Welding Processes and Equipment Settings in Cast Iron Welding - EASA Electro-Mechanical Authority 2021 Conference

Explore the essential aspects of welding processes and equipment settings in cast iron welding discussed at the EASA Electro-Mechanical Authority 2021 Conference in Myrtle Beach, SC. Topics covered include SMAW, GTAW, GMAW, FCAW, safety reminders, proper machine settings, preheating, peening, and AWS publications related to cast iron welding.

• Welding Processes
• Equipment Settings
• Cast Iron Welding
• EASA Conference
• Safety

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1. EASA,ELECTRO MECHANICAL AUTHORITY 2021 CONFERENCE Myrtle Beach S.C. TOPICS: WELDING PROCESSES PROPER EQUIPMENT SETTINGS CAST IRON WELDING DISTORTION FACTORS (VT) VISUAL TESTING

2. Always Remember: SAFETY FIRST!!!!!!!!!!!!!!!!!!!!! SAFETY IS EVERYONES RESPONSABILTY!!!!!!!!!!!!!!!!!!!! SAFETY IS NOT AN OPTION SAFETY IT S THE ONLY CHOICE !!!!!!!!!!!!!!!!!!!!!!!

3. S.M.A.W. / SHIELDED METAL ARC WELDING G.T.A.W. /GAS TUNGSTEN ARC WELDING G.M.A.W. /GAS METAL ARC WELDING F.C.A.W. / FLUX CORED ARC WELDING WELDING PROCESSES

4. https://www.millerwelds.com PROPER MACHINE SETTINGS https://www.millerwelds.com/resourc es/weld-setting-calculators

5. Fact: Without material test records, MTRs, it is impossible to determine the amount of Carbon in any cast iron part or weldment. Also available are PMI or XRF Analyzers that range between $15,000- 40,000 Cast Iron Welding

6. The triple Ps of cast iron welding Preheat Peen Cast iron Welding And PRAY!!!!!!!!

7. AWS Publications A5.15:1990(R2016) SPECIFICATION FOR WELDING ELECTRODES AND RODS FOR CAST IRON Cast Iron Welding D11.2:1989(R2006) GUIDE FOR WELDING IRON CASTINGS (HISTORICAL)

8. S.M.A.W. Cold welding Electrodes, No preheat or post heating. Example: 77 Non Cracking Cast Iron Welding Electrode by Muggy Weld LLC. Cast Iron Welding Nickel alloy electrodes are the most popular for cast iron welding but require preheat and Post weld heat treatment.

9. G.T.A.W. Brazing or Electric Brazing Facts. If you have the equipment and skill set, I recommend using ERCuSi-A Silicon Bronze Filler Metal. Silicon bronze is Ideal for joining dissimilar metals. AC or DC currents. Very little or NO Distortion The silicon bronze rod s lower melting point makes it ideal for joining together thin sheet metal, galvanized steel, and nuts and bolts, too. Cast Iron Welding

10. Distortion in a weld results from the expansion and contraction of the weld metal and adjacent base metal during the heating and cooling cycle of the welding process. Doing all welding on one side of a part will cause much more distortion than if the welds are alternated from one side to the other. Distortion

11. Lincoln Electric : Checklist to Minimize Distortion Follow this checklist in order to minimize distortion in the design and fabrication of weldments: Do not over weld Control fitup Use intermittent welds where possible and consistent with design requirements Distortion Use the smallest leg size permissible when fillet welding For groove welds, use joints that will minimize the volume of weld metal. Consider double-sided joints instead of single-sided joints Weld alternately on either side of the joint, when possible, with multiple-pass welds

12. Visual Weld Inspection: Who is the first Inspector??? (VT) Visual Inspection

13. AWS B1:11:2000 Guide for the Visual Inspection of welds (VT) Visual Inspection

14. (VT) Visual Inspection

15. Credits: American Welding Society Miller Electric Lincoln Electric

16. Thank You!! Jeffery.ball@hgtc.edu