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Mig Welding broken Cast Iron!

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Mig Welding Cast Iron using standard mig wire. YES IT WORKS! In this video i repair a broken leg on a cast iron park bench using standard mig wire. Even though the cast iron was low quality, the repair was solid. Follow along to see the repair step by step. Link to part 2 https://youtu.be/adsLj77zxDI CHECK OUT THE TOOLS & GEAR I USE 🔴 https://www.amazon.com/shop/brandonlund FOLLOW ME ON ⇨ Instagram: https://www.instagram.com/lunddiybuilds ⇨ Facebook: https://www.facebook.com/LundDIYBuilds
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Text Comments (90)
Brandon Lund (9 months ago)
A lot of you guys mentioned I should try "Muggy Weld"...I listened to your suggestions! https://youtu.be/kzbcVb2UymA
mr won (1 month ago)
Love your videos. Take them for granted. Show ing the whole process helps me understand my job as a technical trailer mechanic more.
Brandon Lund (1 month ago)
Thank you very much! I appreciate your support!
Jeramiaha S (4 months ago)
was the MIG wire  with or with out flux in it ?  if no flux have you used the wire with the flux in it?
Brandon Lund (4 months ago)
This video is without the flux (solid wire with C-25 gas). If you want to know more about flux core wire and how strong it is when making a cast iron repair, here you go https://youtu.be/jMyg3rpmCBU
Michael Angelo (5 months ago)
I've welded items like machinery handles, etc, with a mig when I was in a hurry. I never bothered to preheat, yet I never had a cracking problem. I'd get a beautiful weld, however I always ended up with a poor bond between the filler and the cast. It would break apart, under serious pressure.
Brandon Lund (5 months ago)
Spot on brother!
Michael Angelo (5 months ago)
I don't think you'd ever have a cracking problem when welding a piece that was cracked all the way across, as there is really no reason for it to pull itself back apart. Welding cracked engine blocks, etc, is where you will run into that issue... because of the surrounding cast iron structure. I suspect that the separation issue I spoke of before would be much more pronounced depending upon the relative thickness of the piece being welded. Thicker material absorbs heat more slowly because of the extra mass. I assume that this hot/cold junction is shocking the cast, and therefore the cause of the crystallization and loss of cohesiveness there.
Brandon Lund (5 months ago)
+Michael Angelo so it seems you might be onto something. You will have to tune in this Friday for the results because I dont want to spoil it, but it was not as strong as some of the other testing we have done in this series...just how much will be revealed in the video. Cheers brother! :)
Michael Angelo (5 months ago)
+Brandon Lund ...be interesting. Preheating is probably the main key to preventing the problem I was experiencing.
Brandon Lund (5 months ago)
So far so good with this repair. We are going to be doing some destructive cast iron testing with MIG in this weeks episode so we will see how it compares to the other tests we have done.
Jimmy McGreedy (5 months ago)
voluntaryist (1 month ago)
hes peening the metal
Brandon Lund (5 months ago)
I was stress relieving the metal. This video explains in depth everything you saw me doing https://youtu.be/kzbcVb2UymA
Pavestar1 (6 months ago)
What do you think about welding a cast iron light pole outside? Great vid by the way
Brandon Lund (6 months ago)
A cast iron repair will never be as strong as it was before it broke so just keep that in mind. It could be ok
Classic Phil (6 months ago)
groovy baby ! My first time welding Cast iron I almost died under a car when I burst into flames when the differential Gave out and burst oil all over me and under the car in a big flash ! But I lived to tell the tail Ha ! I should of watched this video first Hahahaha 🤘❤️🙏
Classic Phil (6 months ago)
Thank you , I’m really lucky to be alive as the fire 🔥 went out as fast as it started . The oil from the differential blew out of the crack I was welding and caught fire and as soon as it hit the air it went out , it all happened so fast ... and funny thing is the customer never saw what happened all called me back the next day to re weld cos it still leaked . I never responded 😳😳
Brandon Lund (6 months ago)
Classic Phil catching fire is no joke! Glad your around to tell your story! Stay safe brother
Aqib Ali (6 months ago)
helo sir
Brandon Lund (6 months ago)
Aqib Ali hello to you as well :)
Scoblin Dingus (6 months ago)
Good afternoon crimson chin
woog74 (7 months ago)
So the sand is to slow the cooling process? Like an insulator? What temp do you preheat to? 500? Great vid thx for your insight.
