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  1. #16
    Join Date
    Jan 2004
    Location
    Mackay North Qld
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    6,446

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    Hi Joe,
    That l generally looks pretty good but the one thing that is of concern me is the flame setting on the torch picture.

    That is way too carburizing in my opinion.

    The setting is more towards the neutral balance -( identified by a rounded top on the flame ) just beginning to haze the flame as the acetylene is increased

    -BUT ONLY, EVER SO SLIGHTLY.

    I would not be surprised if that the casting is hard.I will be interested to see what happens after a file test.

    I do wonder if the armchair experts in the books had ever welded cast iron?

    Then perhaps, if they did, they did not have their stones ripped off or tried to drill and tap the work.

    They forget that the CI carbon % can be as 3 and higher and then want to add yet more carbon?

    As your first effort is pretty darn good mate!

    Grahame

  2. #17
    Join Date
    Aug 2010
    Location
    Near Bendigo, Victoria, AUS
    Age
    72
    Posts
    3,102

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    I can reassure you, Graeme, that the flame was only ever so slightly carburising. The photo shows what the camera sees (infrared) and not was the flame looked like. Also, the flux makes the flame bright yellow, which makes a picture with the flame near the work wrong.
    I'm about to take the part into the workshop and will test hardness and then grind it smooth. I'm pretty certain that it will be all soft cast iron right through.
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

  3. #18
    Join Date
    Aug 2010
    Location
    Near Bendigo, Victoria, AUS
    Age
    72
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    3,102

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    Well, I found time to clean the repaired vise part up today.
    The weld and surrounding material remains fileable and machinably soft. But I used the grinder to do the cleaning up.
    I must admit that I was surprised by the number of gas bubbles in the weld. I really thought I got rid of them as I was welding... But the weld looks EXACTLY like the rest of the material - no visible difference in colour or texture at all.
    I haven't assembled the vice yet, but gave the repaired part a lick of primer. I'll put it back together tomorrow and put some pressure on it.
    20180830_143955.jpg 20180830_143942.jpg 20180830_143837.jpg

    I left the photo quite large, so anyone interested can zoom in to the welds...
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

  4. #19
    Join Date
    Jan 2004
    Location
    Mackay North Qld
    Posts
    6,446

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    The holes can be removed.
    It was not uncommon to go over and over an area using the "pressure" of the flame probing through the molten puddle to release bubbles.

    Sometimes limited by the depth the flame could reach, we would drop in a pinch of flux and mechanically stir the filler to release gas bubbles.
    A fraction too far and bang, you get sprayed with pellets of molten iron. It was always exciting to say the least.

    I still have some filler rod somwhere but lost the flux in the flood.The filler rods would be quite expensive as I paid around the $70 for a pack prior to 2000.

    Grahame

  5. #20
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    71
    Posts
    5,942

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    Thanks for the write up and pics, Joe. My only comment would be regarding the grinding, I've been told/taught never to grind along the welds, as it could be a starting point or cracking? Maybe someone could confirm/correct me on this, especially on cast?
    Kryn
    To grow old is mandatory, growing up is optional.

  6. #21
    Join Date
    Aug 2010
    Location
    Near Bendigo, Victoria, AUS
    Age
    72
    Posts
    3,102

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    Graeme, I have tried all known sources in Australia now. Cast iron fusion welding rods are no loger available.
    CIGweld still has them on their website, but I rang them today and was told they became obsolete about 8 years ago and no stocks are left. They were able to tell me that they contained 3.25% silicone.... Nt sure how important that is, nor how much silicone is in normal grey cast iron.
    The flux is also no longer available and I can't find any other manufacturer. However, there are several 'recipes' for making your own on the net. The main constituents are Borax (68%), Boric acid (28%) and Ammonium Chloride (4%). Another has 6% calcium fluoride (with a proportional reduction of the other parts, of course).
    Another has 80% Borax, 10% Boric Acid and 10% Iron Oxide - seems a little counter-intuitive, and would colour the flux, while the one I used was white.

    I also found a video of someone using strips of ordinary cast iron (5x5mm) cut off a piece of grey cast iron as filler rod. I intend to try that too.

    Kryn: I have heard that too - stress risers from grinding - I used a flapdisk after grinding to make the durface smooth again. I doubt that it will be problematic
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

  7. #22
    Join Date
    Oct 2015
    Location
    melbourne
    Posts
    473

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    So that bunch of what I assume is ci welding rods in my shed could be valuable and I shouldn't cut up for shelf pins?

    (rough surface - brittle - about 4mm?)

    Russ

  8. #23
    Join Date
    Aug 2010
    Location
    Near Bendigo, Victoria, AUS
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    72
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    Just a final photo and report.
    The vise works well and the weld seems to be fine. I haven't deliberately tested it to destruction, but gave it a good workout.
    Very happy with the overall outcome.

    20180904_161225.jpg

    Cheers, Joe
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

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