In order not to hire a welding master, it makes sense to independently learn this difficult craft. First you need to gain experience when working with parts made of simple steel, since the most difficult to brew copper, titanium and aluminum. However, do not forget about cast-iron products, which are widespread in everyday life (for example, plumbing parts and sewer pipes). We often have to work with this metal, so the article will describe in detail which electrodes can be used to cook cast iron.
Basic Rules
In this matter, the main thing is compliance with safety regulations and professional recommendations. Home craftsmen need to study the following common difficulties and problems associated with welding with cast iron products, namely:
- if the temperature conditions are not observed, it is possible to overheat the alloy, which can lead to the formation of pores and the appearance of tension in the joints;
- welding is recommended in the lower position;
- you must carefully work with this alloy, otherwise the result will be a brittle connection;
- defects (for example, cracks) may appear on the parts if the cooling and heating processes were too fast or uneven;
- if it is necessary to carry out welding work with several heterogeneous elements, the technical parameters of both alloys should be taken into account.
When the question arises of which electrodes to cook cast iron with steel, it is best to use electrodes of the TsCh-4 brand. The main catch in carrying out such work is that it will be necessary to use a graphite substrate to avoid leakage of cast iron.
You can make a reliable connection of parts at home, but the main thing is to properly prepare the surface of the product and conduct welding work taking into account the technical characteristics of cast iron. Self-taught women should not forget: the welding mode and the type of electrode are no less important nuances, which must be taken into account before starting work.
Types of cast iron
This is an alloy of iron and carbon, which includes special additives. The type of cast iron depends on the percentage of impurities (silicon, phosphorus, sulfur, chromium and other substances) . Some alloys lend themselves to welding, however, in this case, it is necessary to use electrodes with certain technical parameters. The features of each type should be described in detail:
- White cast iron has a high hardness, and all the carbon in it is in the form of cementite.
- A gray alloy, in which carbon is present in the form of graphite, lends itself well to processing. Due to the high technical parameters, the material is used for casting. Inexperienced welders may have a question about which electrode to cook gray cast iron. Masters advise in this case to use consumables OZCH-2, MNCh-2 and OZZHN-2.
- Malleable cast iron is obtained by heat treatment of a finished white alloy. This type of metal is used to create cars and agricultural machinery. If the question arises of which electrode to use for cast iron and iron, then the answer is: Zeller 866 should be used. In addition, CC-4 can be used.
- Half-cast iron is used to create parts that will be constantly in operation.
- High-strength alloy is used in mechanical engineering and for the manufacture of gas and oil pipelines.
What electrodes to cook cast iron and steel without preheating? Professionals claim that Zeller 888 and Zeller 855 consumables can be used for this.
Welding methods
The work is carried out using different methods, for each of which certain advantages and disadvantages are inherent. Specialists identified three main methods for welding cast iron parts:
- The hot method, the specificity of which is that the alloy must be initially heated at a temperature of 500-600 ° C. To create seams, OMCH-1 electrodes are used, the diameter of which is 8-16 mm.
- The use of inert gas is a method that is used to repair cast iron pipes and automotive parts. In addition, the method is suitable when it is necessary to weld heterogeneous metals.
- Welding cast iron with an electrode at home is a feasible action in which it is recommended to use the cold method, since it will not be necessary to heat the workpiece.
Home craftsmen should study the composition of cast iron and its technical properties. Experts say: it is easier to work with gray alloy.
Parts preparation
If the initial measures for cleaning the product were successful, then the welded joint will be easier to make high-quality. Details should be prepared in the following order:
- Clean the surface of the product from dust and debris.
- Degrease the structure with solvent.
- The use of linings is an important condition if you have to work with thin cast iron.
- Edging is performed before joining thick-walled parts, in this case a file or grinder is used;
- Before starting welding work, cracks in the products must be cut and the ends rounded.
Popular electrodes
Above were already mentioned some consumables for welding. The main brands of electrodes for cast iron include the following:
- OZCh-4;
- OZZHN-1;
- CC-4;
- OK 92.18;
- OZCh-2.
What electrode to cook cast iron to metal? From the above list, a consumable of the -4 brand is used for these purposes.
Cold welding: key principles
First you need to purchase equipment and special electrodes containing nickel or copper. The main difficulty in performing welding works is that in the weld area, the brittleness of cast iron increases, since the alloy is subjected to excessive hardening. What electrodes to cook cast iron by electric welding? There are many rods, but experts recommend such domestic brands:
- OZCH-2 and OZCH-6 - electrodes with a copper tip, which is treated with iron powder.