Brandon Lund (7 months ago)
Thank you! I like to have it around 400-500 deg. F if possible and the sand helps cool the part slowly in an effort to minimize cracking
My Sharona (8 months ago)
I welded two brake rotors together to make a grinding pedalstool base. They welded horrible together. Not realizing they are cast and preheating is essential to a better weld. My pedastol looks good although live and learn. Nice video.
CUBETechie (8 months ago)
Why do you use the hammer and hit the weld? You used MIG
Brandon Lund (5 months ago)
Here is a video that explains the process a little better https://youtu.be/kzbcVb2UymA
Brandon Lund (8 months ago)
CUBETechie it relieves stress between the weld metal and base material.
Ronit Singh (10 months ago)
great stuff, brother thumbs up!
Brandon Lund (10 months ago)
Thanks man!
Kevin Murphy (10 months ago)
Arc weld cast iron with 77 rod
Brandon Lund (9 months ago)
Kevin Murphy your video suggestion is up! https://youtu.be/kzbcVb2UymA
Brandon Lund (10 months ago)
Thanks for the suggestion Kevin, I am in the process of sourcing some 77 rod so be looking for this in an upcoming video! Take care brother!
Matt McMullen (11 months ago)
do you use stainless wire?
Brandon Lund (11 months ago)
You could, but I just used regular mild steel .030 mig wire.
Jay Bee (11 months ago)
I'd say it was a success considering it was your first time. I've seen much worse from experienced welders.
Brandon Lund (11 months ago)
Jay Bee thanks man! Still holding strong!
Gino Asci (1 year ago)
What's the sand for?
Brandon Lund (1 year ago)
Gino Asci the sand keeps the part insulated by holding in the heat. It makes it so the part cools down slowly, making it less likely to crack.
Tony Case (1 year ago)
Great video thanks for the post.
Brandon Lund (1 year ago)
Tony Case Thanks Tony im glad you enjoyed it!
Joseph Lockhart (1 year ago)
I have been welding cast with mig for years. Well done a good job.
Jonny boy (2 months ago)
I'm confused, in highschool they always told us you cant weld cast iron, we used to braise it but only if it wasnt structural. I have a cast part for a commercial metal cutting band saw (arm that supports the saw blade as it cuts) that cracked in half do to human error. We ordered a new part but its gonna take 8 months. Think we should take it to a welding shop???
Brandon Lund (1 year ago)
Joseph Lockhart great to hear and thank you! :) it's still holding strong!
The Repair Shop (1 year ago)
I have welded many cast iron things using MIG welder and standard wire. I prefer to preheat the entire piece in an oven, weld and stress relieve a short section, return to the oven to reheat, repeat until piece has been completed, then cool in sand. I have not been 100% successful but the process has been good to me over the years.
Ringo Gingo (9 months ago)
I never stress relieved anything so I'm not to sure about stress relieving , but I need to weld a large patio chair arm that got broken in the storm. How can I stress relieve it after welding it ? I can heat it with torch.
The Repair Shop (1 year ago)
Brandon Lund What has worked for me is to be very sure my weld joints are clean and I like to clean past the joint by around a quarter in on all sides to reduce potential porosity. The next big factor is to not get greedy when dropping a bead. No more than half an inch at a time followed by stress relief. I like to weld on one end of the repair then the other along with the appropriate reheat cycles. The idea during the whole repair is to minimize the amount of stress and shrink your weld will have to endure.
Brandon Lund (1 year ago)
Good to know! This was my first experiment with this type of process and I was a bit concerned considering I believed the cast iron was probably not the best. Its good to know that someone with more experience with this also has had some good success. Thank you!
Michael Murphy (1 year ago)
very clever handiwork brandon! thanks for making the vid!
Brandon Lund (1 year ago)
Thank you very much Michael! Glad you enjoyed!
