
Cast Iron
Cast iron is strong, wear-resistant, and inexpensive. Because it's an extremely versatile material, this metal is used in literally thousands of industrial products. Therefore, welding cast iron is an essential process that welders and craftsmen in the industry must learn. Despite the brittle and temperamental qualities of cast iron, welding it is not impossible to do, provided that you have the right materials on hand and use proper cast iron welding procedures.
Cast iron can be difficult to work on because most nickel rods used by welders are harder compared to the base metal. Welding cast iron increases the base metal's tendency to crack, just like how a window with a rock cooled in the center is more likely to shatter into pieces. However, our electrodes possess a different metallurgical makeup—they are softer, highly machinable, and have unique properties that allow the weld to stretch and elongate up to 300 percent more than other rods. This helps prevents the base metal and weld from cracking in the cast iron welding process.
77 Non-Cracking Cast Iron Welding Rod | 72 Burnt Cast Iron Welding Rod | 75 Nickel Iron Electrode for Malleable, Ductile, and Nodular Cast Irons | SSF-6 High Strength 56% Silver Solder | |
---|---|---|---|---|
Sizes Available (in.) | 5/32in, 1/8in, 3/32in | 5/32in, 1/8in, 3/32in | 3/32in, 1/8in, 5/32in | 1/16in |
Sizes Available (mm) | 3.96mm, 3.17mm, 2.38mm | 3.96mm, 3.17mm, 2.38mm | 2.38mm, 3.17mm, 3.96mm | 1.58mm |
Arc - TIG - Braze | Arc - TIG | Arc - TIG | Arc - TIG | Braze |
Works on engine blocks? | Yes | No | No | Yes |
Works on large cast iron holes? | Yes | Yes | Yes | No |
Joins cast iron to steel? | Yes | Yes | Yes | No |
Joins cast iron to metals other than steel? | No | No | No | Yes |
Works on exhaust manifolds, woodstoves, or other burnt cast iron? | Good | Great | No | Good |
Works on thin cast iron? | Yes | Yes | Yes | Yes, even very thin |
Color match? | Good | Good | Good | No |
All position? | Yes | Yes | Yes | Yes |
Machineable? | Yes | No | Yes | Yes |
Paintable? | Yes | Yes | Yes | Yes |
Works over existing welds? | Fair-- better on unwelded surface | Fair | Over nickel, yes | Great |
Crack resistant? | Yes | No | No | Yes |
Depth to bevel cracks | 3/4 through | 3/4 through | 3/4 through | 1/2 through |
Cast Iron Welding Videos

Pot Metal
Inexpensive casting alloys or pot metal can be difficult to work on because of their low melting point. Whether you're soldering pot metal for a repair job or restoring original pot metal classic car parts, you can work on the alloy with ease and prevent it from pitting or breaking easily when you use quality pot metal restoration rods from Muggy Weld.
Other rods melt at 700º F and can be dangerously close to melting the pot metal before you even apply them. On the other hand, Super Alloy 1 pot metal restoration kit from Muggy Weld has a melting point of 350º F and unique properties that make pot metal welding and repairs easier than ever before. To help you prevent damaging the base metal, the non-corrosive flux acts as a temperature guide turns root beer brown when the base metal reaches 350º F. As the rod and flux work synergistically, Super Alloy 1 helps you make repairs that are as strong your base metal.
Super Alloy 1 Multi-Metal and Pot Metal Solder | |
---|---|
Sizes Available (in.) | 3/32in, 1/8in |
Sizes Available (mm) | 2.38mm, 3.17mm |
Melting temperature | 350° F (177° C) |
Bonding strength | 20,000 PSI |
Flux type and shelf life | Honey liquid, 2 year shelf life |
Recommended torch | Propane, MAPP, butane, oxyacetylene |
Contains cadmium? | Yes |
Alloy color | Silver |
Metal warpage? | No |
Can bond thick to thin metals? | Good |
Can join copper, brass, and bronze to other metals? | Yes |
All position? | Yes |
Can be plated? | Most metals except aluminum |
Can be polished? | Yes |
Takes powder coating? | Yes |
Pre-cleaning necessary? | Yes, with a wire brush, sanding, Dremel etc |
Pot Metal Welding Videos

