes: 2 rods 77 electrode 2 rods 72 electrode ..

Cast Iron Combo 3/32"
Cast Iron Combo 3/32"

Kit Includes: 11 rods 77 electrode 11 rods 72 electrode ..

Cast Iron Combo 1/8"
Cast Iron Combo 1/8"

Kit Includes: 7 rods 77 electrode 7 rods 72 electrode ..

Cast Iron Combo 5/32"
Cast Iron Combo 5/32"

Kit Includes: 4 rods 77 electrode 4 rods 72 electrode ..

1/2 lb 77 Electrode 3/32"
1/2 lb 77 Electrode 3/32"

Save those expensive parts: cast iron exhaust manifolds, cast iron engine blocks, Caterpillar parts..