New Process for Welding Cast Iron

Hello, I read your suggestions on welding cast iron exhaust manifolds and thought I would tell you about how I fix them. So far none of the manifolds I have fixed have ever come back because of breaking again or cracking by the welds. I fixed one manifold off of an old 1960's tractor, it was even missing some of parts where it had broken. I replaced the missing parts with some steel and welded the rest of the cracks and to date it is still working. I use a Castolin Eutectic Eutalloy B Torch and Eutalloy 10224 alloy powder(mostly nickel). Using this torch you spray the powder through the tip of the torch after your base metal turns to a red heat and the powder fuses to the base metal and melts creating a bond without porosity and without bringing up all the junk in the casting. I've also used it for building up worn cast iron pulleys for machining new surfaces onto them. In fact in the past two weeks I've done 2 of these pulleys that had a worn surface where the crankshaft seal had worn a groove on the pulley(sheave). First I machined off the worn surface. Then built it up with the nickel powder and the torch. As soon as I was done welding, I put the pulley in floor dry for it to cool slowly. After several hours it was cool and ready for machining. I've tried all kinds of different cast iron welding rods and none compare with the quality of weld that I can accomplish with the Eutalloy B torch and the 10224 nickel powder.

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