WELDIG OF CA5T IROW

CASTIRON
Cast iron may be said to the
pia inon that has
been nefixed in eómpo Sibion and stength
br bein
re melted in the cupola funace,with .addition
of Centain Subs tances in definite
pro porntiom
ond east into moulds. Cast iton include
bex of inon-base matanials that contain -num-
a

Canbon 17 to 4-5 Silicon 0:5..to 37.

Manganese o:2 to lS7.. -.

Phosphouus O-8 Mar.|

Sulphan O-2/. Ma.
TYPES OF CAST IRON
Cast ion can
ci Gine Cast Ixon.be.classified
**** as -
ilcii) White Cast 1n0n
Cii Malleable Cast Iton
tiv).Nodulan .Cast Iron *** ******

o Gaey Cast Ixon

a. Tt shows a 2reyish
b. It contains - Susface.shen fracture
25 to 3-8 Z st , 1:1 to 2-8 7.
Mn O4to 1:0%.,P.0-15.Z
S 0:10 Fe Balance.
c. Ttis marked by the presence of
na phite.in a matain aseaite flakes of
d.It eontains a poation of Casbon. in axpearlite
freefoBma
Raphite {laKes and the.hest.inthe combined
a s Cementite, Pectlite ete..
e. Grey Cast non pass eSs2s-lonest
melting
point of all the sestous allays Cabout
.Cast i*on is baittla in nature. 417).|
. Gisray Casti*On is. pSto bablr the
o al metals to tweld most.diificult|
les tha numbea of qeyeconomical. Neven the
bn easWrgs made .
and tha inevi tabk. hih peseentage o beakoges
 -weldingneeAAa|

occun in Senice mare

that
hite Cast Iron
White izon. is_produced.fHom pig-iton
cast
Vexy 9uapidl he
by Causing the Casting to Caol
and his does not
dte of cooling is tao tabid cau-
alloua the cauban to Sapahate fom the.iHon
bide compoundConse9uentlp the Cathon founod
in1ahite cast iton exists inthe.combined fam.
This tpe of. Cast inon is. vert.handl and.britdle.
nd.is not.weldable and.also not.easiltmach-
|inable. -

cio Malleable Cast Iron

a.Nhese as. iqr@cast. iron the 9*aphite has
a laxe abpeaLande, i t possesses a quasi-
Sphenoidal (tempes Canbon) oppeanance in
malleable . iaon.
b. Maleable iton is obtained shen tahite Cast
inon is heated to T60°e fo 24 hous p e each /|
25 m.m. of thickness and then cooled slowl.
This heat treatment Convents qtaphibe fom
lake foum to quasi- sphenoidal shape.

c. Welding malleable inon destroye thi» hoavt

theatmeh and turns the metal into white o
C a s t inon .
d. Malleable iron Contains -

C2 to 37 Si 0.6 to 13 7.
Mn O2 to O-67 P 0.15 S o1o 7.

e. Malleable iron has a solidifi cation tange

1130'c
of 1400 -
cinNo dulan Cast Izon
a. Whe r e as in 9rey cast iron the 9naphi t a
ha s aflake apbeaaance it poSSes es a SPh-
enoidal appeaance in nodulan Cast iton2.

b. The ephenoidal gmaphite ohich is the nesulttof

Smal additions of magnesium, cetium e
Cadmium to the cast iaon, gives to it supenio||
duetiity and toug h ne SS.
. Nodulat, Duetile ox sp.heoidal east iro
Contains .
C 82 to 42 Si 11 to 3:5
Mn O3to O8 P 0:08 7

WELDABILI TY OF CAST TRON

Most o the welding is dene n qnet Cast
iron. Malleable cast,19ron iwelding andnodulani|
cast i o n welding are eomparattvely less COmmo