Aluminum
These days, more and more parts are being replaced with aluminum parts. Why? Aluminum is lightweight, durable, and inexpensive in comparison with other metals. The problem is, most aluminum welding shops have been trained to believe that expensive machinery is needed to properly weld this versatile metal, leaving consumers in need of an easy way to weld aluminum.
Aluminum melts at 1218°F and does not turn red like other metals before it reaches the point that it liquefies. If you have ever tried to weld aluminum you know that without an accurate temperature guide, you may end up cleaning aluminum off the floor. For this reason, many auto body shops previously recommended replacing aluminum parts rather than repairing them—which is not only expensive but unnecessary. Fortunately, times have changed, and there’s now a simple way to weld aluminum.
Muggy Weld's aluminum welding, brazing, and soldering store contains a unique line of aluminum welding, brazing and soldering alloys and fluxes that work synergistically to act as an exact temperature guide when torch welding aluminum. While many aluminum brazing products are sold without flux, we believe the use of flux to be superior for several reasons.
First, it allows the rod to flow and bond better than aluminum rod alone. Any welder knows that flow is an important factor in a successful aluminum soldering procedure.
"Where flux flows, rod goes"
Also, our flux acts as an exact temperature guide:
*Super Alloy 5 turns from powder to liquid at the exact moment when the rod should be applied
*Super Alloy 1 starts as a liquid and turns brown when ready for the rod.
Finally, our Alloy 5 flux chemically reacts to clean up oxidation as well as other contaminants, which is very unique in aluminum repair procedure.
Super Alloy 1 Multi-Metal and Pot Metal Solder | Super Alloy 5 Aluminum Welding and Brazing Rod | |
---|---|---|
Sizes Available (in.) | 3/32in, 1/8in | 3/32in, 1/16in |
Sizes Available (mm) | 2.38mm, 3.17mm | 2.38mm, 1.58mm |
Melting Point | 350° F (177° C) | 600° F (316° C) |
Bonding Strength | 20,000 PSI | 30,000 PSI |
Flux type and shelf life | Honey liquid, 2 year shelf life | Powder, 1 year shelf life |
Recommended torch | Propane, MAPP, butane, oxyacetylene on larger or thicker pieces | Propane, MAPP, oxyacetylene on larger or thicker pieces |
Can be polished? | Fair | Excellent |
Can be plated? | Yes | Yes |
Takes powder coating? | Fair | Excellent |
Can be used on thick aluminum? | No | Yes, with oxyacetylene |
Can join aluminum to other metals (brass, steel etc)? | Yes | No |
Can repair radiators without burning fins? | Yes | No |
Potential for metal warpage? | No | Potential |
Can be used with TIG? | No | Yes |
Can repair cast aluminum? | No | Yes, with oxyacetylene |
Pre-cleaning necessary? | Yes | Yes |
Can repair aluminum boats? | No | Yes, with oxyacetylene |
Can be anodized? | No | Yes |
Can be used with a soldering iron? | Yes | No |
Demonstrated on pop cans at the county fair? | NEVER | NEVER |
Aluminum Welding Videos

Stainless Steel
Although stainless steel is one of the most widely used metals, stainless steel welding can be extremely challenging. Cutting, drilling, soldering, and welding stainless steel is difficult mainly because the metal is a poor heat conductor and has a high rate of thermal expansion. It also reacts badly to excessive heat, causing it to warp. Thankfully, we have a unique line of products that can help make stainless steel soldering and brazing tasks easier.
Super Alloy 1, SSQ-6, and SSF-6 silver solder are all designed for use with stainless steel. Allowing for easier and more effective repair and welding jobs, many of our products melt at high temperatures and can be used on a variety of metals, such as brass, copper, bronze, cast iron, and stainless steel. For soldering and brazing tasks, or for welding stainless steel, SSQ-6 and SSF-6 can also be used with any heat source and can last for long periods with minimal care.
Super Alloy 1 Multi-Metal and Pot Metal Solder | SSF-6 High Strength 56% Silver Solder | SSQ-6 56% Silver Solder Paste | |
---|---|---|---|
Sizes Available (in.) | 3/32in, 1/8in | 1/16in | N/A |
Sizes Available (mm) | 2.38mm, 3.17mm | 1.58mm | N/A |
Melting temperature | 350°F (177°C) | 1150°F (622°C) | 1050°F (566°C) |
Bonding strength | 20,000 PSI | Over 70,000 PSI | Over 85,000 PSI |
Flux type and shelf life | Honey liquid, 2 year shelf life | Flux coated | Mixed in, 9 month shelf life |
Recommended torch | Any | Any | Any |
Color match? | Yes | Yes | Yes |
Contains cadmium? | Yes | No | No |
Works in all positions? | Yes | Yes | Yes |
Will clean oxidized stainless? | |||
Will wet to burnt stainless? | No | Yes | No |
Will join stainless to brass, steel, copper, cast iron? | No | Yes | Yes |
Can work as a jig? | No | No | Yes |
Recommended for heat sensitive parts? | Yes | No | No |
Stainless Steel Welding Videos

