How to fix a Cast Iron without Welding?

Iron comes to us in many different shapes and forms.  Among those forms is Cast iron that usually takes more than 2% carbon alloys and if the carbon alloys are less than cast iron’s carbon alloys it would be called steel. It cannot be molded not by huge effort but by casting (pouring into a mold after heating) and that’s why it is more likely to crack or rust because of its liable hardness.  It gets cracked because of several reasons one of them is extreme temperature swings. The railway lines are made up of cast iron in old days, even today, that’s why in hot summers these railway tracks get loosen a bit than their actual size and in winters they get shrunk.

After this short intro to cast-iron now let us move to fix it.

How to fix a Cast Iron without Welding?

Welding a cast-iron is not a piece of cake. You need mastery over holding and using MIG or gas welding guns. And if you show any negligence you may have been caught in trouble. That’s why in the following a few methods are given that can be used as a substitute to welding cast-iron pieces. These ways are less prone to danger as well as quicker and safer than welding.

Epoxy putty

Epoxy putty is a glue-like but a bit hard material. It is used to fix the cast-iron cracks but it fixes temporarily until a permanent solution is taken up. This epoxy putty adhesive substance, at room temperature, is used for space-filling.

Epoxy putty

Procedure: It is the easiest way to fix the cracks on cast-iron-made things. You can simply mix it or place it directly to the surface and get the surface crack-free.

Brazing

Brazing is another way of fixing cast-iron surfaces. In brazing, you need an extremely high-temperature brazing rod. This method is to fix two uneven surfaces that might have been broken due to pressure.

Brazing

Precautions: while using the “Brazing” technique you need to take care of some of the things. As brazing is a process that gives the most temperature to both of the structures, kept for joining purpose. These two structures can be a water pump of cast- iron and its broken piece or a pan and a handle and things like that. Clean the broken surface carefully without hurting yourself. Wear safety gloves and apron as due to extreme heat your hands may burn. Wear glasses as well as not letting any particular get into contact with your eyes. After brazing both of your structures avoid touching them until they get set and cold down.

Procedure: First of all you need to clean up the cast-iron piece leaving no dust particles on it. Later, heat the cast-iron surface with a brazing gun and place a 3/32 aluminum, steel, or iron rod having coated with flux this can be 18 inches long rod. Keep it for 30 seconds while giving a temperature of about the highest degree and then let it cool down.

Seasoning:

If your cast-iron pieces Like pans etc are rusting you may try seasoning. It includes the following procedure:

Procedure: Wash the cast-iron for once with 50/50 water and vinegar solution. Keep it in the solution for half an hour. Oil it a bit, unrefined oils are much better in this regard.  Now start seasoning, apply thick coding of oil on the pan wipe it with toilet paper put it in the oven for 5 minutes at 200 degrees centigrade. If you want the good seasoning to repeat this process 5 to 6 times. This will lead you to a fine cast-iron piece, free of rust and cracks.

Cold Bond Metal

Cold bonding is another way of joining two broken structures. If your water tank, pump or anything made up of cast iron has broken or gotten a crack or hole you can try the cold bonding technique. This technique does not require any heating so there would be no chances of burning; moreover, there would be no ugly-looking joint as in brazing or welding. It is rapidly becoming popular formula in different industries. This method is chosen by the industries is the usage of a composite material. It is a solvent-free and 100% working technique. This method is usually for plain surfaces like tanks etc.

Cold Bond Metal

Procedure: Prepare the surface of cast iron. Grind the surface, if rough, for smooth finishing. Tape around the borders so that any excess of bonding material can stick to any other part of the surface. Then, clean the surface to remove every particle left after grinding. Now is the step to mix the cold-bonding material. Mix it well then put it on the main and broken part of the cast-iron piece with a stiff brush. Make sure that you have made it coated, well. Join both of the coated parts and press them strongly or using great force. While pressing you will have the excess coating coming out of the sides of the part you are pressing. Remove the excess bonding material. Remove the take and see how perfectly the two of the parts are joined as they were before getting crack or being broken.

Conclusion:

In the end, it can easily be understood that wrought cast iron can be fixed without unlevelled welding which is not only a difficult task but also a risky one as the temperature exceeds a safe limit that may cause burning. So, you should move to the safer ideas rather than opting for welding to fix your cast iron-made things such as water pumps, pans, drums so on and forth. These ideas aim only to produce pieces of showroom quality that could be pleased having been in the gallery, home, or office.

About Dave Walker

Dave Walker, a professional welder who has been welding from an early age. Now aims to help others by making them learning skills and finding them new opportunities. He has written for many welding blogs and helped many pursue their welding goals by helping them in choosing the best welding tools of the time.

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