Mark Fryer (1 year ago)
One important thing to remember is that this project was cast with Modern cast iron as opposed to cast iron from 50 to 100 years or more which I believe would have a slightly different makeup as well as exposure time to corrosion.
Brandon Lund (1 year ago)
+Mark Fryer Spot on Mark! Any cast part can be hit or miss depending on how "pot metal" is involved :)
Charlie Marks (1 year ago)
I really liked your video. I never realized I could use my everlast welder to fix cast iron like that.
Brandon Lund (1 year ago)
+Charlie Marks Glad I could help! :)
Common Collective (1 year ago)
nice video! The explanation was nice too for someone like me who is new to welding.
Brandon Lund (1 year ago)
+Common Collective Thank you and I'm glad I could help! :)
The Pallet Hippie (1 year ago)
Are you gas or gasless Brandon?
Welding Junkie (1 year ago)
Brandon Lund what wire was used?
Brandon Lund (1 year ago)
+The Pallet Hippie Great to hear and glad to hear the information helped! Cheers!
The Pallet Hippie (1 year ago)
It did! Cheers man!
Brandon Lund (1 year ago)
I think it would work with the same results. The gas just eliminates much of the slag. I like your screen name! "The Pallet Hippie". I like pallets also!
The Pallet Hippie (1 year ago)
Ok, sorry, just watched to end and you answered my question! How do you think it'd work gasless?
Mr Chevy 57 (1 year ago)
Great video thank you 👍🍺😎
Brandon Lund (1 year ago)
Thanks for watching!
Francis Dooley (1 year ago)
your mig weld is just as good if not better than I have seen with nickel rods . am about to try to fix a broken trunnion of an old bandsaw will try the mig first having seen your vid Thanks..
Brandon Lund (1 year ago)
+Scott Thomas I'm glad I could help. Good luck on your repair and let me know how you made out!
Scott Thomas (1 year ago)
I love your video. I've got a cast iron part that I want to try this out on with my everlast mig welder. I was going to try stick but I don't stick weld that often and I'm concerned about slag inclusion
Brandon Lund (1 year ago)
Thanks for the compliment Francis. Give it a shot! If you do all the steps, you shouldn't have any trouble. Good luck and be sure to post back to let me and others know how it worked out.
Josh Lawrence (2 years ago)
Anyone know what type of sand was used? And can I just use regular sand?
Brandon Lund (2 years ago)
+Josh Lawrence I used "play sand" from our local home depot. I think it was around 4 dollars. You want the sand to be dry to allow the part to cool as slow as possible. I'm from Maine, so all our sand is fairly damp and would not work well for this.
Shaq Deisel (2 years ago)
Nice. Did throw away the piece or used it?
Brandon Lund (1 year ago)
+John Hagenbrock Yes, that is an upcoming video. I have tried to break the repair (within reason) and it did not break. :)
John Hagenbrock (1 year ago)
Brandon, have you reassembled the piece back into a bench and does it hold weight?
Brandon Lund (2 years ago)
+Shaq Deisel I kept it. It's going to be in an upcoming video.
Ed Riggall (2 years ago)
great video
Brandon Lund (2 years ago)
+Ed Riggall Thanks!
brian willoughby (2 years ago)
"muggy weld" works well I heard
Brandon Lund (2 years ago)
+brian willoughby I believe that process uses the nickle rods also.
sepoooe (2 years ago)
Brandon, why do you hammer the welds? Did the pre-heating help? I tried to weld something to a cast brake disc some time ago (stick welding though).. was a complete fail… the weld separated at the cast part… any idea how to prevent it?
Brandon Lund (9 months ago)
+brian willoughbyhere is your video suggestion https://youtu.be/kzbcVb2UymA
Brandon Lund (2 years ago)
Justin Hartwig Thanks a lot! It was a first for me but I'm really happy how well it worked.
J Wig (2 years ago)
I thought you were using fluxcore. I use fcaw for casting repairs here at work. Nice vid!
Brandon Lund (2 years ago)
+IDUS Haha no worries :)
IDUS (2 years ago)
Brandon Lund o didn't see the replies. I suppose redundancy isnt a bad thing.

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