Cast Iron Welding Repair using Flux Core Wire. Follow along as I repair this broken cast iron using Matheson .030 Flux Core welding wire. For this demonstration I explain the benefits of a preheat as well as controlling the cool down rate by burying in dry sand. Be sure to check out the other repair videos in this series to see how this welding repair method compares to the rest.
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Disclaimer: These videos are intended for entertainment purposes only and as such, you should not attempt to do any of the things you see me doing. Always read and follow the manufacturer’s safety guidelines before handling tools. Seek professional advice and training before using any welding equipment. Never operate any tool without wearing the proper personal protective equipment. Final warning, Do not attempt to do any of the things you see me doing!
+Brandon Lund That be some feast you could cook in that pan at 90 odd pounds !!!! Quite amazed at the strength especially because of the leveridge in your setup ! Welding in general is brutally strong but 90 pounds is astounding, I was expecting around 30-40 max ! :)
+Brandon Lund You are very welcome Sir! I have been a welder/fabricator/woodworker/blacksmith for over 40 years and I get really tired of the old way of thinking where creativity is squashed by old farts teaching the young people coming up that "their way" is the only way! You are willing to try new ways of doing things and then proving their viability through destruction testing thereby "proofing" i.e. PROVING the end result. . .
ALL THE BEST SIR!
I should have said it was combustion we were seeing. On job sites (especially during winter) we always had to heat the steel before welding. It removed moisture ON the steel, not IN it as you pointed out. I misspoke
What I do sometimes I go to the yonkyard and get some of the fiberglass hose protector out of Honda or Nissan cars from the motor and I use that as a nossle protector and is very cheap in case that you don't have another option.and it works fine.
Good video AND I subscribed, immediately!
Question, though this video has NOTHING to do with cooking, is using the flux core wire on the cooking surface safe to cook on?
That may be something you don't know as your video was only for welding purposes.
I have a cast iron griddle that is cracked and I want to see if I can repair it with the only welder I have which is a flux core welder.
I HOPE it will be safe to use for cooking purposes after using the flux core wire.
If anyone knows whether this is safe, I'd appreciate knowing.
I can be reached on Facebook.
Thanks, Brandon. Keep producing these great and informative/instructional videos!
Thank you very much Kim i truly appreciate the support and sub. I cant say if its food safe but here is my take on it. The pan is obviously made of metal, carbon and a bunch of other elements. The wire is made of steel with a flux in the core. The only purpose of the flux is to shield the molten weld puddle until it solidifies. Once that happens, you chip away that flux /slag layer leaving an exposed steel weld bead. I personally dont see any health risk (no different than cooking with a steel pan) but I'm not an expert. I can say however I would not eat out of something that was repaired with nickle rod. Nickle is a carcinogen. That's my 2 cents anyways. Cheers :)
You typically would change the gooseneck out as well, for fluxcore. They come coated in a braided Kevlar something material, and a threaded end to screw on a small ceramic end piece. Also if you want to have the best weld experience and results, use ESAB wire there is no comparison, Lincoln is subpar.
No problem, but I meant the the gooseneck not the liner.
-Lincoln Electric XM13304-6 K126 Squirt Gun Tube with,
-Lincoln Electric XT12313 K126 Squirt Gun Tube Thread Protector. Also, you should really give Esab a try, depending on the type of welding your doing we use the core shield 8 for bridgework. I would imagine the core shield 40, 6, or 7. 👍🏻
Thanks Mike. Interesting. I have never heard of swapping liners for flux core. I think the liner I'm using in this one is teflon but I cant remember. Surprisingly enough I have never run ESAB wire. I might have to give it a go. So far, this Matheson wire is probably some of the best I have ever run.
The moisture during preheating is condensed water vapor from the flame on the still cold metal. When the metal reaches about 70°C the water does re-evaporate. There is no water in metal.
It worked here, but cooldown in cold sand is actually worse than just in plain air. Packing it in heat resistant mats works well.
No clue. Maybe he's just curious, Maybe he doesn't own a flux core machine and wants to know if it works before he considers buying one, maybe he has a piece of broken cast and doesn't want to spend his money on wire if it doesn't work. I have no idea. It could literally be 100's of reasons.
