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Cast Iron Welding Rods

Testimonials

Mike, I have to tell you that your 77 cast iron electrodes are fantastic--I need to order more to have it on hand.

 

I just welded a small block Chevy 400 engine with a broken ear on the starter mount. The engine was sitting on a 3 wheel engine stand and fell over breaking the mount. I placed a mild steel bolt in the broken mounting hole and built the whole corner back up, then I removed the bolt and re-tapped the bolt hole with no problem. It's looking pretty good.

 

I work on hard to find and restore irreplaceable antique cast iron parts. Your 77 welding rods are better than anything I've tried in the past. I'll try to remember to send you photos of my next cast iron job.

 

- Bob Carpenter
Ephrata, WA
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77/72 Cast Iron Welding Rods

Cast iron typically has a carbon content of two to four percent, which is roughly 10 times the amount found in most steels. This quality makes cast iron brittle and often difficult to work with. Instead of having to form new castings, 77 and 72 cast iron welding rods from Muggy Weld helps users save money and make effective repairs on existing castings.

 

Working with Cast Iron

 

The single most important thing to remember when working with cast iron is to keep it out of the 150 to 500 °F range. Use both cooling and heating, and make sure not to change methods in the middle of a weld. Preheat the entire casting slowly and uniformly in the 500 to 1200°F range and see to it that it doesn’t overheat.

 

During and after working with cast iron, remember to allow the casting to cool slowly, or keep it cool but not cold. Using our cast iron electrodes, make short 1-inch welds to avoid overheating, and peen the weld between passes if possible.

 

77 Electrode 72 Electrode
Sizes available 5/32", 3/32", 1/8' 5/32", 3/32", 1/8"
Arc - TIG - Braze Arc - TIG Arc - TIG
Works on engine blocks Yes No
Works on large cast iron holes Yes Yes
Joins cast iron to steel Yes Yes
Joins cast iron to metals other than steel No No
Works on exhaust manifolds, woodstoves, or other burnt cast iron Good Great
Works on thin cast iron Yes Yes
Color match? Fair Fair
All position? Yes Yes
Machineable? Yes No
Paintable? Yes Yes
Works over existing welds? Fair-- better on unwelded surface Fair
Depth to bevel cracks 3/4 through 3/4 through
Crack resistant? Yes No

72 Information

Available in  3/32", 1/8", 5/32" 

There are occasions in industry where exceedingly dirty cast iron is encountered. 77, which bonds well to most cast iron does have a limitation. Since 77 has controlled penetration, which is ideal for non-cracking and machinability, it may not be able to bond exceptionally dirty cast iron. 72 should be used instead. It has a high penetration, can anchor deep into the subsurface of dirty cast iron, and seals in porosity generating contaminates prior to finish welding with 77. 72 is used for a cladding operation, then the weld is completed with 77.

 

72 is our recommendation for welding cast iron exhaust manifolds.

 

Welding positions: flat, vertical (up), horizontal, vertical (down), overhead

 

Welding techniques: Use stringer or moderate weave technique. When cladding, cover the entire base surface prior to finish welding.

 

Applications: for non-machinable welds on exhaust manifolds, furnace grates, cast iron stoves, machine bases etc.

 

How to Apply

Begin by beveling the joint. Drill holes 1/2 from each end of the crack to prevent further cracking while welding. Tack weld to retain alignment. Use AC or DC with reverse polarity. (50- 80 amps for 3/32" rods, 70-110 amps for 1/8" rods, 95-140 amps for 5/32" rods)Maintain a short to medium arc and make short passes and peen each pass promptly to chip off slag before cooling. Continue back whipping and overlapping until all deposits are connected. Cool naturally.


77 Information

Available in  3/32", 1/8", 5/32" 

 

How to Apply

 

Begin by beveling the joint. Drill holes 1/2 from each end of the crack to prevent further cracking while welding. Tack weld to retain alignment. Use AC or DC with reverse polarity.... (50-70amps for 3/32" rods, 60-110 amps for 1/8" rods, 90-140 amps for 5/32" rods) Maintain a short to medium arc and make short passes and peen each pass promptly to chip off slag before cooling. Continue back whipping and overlapping until all deposits are connected. Cool naturally.

 

Welding positions:  overhead, flat, vertical (up), horizontal, vertical (down)

 

For more information on 77/72 welding rods and to watch instructional videos, click the links below:

 

Cast iron Welding Videos

Cast Iron Welding a Stover Pump BaseNew!

MuggyWeld.com customer testimonial on 77 cast iron electrode.

1986 580 E Case Backhoe RepairNew!

Welding a cast iron front axle on a 580 E Case backhoe.

Crack Free Cast Iron Welding New!

Whether you're working with gray cast iron, malleable cast iron, or nodular cast iron, Muggy Weld 77 electrode can make the repair--simply, quickly, and without pre-heating or special cooling procedures.

Cast Iron Welding: How to Weld a Cast Iron Engine Block

1989 Continental Diesel Cast Iron Engine Block with a sizable hole punched through from a rod was welded with MuggyWeld 77 Cast Iron electrodes. Our customer used TIG welding for this motor, but many of these engines have been repaired using arc or stick, even with an old buzzbox.

Welding a Jeep Wrangler Engine Block

A 2004 Jeep Wrangler engine block with a piston skirt hole is welded with 77 cast iron electrode

Cast Iron Welding: Cummins Diesel Cast Iron Exhaust Manifold Repair

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.

Cast Iron Welding: Cast Iron Fireplace Stand Repair

This fireplace stand had a broken-off leg, so we wire wheeled the paint off and used our 77 electrode with a 130 amp mini welder to make the repair.

Cast Iron Welding: Cast Iron Diesel Marine Blower is Repaired with 77 Electrode

This blower has a large cut into the cast iron. We used a grinding wheel to bevel halfway through, and made the repair with our 77 cast iron rod and a 130 mini amp welder. After making the repair we used a grinding wheel to smooth the surface, and the part was as good as new.

Cast Iron Welding Articles

 

Cast Iron Welding

A 1989 Continental cast iron diesel block is welded with Muggy Weld 77.

 

Cast Iron Exhaust Manifold Repair

Lincoln cast iron water pump being welded with 77 electrode.

 

Cast Iron Exhaust Manifold Repair

Cummins cast iron exhaust manifold is welded with 77 and 72 rod.

 

Cast Iron Manifold Repair

Cast iron CASE engine block with a 15 inch crack and large hole is welded with 77 electrode.

 

Cast Iron Engine Block Welding

A thrown rod resulted in a quarter inch hole in this engine block. The repair is accomplished using 77 electrode and a small buzzbox.

 

Cast Iron Welding

A Muggy Weld customer blog post of how to repair dreaded 53 Cummins engine blocks.

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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..

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..