163 1989 Continental Diesel Cast Iron Engine Block with a sizable hole punched through from a rod was welded with MuggyWeld 77 Cast Iron electrodes. Our customer used TIG welding for this motor, but many of these engines have been repaired using arc or stick, even with an old buzzbox.
These engines are found in Miller Big 40D welders and Case Skid Steers. Cory broke the flux off the stick and cleaned the wire with scotch brite before welding. (some welders choose to leave the flux coating on when TIG welding)
The cast iron was sanded or ground down just to make sure there was no debris, grease etc. that could’ve been trapped in the pores of the weld area. Small tack welds were used. The broken cast iron pieces were TIG welded using a 2% Thoriated Tungsten and Argon Gas. Cory tack welded the whole piece (mounting base) into the block.
Tack welding is an important step as it holds the part in proper alignment until the final welds are made. He also pre heated the cast iron with a torch and post heated as well to ensure even cooling.