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Welding a Diesel Motor Block

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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Many people would have said goodbye to an engine block in this shape, but Muggy Weld customer Cory Canning was thinking outside the box when he aspired to weld this cast iron 1989 Continental Diesel Block (commonly found in Miller Big 40D welders and Case Skid Steers)



As with all cast iron, you need the right tools for the job--in this case, Muggy Weld 77 cast iron electrodes and a TIG welder.



To prep for the repair, Cory broke the flux off the electrode and cleaned the wire with Scotch Brite(some welders choose to leave the flux coating on when TIG welding)

 

Cory then located all the broken cast iron pieces necessary to make the weld


 

Notice the sizeable hole caused by throwing a rod through the engine block--a common occurrence in improperly oiled machines.


 

After sanding/grinding the part to ensure all debris had been removed, Cory applied tack welds to ensure proper alignment while welding.


 

Cory TIG welded the pieces using a 2% Thoriated Tungsten and Argon Gas, and finished with a sanding disc and/or grinder. Note: Repairs such as this have been successfully performed with an arc/stick welding process...even with an old buzz box!


 

Just to give perspective on the size of the hole to be welded.


 

Cory tack welded the whole piece (mounting base) into the block and pre-heated the cast iron with a torch. He later post heated the part to ensure even cooling.


 

Another successful cast iron engine block repair using Muggy Weld 77 Cast Iron Electrodes.



Cory’s comments: My engine guy wanted me to use Lock & Stitch, but I saw your specialty wire and told him I was going that route. He warned me and doubted that it could be done. He was absolutely amazed when I dropped the finished block off.



Cory, thank you for taking the time to send us these photos. Another successful cast iron weld with Muggy Weld 77 electrode!

 

77 Electrode Products

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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..

1/2 lb 77 Electrode 1/8"
1/2 lb 77 Electrode 1/8"

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

1/2 lb 77 Electrode 5/32"
1/2 lb 77 Electrode 5/32"

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

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

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

1 lb 77 Electrode 1/8"
1 lb 77 Electrode 1/8"

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

1 lb 77 Electrode 5/32"
1 lb 77 Electrode 5/32"

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

5 lb 77 Electrode 3/32"
5 lb 77 Electrode 3/32"

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