Steel
Steel is an alloy composed of iron and carbon—the higher the carbon content, the stronger, harder and more brittle the steel. There are many types of steel that can be used for steel welding jobs, all of which are categorized based upon various physical properties and carbon content. High carbon steel is very strong and it is used for files, cold chisels and various metal tools while low carbon steel is used for tubing, nails and castings.
Before you start welding steel, you will have to first determine the weldability of the metal. This is inversely proportional to its ability to be hardened by heat. Basically, this means that varieties of the metal with fewer alloying agents can easily be welded better than others.
Next, measure the equivalent carbon content of the different alloys of steel. This compares the properties of any steel alloy to those found in ordinary carbon steel. If possible, use only high strength, low-alloy metals specifically designed for welding steel.
Most jobs require only a hand held propane torch. Super Alloy 1 is recommended when heat or aesthetics is an issue. Otherwise we recommend our SSF-6 Silver Solder for torch welding: with a holding strength of 71,000 PSI, SSF-6 is as strong as a MIG or TIG weld, with a beautiful finish.
Steel repair on stainless steel can be very difficult; it is difficult to cut and is prone to distortion because of its high thermal expansion. Control the amount of ferrite in the weld to minimize hot cracking, preheat, and use steel welding and solder products such as Super Alloy 1, SSF-6, and SSQ-6 when working on different types of stainless steel.
Super Alloy 1 Multi-Metal and Pot Metal Solder | SSF-6 High Strength 56% Silver Solder | SSQ-6 56% Silver Solder Paste | |
---|---|---|---|
Sizes Available (in.) | 3/32in, 1/8in | 1/16in | N/A |
Sizes Available (mm) | 2.38mm, 3.17mm | 1.58mm | N/A |
Melting temperature | 350° F (177° C) | 1150° F (621° C) | 1050° F (566° C) |
Bonding strength | 20,000 PSI | Over 70,000 PSI | Over 85,000 PSI |
Flux type and shelf life | Honey liquid, 2 year shelf life | Flux coated | Mixed in, 9 month shelf life |
Recommended torch | Propane, MAPP, butane, oxyacetylene | Any | Any |
Contains cadmium? | Yes | No | No |
Color match? | No | Good | Good |
Works in all positions? | Yes | Yes | Yes |
Works for heat sensitive parts? | Great | Fair | Fair |
Steel Welding Videos

Copper, Brass, Bronze
While copper, brass, and bronze may not be applications that are used every day in welding, industries such as refrigeration, electronics and plumbing—as well as ornamental artists, encounter these metals and perform brass, bronze, or copper welding jobs daily.
Here are some things to remember when working on brass, bronze, or copper:
Brass melts at around 1652-1724º F range and is fairly easy to cast. During any brass welding job, use high quality filler if the color doesn’t have to match the metal. Because of its relatively high melting point, low zinc brass can be braze-welded.
Super Alloy 1 can bond all of these metals in any combination, and can be used in bonding with other metals such as aluminum—at 350º F.
SSF-6 Silver Solder is 56% silver and is especially useful when high strength is needed, or when you need high flow to get to those hard to reach areas.
SSQ-6 Silver Solder Paste is the same formula as our SSF-6, in a convenient 1 oz syringe.
Super Alloy 1 Multi-Metal and Pot Metal Solder | SSF-6 High Strength 56% Silver Solder | SSQ-6 56% Silver Solder Paste | |
---|---|---|---|
Sizes Available (in.) | 3/32in, 1/8in | 1/16in | N/A |
Sizes Available (mm) | 2.38mm, 3.17mm | 1.58mm | N/A |
Melting temperature | 350°F (177°C) | 1150°F (622°C) | 1050°F (566°C) |
Bonding strength | 20,000 PSI | over 70,000 PSI | over 85,000 PSI |
Flux type and shelf life | Honey liquid, 2 year shelf life | Flux coated | Flux mixed in, 9 month shelf life |
Recommended Torch | Any | Any | Any |
Alloy color | Silver | Silver | Silver |
Contains cadmium? | Yes | No | No |
Works in all positions? | Yes | Yes | Yes |
Potential for metal warpage? | No | Yes | Yes |
Bonds thick to thin metals? | Good | Great | Great |
Can join copper/brass/bronze to other metals? | Yes | Yes | Yes |