Cast Iron Welding 
In the past, cast iron was always difficult to repair: heat the part slowly in an oven, make the weld with a nickel rod, slowly cool the part in an oven--and hope the cast iron would not recrack (it frequently did). Most welders wouldn't even attempt to weld cast iron due to the tempermental nature of such repairs. Fortunately, times have changed. Muggy Weld offers two solutions for cast iron repair: arc electrodes and gas torch rods.
How are our electrodes different? First, the elongation is up to 300% higher than nickel-type electrodes for cast iron--which allows the weld to stretch and absorb weld contraction (and prevents cracking for the base metal AND the weld). Second, the metallurgic makeup of our rods are softer than nickel rod. Ni rod cools and forms a hard spot in the cast iron, which is a magnet for cracks--(envision a glass window with a rock cooled into the center). Third, our rods are highly machinable, which is atypical of most cast iron electrodes.
The combination of crack resistance and machinability make Muggy Weld electrodes the rods of choice for cast iron welding.
For torch welders, we offer our 56% silver solder for cast iron repair. While we prefer our arc electrodes, this high strength alloy is suitable for thin castings, exhaust manifolds, and small cast iron cracks.
| Compare |
77 Electrode |
72 Electrode |
SSF-6 Silver Solder |
| Sizes available |
5/32", 3/32", 1/8" |
5/32", 3/32", 1/8" |
1/16" |
| Arc - TIG - Braze |
Arc - TIG |
Arc - TIG |
Braze |
| Works on engine blocks |
Yes |
No |
Yes |
| Works on large cast iron holes |
Yes |
Yes |
No |
| Joins cast iron to steel |
Yes |
Yes |
Yes |
| Joins cast iron to metals other than steel |
No |
No |
Yes |
| Works on exhaust manifolds, woodstoves, or other burnt cast iron |
Good |
Great |
Good |
| Works on thin cast iron |
Yes |
Yes |
Yes, even very thin |
| Color match? |
Fair |
Fair |
Fair |
| All position? |
Yes |
Yes |
Yes |
| Machineable? |
Yes |
No |
Yes |
| Paintable? |
Yes |
Yes |
Yes |
| Works over existing welds? |
Fair-- better on unwelded surface |
Fair |
Great |
| Depth to bevel cracks |
3/4 through |
3/4 through |
1/2 way through |
| Crack resistant? |
Yes |
No |
No |
Please see the videos below to compare.
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