Some years ago I was stuck with a broken iron casting, can'r remember what it was now but nothing critical, just had to stick it back together. I used a stick welder with normal steel electrodes. Looked like crap but it held together just fine for as long as I needed it to. I didn't know about nickel electrodes then, I'll use those if there's a next time. Which there may well be! This video was very informative and very well done, thank you for that.
+Brandon Lund Hi Brandon, it was about 30 years ago! I can't even remember what it was that I welded, I just remember that it was something that I had to do with the resources that I had available at the time.
These ones are just basic leather and nylon I got from home depot. You can get away with using these mig welding as long as your careful but for stick welding they are too flimsy. You might find that a tig welding glove would work well if you dont like the bulk.
That's cool , my first experience welding cast was needles on a ha baler. I was 12 years old. I used to braze them, they worked. My next venture was an engine block. It was a disaster, I was 29 at the time it bugged the hell out of me, failure , I don't take very well. Short time passed I got a job in steel mill in Pueblo Colorado. I was operating an overhead crane on the hotside of the tube mill. I always pulled doubles after my shift with the millwright s . And afellow showed me how to weld cast with the stick. Nickle rod but he had to pre heat with the rosebud first. And like you did bury it in sand. That was interesting . Keep up the good work. Always more than one way to skin a cat.
I wished you can make a video of same cast iron welding project by using regular cheap arc stick welding machines, in our country mig welding its so expensives. Thats gonna be great and really much appreciated sir thank you.
god bless you sir.
Check the videos in the welding cast iron playlist and the videos in the beginner welding series. I've done a bunch of repairs and projects with budget stick welders and I have the links for you too! Cheers brother!
I repeatedly coated the end of a brazing rod with a silver dime and first with the silver,then with the brazing rod ,brazed a 3 inch piece back into a big lincoln V8 valley under the carb . It had frozen and popped out.I propane torched it before and after,slowly drawing it away during 30 minutes.It held several years,until the engine wore out. Cast Iron loves silver.
Brandon,you have a new subber,next,i want you to try to try a repair with 6013 rod,it is the most common due the welding sources across Romania and any handyman has one for himself since the '90's,cheap and reliable transformes did a fairly good job over time (deeeeespite that has a lower strenght) yet worth a try,preheat it and try to welt over a stainless wire IN THE GAP of the place where u need to weld,and try to wrap also a copper wire around the 6013 rod and weld that,very old techniques still do a pretty fair job,test it and you will be surprised ;-) ( *wink* )
I enjoyed your video very much but I must say you should have weighed the results without the plastic bucket full a metal the bucket alone looked as though it could have weighed 40 or 50 lb who's to say it it wouldn't have broken the frying pan with just five pounds of that bucket weight would be great if you had some lifting weights to put in there adding all that way to the end kinda messed up your calculations
Thanks joe. I dont really know how much the bucket weighed but the pan took pretty much all of it as I was letting go. I'm guessing the final calculation is within a couple pounds and within the same range as the other tests weve done
I've always wondered if I could just fix my cast iron , I've got a lot of them that I have broken over the years , I feel that you have shown me that I can , great video and I'm glad you added the part about the heat up and cool down , without that I most likely would have just waisted my time trying this out ,... Now for my favorite part of the day , I'm going to weld something 🙃🙃🙃🙃🙃
when I was in the Navy, 20 yrs old,I was working in a weld requal shop. Some guys came to me with a broken bench vise. I wasn't sure what to do, so I heated it in the rod oven and welded it with a stainless stick. I guess it worked. They didn't bring it back again.
+Jeffery Shurtleff That's not completely true. I dont want viewers with a flux only machine thinking they need gas to make a proper weld. Flux core wire is actually self shielding and does not require a gas. Although gas can be used to help prevent the issues you mentioned, it is not required and often not used. One of the advantages of a self shielding wire is it can be used in the field and outside where running a gas is not practicle due to wind blowing your coverage gas away. I have run self shielding wire on commercial jobs for years without any gas. It's very common. Cheers
Well perhaps a MIG welder isn't acceptable for a cast iron machine repair but if you can get it to hold 90 lbs I'm sure it will fry my eggs and bacon for years to come. Later, I've got an old skillet to repair and all I own is a MIG welder. Thanks.
Just found, and definitely subscribed, to this channel! I definitely watch my fill of YouTube and I do like your approach! Wasn’t too keen on destroying what you just fixed but I did learn from the result of you destroying the piece and I’d say that’s what your aiming for so job well done! Don’t worry so much about the keyboard know-it-all’s, it’s almost as annoying listening to a creator bitch about them as it is reading them myself. That’s my own opinion though. You do you no matter what.