White cast itomn 1s vey hand and btitlle

and is not weldable and &lso not easilt machjnab

PROCESS OF WEL DING GREY CAST IRON

The. follosing process. are employed fo
wel ding arey east isron
a Metdl Ane Weldin1.
6 Ox- acetzlene gas weldin
C) Btaze welding
Bozina
e Thermi Welding. *
****

OXY-ACE TYLENE GAS WELDING OF GREY

CAST IRON **

**

INTRODUCTION **

GHey. Cast izon is Suecessfulytelded.

by8as lelding but _it requi nes.massive inputis
o eat, bothin preheating andduning the
telding opeati
This lange heat inpLut may.Cause distoa-|
tion o9L dimensianalchang2esof the..componets
The slowe cooling ate. 9tesulting Nom
The
9a8.LweldingHoweMe, lessensthe bendene
or hardening of the heat affected z.one.
.

JOINT PREPARATION
Ci A. 60 to 90 Vee 29LOOve. Should.be qnound
On Chipped
aut on Cut toith.o.cutin9 toreh|
On Cuting electkode.
- ** "*

ICii) Fo than Sections. a. t5. to 90 v e e joint is

9enena used Eo. venx heov Seetions
f 25 ma...and abave a so double vee joim
is often necommended.

||ii) When weding Can be made fnom one

Side enlt the qnoove anglo should he in-
CHeasod to about 120 deaees.

Civ When the 2toove eztends th*ough the cask

backinga uf with a qnaphite backing ploata
Should be p*ovi ded.
V When rebpairing
CHacKs a hole should 6e
dailled at each end of the ctacks priot to
eldtna to
the eHàck. prevent furthe* phopagation o
PREHEATING
The
THE JOB
job befoe welding is preheatad at
620c ina funna.ce and ther covexed with
asbestos cloth, exposina onlt the.cavity to be
Welded .
15
funace is not availabla, he casting
a

llean be covered oith asbestos eloth amd locall

heated by gos fuHnace
Thin Seetions may be pieheated..kocallt
Lohere as heav Seetions should be preheatel
in thei
entiney i n a fuinace.
GAS WELDING RODS
i Fost weldinsf arex Cast iRon Cast iton iller
,

tods having the Same

Composition as the base
metal and 'eontalning a minimum of Sulph
amd phosphotus a«eisad.

Cü Welding xods shoua Contaia enouqh Cabon.

and silicon to allon fon lossos of tKes Rlem- **

ents duning welding - -

**

Citi Special tods Containingtitanium and

toith||
a.high.Silicon.Content adaloa emploed Sometme.
G he, weldng tods are inthe fo*m of Squohe
9tound e st baNS .

) At pi cal Cast inom welding compo Si4ion

ma ae C 3-25 to 3.5o (7)| Si 27s to 3-
Mn O-60 P 0 s o t 0 7s
S O.1o Ma..
WELDING FLUX
Flux inereases the flui dity of the fust|
ble iror- Silicate Slag,as well as oaids in
the temaral of{ the. stoa.
Fluxes fo2cey cdst inon flen tods ardt
usuallt Composadobotates, Soda,ashond
)
Srmall
Smalamounts of ommoniwm Suphate 1HOn
Oxide exe.
WEL DING PROCEDURE
*'**" '

. **

lIC Prepase theedges.to.be welded

bed eanlien. .
asdescri
Ct Clean the. plata edges and around to remove
foeign mattesL Hnom the. Suufa ce.
Ci Taee.a Suitable lle tod and flux.
Civ) Select a welding tip one Size lahges than
foSteal ofthe Same thickness.
) Adiust the Lwelding toreh fon a neutral
lame
vi) Move the gas flame along the Sides of the
Vee qoove untal the entite joint is
to dull 9rad.. þreheata
vi) Concen tsratethe flame at the bottom of the
vee ad the
stanting.point. Keap the bip of the
tnnen.Cone abaut 3-0 to 6 0 m.m. from the
metal surface.
lvi) As. the bottom of the vee is thoroughly
move the {lame from Side to fused4|
side, meltimg don
the sides gadualSo that the
9tuns down and eombines with the
liqwid matal
moltem
matal at the bottom ef the vee.
Cix) Rotato the toreh ina o icilah motion So thot
the sides and bottom ef the v e r a r a Kept ini
molten condition. 1} the metal qets too hot
n d tends to «un awo, naise the {lame