- Iron-nickel rods OZZHN-1, OZCh-3, OZCh-4, which are used for welding cast iron with direct current.
- MNCh-2 consumables are the best option for welding, but they have one drawback - high cost. The manufacturer will use alloys of metals from copper, manganese, iron and nickel for the rod.
But self-taught people can still wonder what electrode to use for welding cast iron is best, which can be answered: it is recommended to use MNP-2, since using these consumables you can make a high-quality seam. In addition, such a connection will be protected from the negative effects of aggressive environments and hot gases.
Hot Welding Electrodes
Masters use different heating temperatures of the joints:
- from 500 to 600 ° C - hot welding;
- 300-400 ° C - half-hot;
- 150-200 ° C - warm.
But cast iron is iron, which, with strong heating, changes its structure, so that the alloy cannot be heated above 650 ° C. In addition, the product should cool gradually. What electrode to cook cast iron? It is recommended to use consumables of the -4 brand if the work is carried out using hot welding technology, and OK 92.18 - at a warm temperature.
Electrodes for welding steel and cast iron
Consumables of the -4 brand are used to connect products from heterogeneous metals. All technical requirements for cold and hot welding must be observed. Such electrodes can easily eliminate defects. In addition, such consumables are used if it is necessary to apply several layers to prepare the part for subsequent welding operations.
What electrodes to cook cast iron with steel? ZELLER 855 and Ficast NiFe - these are the popular brands of consumables for welding, with which masters connect different types of alloys. If the materials have not been previously cleaned and processed - this is not a problem, since professionals can work in this case with unprepared products.
Principles of welding steel and cast iron
The first thing to do is prepare two heterogeneous metals. You will have to spend a lot of time to clean up the place of welding using a sandpaper or steel brush to a shine. Cast iron is a porous metal into which fats and oils penetrate deeply, therefore it is recommended to thoroughly clean the contaminated area.
You should go to the welding process: so, if the voltage of the welding machine is not more than 54 V, then the work must be carried out using direct current of reverse polarity. Otherwise, alternating current must be used. To prevent strong expansion at the weld site, both metals are heated to a temperature of about 600 ° C. However, during cooling, the weld joint may crack, so it is necessary to carefully and carefully carry out the initial work.
If you have to cook thick-walled parts, you will have to follow a different instruction. In this case, you do not need to do the heating, since two heterogeneous metals can be welded using small rollers, each of which should be no more than 2.5 mm long. This is a complex process in which the tightness of the seam is not important. With this technology, each roller must be applied to another, previously cooled. Such a weld, even made by a master, will turn out to be extremely fragile.
Non-consumable electrodes
Cast iron billets can be connected using carbon, graphite and tungsten electrodes. The main thing is to choose a filler element, which may be steel, copper, cast iron and aluminum rods. The welding process is carried out by means of an inert gas or drill (flux). As a rule, experienced welders use tungsten consumables with a nickel additive.
Application of UONI electrodes
In special cases, during welding with cast-iron products, copper-steel consumables are used. To make such electrodes, it is necessary to wind a copper wire on the SSSI 13/45, the thickness of which is from 1.5 to 2 mm. The main thing is that its mass exceeds 5 times the weight of a metal rod. If the question arises as to what kind of electrode to make cast iron, then it is safe to use SSSI.
You can achieve better results if you use UONI-13/55. However, in this case, the main thing is to prevent overheating of the cast-iron part, since cracks may appear on the weld due to this. In addition, it is necessary to ensure that the metal does not get very hot near the joined area.
German electrodes
In Germany, high-quality cast iron electrodes are produced, which are widely used in Russia. For example, this includes the UTP 86 FN brand and the UTP A68 HH stainless filler bar. The German company UTP Schweissmaterial makes nickel electrodes that are suitable for welding with cast iron. The welder will make high-quality and crack-resistant joints.
Capilla 41 - electrodes from another German company, with the help of which work is carried out using hot welding technology. If the cold method is chosen, it is better to purchase Capilla 43.
Manufacturers have also taken care of people who are interested in how to make cast iron with steel. Experts advise buying coal products from TEAM BINZEL, as they produce consumables, with the help of which they work with many types of metals (for example, copper and stainless steel).
Finally
Each experienced or novice welder has the right to decide for himself which electrode is best for cast iron, since there is a large selection of similar materials on the construction market. In this case, the main thing is to choose the right electrode. The article cited the popular brands of materials with which masters make welds on cast iron products. In addition, if an experienced welder sets to work, such work can be carried out with different types of metals.
If you responsibly treat the described rules and recommendations, it will turn out technically correct to weld cast iron products.