+FLIPPIN CAMPER!My dad died of cancer. I always try to wear a respirator, especially when there is not much ventilation. Most everything welding related is a carcinogen including your grinding dust. Your best bet is to limit your exposure as much as possible.
+19882fast4u your welcome! This was part of a series we are doing and then we break test them at the end. If you havent seen the other videos similar to this, they are in a "welding cast iron" playlist on the channel. Thanks for the great comment! Brandon
Well this was something I was always told never to do....... But now I can clearly see I was talking to the wrong people. Love the video and I'm going to start practicing on someone scrap to skill myself in this new art lol.... Thanks!
I don’t see why a lot of people hate flux core. I get that other ways are so much better but flux core is perfectly fine if welded truck frames I’ve welded rear and front differential that are daily drivin on that now locked rear end and it’s been over a year and more and still holding great
living in a desert in all my honestly stick welders are great for that job and any other welding types. But flux core definitely gets the job done. If it was welded and the new crack is out on the side of the weld that’s common since now all the stress is there. Your gonna wanna grind everything flat drill a small hole above the crack to keep it from cracking again and weld in a reinforcement plate instead of just welding the crack only
Truck frames with flux core..mmmmm then thats what i need..I have small crack..looks like someone used stick welding but it cracked next to it..I used jb weld on it but this one crack isnt having it..have never welded in my life..this will be fun...
People get spoiled and sometimes they have a tendency to stick with one process. When you go from solid wire to flux core it feels "dirty" so you stay with solid wire (until you need to weld outside in the wind). Same thing when you go from stick to solid wire. Solid just feels "cleaner". Personally, I don't care. I pick which ever process seems like it will work best for the job. Usually with a little creativity you can make whatever process you have work. That's what I try to demonstrate in many of my videos. There is always more than one way to get the job done!
+The Ghost of the Flying Dutchman Ahh. OK I see what your saying now. LOL I dont know what I was thinking when I replied back lol. I deleted the comment so that people wont get confused. Thanks for bringing this to my attention. It sucks getting old...brain fog I guess lol.
Seriously? I'm going to have to look into this. If what you are saying is true, I will certainly do a video on it and I will mention you! You are the 2nd person this week to mention panning for gold. I recently uploaded a video where I drained and serviced my hot water tank and a viewer told me he pans his for gold when he cleans his (he has well water) I can only assume that if these are being sold with 5 dollars worth of gold that someone has caught on and they are no longer selling them. I only paid 3 dollars for the sand. You have me very curious now!
Gotta say, really glad I've seen this. I got an old cast iron stove that I broke a couple small decorative parts on and part of the damper handle. All I have is the mig with flux core. Seems like this method will work for me.
Wait up... The cast broke, not the weld so we need to rethink if nirod is best. A new crack may have developed as that break was really clean and rather straight. Maybe more heat and a slower heat buildup was needed and a proper cooldown performed with heat blankets.
pnbliveca Where I live you have to generally dig INTO the ground to get sand (it's too wet for this purpose). However, if you go to the beach, the sand is on the surface and is very dry (especially near the shoreline). That is the sand that would work for this and what I was referring to. I tend to forget that not everyone understands our climate and geography.
all my years of vo tech & real life experience tells me your not supposed to do this ever! however hahahah I agree with everything you just did! when I weld cast spike tips to my ornamental iron I ALWAYS USE FLUX CORE! , depending on the situation, cost, time, what its used for , I always keep my eggs under 90 lbs! good video OUTSIDE THE BOX!!
+Brandon Lund yep, way back when I started vo tech I build an anvil pedestal out of two huge 4'' thick chunks of tool steel with an "i" beam in the middle, welded the anvil to the tool steel with 7018 ahahahaha it never broke! recently built another one tried "nom cast rods to weld 45lb weight plates together works as it was intened to then overlaid it a bit with flux core :)
Great information. Been planning on fixing a crack in a small pot and all I have is a flux core wire welder. If it works I gained a new pot to my collection if not... well I got the pot from the scrap yard so no loss. Thanks. Love the videos
There is always that chance of cracking down the road because the repair will never be as good as before it was cracked, but 90 lbs of pancakes is a lot! If you need help eating those pancakes, I'm in!
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