Cold Welding Cast Iron With MIG......

by Denny

Hey guys,
A couple years ago I had several cast iron repairs needing welded. Cracked intake & exhaust manifolds, wood stoves, & some decorative cast iron pieces. After 6 months of research, & getting several broken cast manifolds from my brothers' engine shop, I experimented with an old-time process called "Cold Welding Cast Iron With MIG". Depending on thickness, the amperage ranged from 80 to 120A, cracks beveled, end of cracks drilled, metal wire-wheeled to clean, bare, & sometimes a light grinding with fine grinding wheel.

I use .030/309L(.01 carbon content), C2(98AR/2CO2)shielding gas @18cfh, tacking at the center to start & immediately peaning with a slightly rounded end on my chipping hammer. The idea is to weld in very short beads not exceeding 1/2", peaning immediately, & allowing to cool back to room temp. I vary location with each bead with immediate peaning. When doing this, you can take your glove off after the bead & lay your bare hand on the weld & it will feel barely lukewarm. This process eliminates the expansion & contraction of the cast that is the main cause of continual cracking.

This process takes practice & you must learn parameters with amperage & I use the "pull" technique. I have had 100% success so far. Here's some pics of one of the several Rolls Royce exhaust manifolds I did that was broken & had been previously welded with SMAW that rusted away.


thanks for the excellent post,


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Aug 03, 2015
Welding Cast Iron! NEW
by: Susan Fernando

The trouble with weld cast iron is it will chink when it shrinks as it cools. A time-consuming but sure technique is to use what is called cold stitch welding, which will work for your plan as well. emilia clarke terminator genisys jacket

Mar 13, 2015
Good cast iron welding tips and results ... NEW
by: Anonymous

Thank you for sharing those cast iron welding tips and the images. Looks like you have got the hang of it. Found some additional cast iron welding information and techniques at:

Jan 08, 2013
guard NEW
by: guardian

Wrought iron welding is used in projects such as building fences, gates and ornamental garden art.welding repairs

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