suady
 t h e held metal gets.ovenheatad,excoive|
2as will generato whlch is liabla to become sopp
e in the weld metal cau sing Potosi
C1 Once the molten metal paol fonms heat the ,

fillen rod end by bnin9ing it intoheatndoutes

the.
tod
envelope of the "flame. Dip the
end into the {lux.

C The ux stnieken fillen stod is inttodu ced

tnto the molten pool. The {lame applied
is
the tip -o the illen rodand welding is Coy|
ed owt using back hane teehnàque.More. Cas
bach
l tempetatwa Contarol is Possiblo with
hand teehniquo, Since i t diceets. the {lame.
tod.
back ubon the weld metal. and fillen
Maintain {lame tip about 6:4to 19 mm. isom
the Suface of weld Pool as Þer CAoss -Seet-
Lon of the matonial.

out
|Ciid Neven ao om dipping the fllen nodin and
of the puddle it ma get Contaminated loxidizal!
by the atmoe phere.The rod. Should.alnoys be.
held in side the {lame lsetd .-

**
**

Civ) As the fillen Hod.mets., the.madon metal.taill:

ise in the qmoove. As the seetion othe vee
is built slightin above the lexel o the Neat of
the casting meve the puddlafortdandl. In othen
Worde when one Section 25 m.a. 0t Solong.is. .
built up oith fillea matal, the bsttora of the
vee
adjoac ent to t is next meltad and the
operati on is Lepeatacd.

v) When whtte spots ox gas bubblos appeah inth

 uddle o at the edges
Lu and ploy the of the Seam add mcAe
the impuities flame atournd the Specks
loat to the top. Thes2
aSe skimmed frcrn until|
od which is the weld with the Impusuties
tale to emove thentapped help of filles
therm {tom agatnst. the wonK
the jillen tod.
i ) As the.
weld in complete ***

asbestos. ,coven it 1oith

The iob. 0t0ny..othex insulting
to i6.allo~ied
minimize The
to Cool
ta. slosly.Mateuial.|
Codl soSn
C9tacn Fomatiom.tendeney i
to. hatdenimd»|
o9das
omd
(6it) All slag and
not oxide.:
muet
hammered) awo must be iled
Lt is cold. om filled
the weld Cand
Cand
befoe
i Cast ixon
PoSsi ble. Should be
welded as
fast as

Ge east 1«on
done .welding of long .tobs
intescmitentl u`ing
using skip welding Should be
STRES35 RELIEVING weldlima ete.
elieving is recommended Post weld stress-
castings ot whene pati culat Jo*
The accunate will Complex
is at casting should machining
the Same beplaced ina fuxna ce follow.
iatay upon temberoatue as the that
completiom
|heated to 593 Casting immed
to 6 50c of tdelding and
ofthicness; fo one hour giaduallr
at a ato no imay thn be cooled to 260c Pë9 25 m.m.i
fasted than 28'e Pea on
below
houn
hough 2as weldirg of
Successful, yet 3e cast tnon is
itis replaced b eleetsuc higkui
Weldin oeovenheod
'wellingis reauined. ane
 TIG EL DING PROC£SSMMA WELDING PROCES
6TUGleldinq pnac ss pzodu-6. ln MMA 2eldinq alith uz
ces SoundLeld hecauSe coated stiex electnodeS
hene is 13eny Little Smore,thene is eueny dangerof
umes Oz SpaarsSince helSmóxes, Lumes leading E
Shielokng gas_àround the staq inclüsionsgas porosi
a2eis_transharent, he |hydaojen ah.sonpEion eER.
Ladeldencan_obser23e the a the aeld.
Lleld easily-
ADYANZTAGES O TIG WELDING PROCESS
OVER OXY-ACETYLENE ELDINGPROCeSss
TIG NELOIWG PROCESS_ OXy-4CETYLENE WELDING PROCESS|

