this is to roy who had trouble welding his manager's chair: i too ran into the same problem, so i used a gusset to increase the welded area plus i used a stainless steel electrode because i wasn't sure about the composition of the metal.
Oct 28, 2009 Rating
interesting thought. by: Roy
Pot metal consist of alloys that always has base of zinc or cadium. And always melt at lower temperatures than base metal. Reportedly melts less than 500 degrees. So simple torch or mig weld will deform the area due to steel heating. Might not be the pot metal issue.
But the suggestion on grounding and paint is valid reasoning. the mfg's weld area (where snapped off) does not have paint or burn (from paint burning).
I did use my grinder, stripping paint off my selected area that I did weld on. I clamped ground to collar, not the base.
I shall attempt a test weld in few days, by stripping the paint off (two random area) on the base alone and weld for a penetration test.