LIn ThG nelding are temperat-Ln_oxy-acekylene alding, the

eeisas high as 6000c apdhelame temperatune is natmare
nee elding heatis much higher|than3500'c for the neutealLla-
is posstble ka reld isith naen-me, and loaenheatinhutin thel
amer prepanabians ahich méa-4lame callslon the 2idenpeep-
ns_ mare ecanamica/use a atakians lan theweld joint,
Ller ine andhiqhereldinghence langen azmauntoLiller |
speed Line nd sloaen weldino sheed.

2Shieldin qases Argan,Heliua Thermalisouneein ory-aceiyl

are tatatiy inent andnon= ene weiding isanly byhurning f
actine Heneeeldingdloneacetylene in orygen Hence thene
6 y TIBpeacess . alaays cleaoisalaay.s a chance of Oxyaen ge

and without_any axidafion.. i n p toueh mith hat leldnetal

i.eoxi dakian ) and there is ch-|
ance ohorosit hy £he liberated
|Carbon-mon0zide.
3, In TIG elding,Suitability |3,Since itis
oxy-4uel, khe nea-
LLon ioinin /aleldinq reickiue|ebine matenialsCan
matezials CLixe aluninium anlyin the presence afbe melded
magnesium te)is excellenk|Ltinq luz Led alonq_mith lau2en me
Ehe lil=
Len pod. This does not ensune.
00 delect nee tield debosits,
 ADVAN TAGES OF TIG NELDING PROCESS OVER MM.A..
TIG WELDIMG PROCESS
MMA WeLDING PROCESS
TIL,hracess intoaduces only L MAA2 Cannat inEroduee
heat to the part lheing leldedheat nithout the
ithau1f dehositing lhe metal |metal dehositiaq he
a2ithEhisbracessthe Hence, theie are cis-
iller netal is.anly added
hen iE is neededand_ Ehis SoLlacz o Lasion, Slag in-
need not Lae linxed to the lelusiozs.iom £he eleei2ade
Aleldinq unnentE |coating and Laex af6ene E-
ation, QSsociated in sleldin
L2.TIG Meldlinqpnaeess
neithen2iCodted electnodes are
adds2an Subtraets leme:shecia!ly
entsLrom the métal nhiechleaating made nith Llaz
iE siply bnngs eontaining alloyin
Lausionelements
Henae he bnacess|Lassduniiq f maxeup fan the
is_ast SuitableLan jàining MMAWeldinq
metaLs IixeSkaipless steel Langely,the pzocess is
pestni2ted
Aluminium and its alloys, Cohbeand to only Mildsteel|
nd iEs alloys caahon Steels
znd allay steelsarbonSteels:

3Hiqhly neaetine mateeials |3

z e itanium MMA2þroeéss is not a t
andMaqnestum|all
nd Ehein allaysané Scuitable fon Sheets and
Suee-lplakesoL aluminium, Titani
ssuly unelaled hy TIG hlelding|um
on athen aeackize zmetals
TIG Lleldinqpnoeess oLfers
MMA Nelding qenenally
cehtionall-penlectcleau|Suferinom
eld and anAbsence alsAatteeh ane
ence bot spoEs iaspatEen and
bhe base
metal néan _Ehe weld jaint_
TIG uleldinq isthg easiesH
o aukomate4on 5.SHcx electnodes in MMAN
thefro-hes
Lefiop oj Yolnts aS2g naE o{{enleaihility tan
aatomotion.
Men.Sionson 1geny ditLie-|
Eo aecess.
'