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Old 04-25-2007, 02:19 PM
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Welding/Brazing cast iron...

OK I need some welding help please! I have an old reciprocating hack saw. I can cut any metal object up to 4"dia. in a nice straight line ...with no effort, except to mount the piece and turn on the switch! ...OR I did. The arm with the guide on it had developed a crack. So I drilled a small hole (3/16") at the end of the crack and beveled the edges and brazed it up ...came out pretty well actually. BUT the heat into the piece changed the angle of the cutting blade and I couldn't cut anything straight! I tried heating it up again and cooling it on the side to "twit" it over ...but after the 4th time it developed a large crack and the piece broke in two! SO I got to looking at it and thought IF I attached the two pieces together to set of super thick washers I could set the angle on the blade super easy! PROBLEM ...I re-made one end out of steel and will weld this too one of my washer by stick welding. I was going to do the same to the cast iron part using a NICAD rod ...BUT a portion of the cast iron guide has that brazed area! I'm guessing when the NICAD liquid pool hits the braze I won't get a clean weld! SO ...do I cut my loses and just braze this end to the washer? ...OR NICAD weld two sides of the part and then braze the third side? ...Any real welder have any suggestions? THX! ...Mark
PS ...NO I can't buy a new part ...they don't make this saw anymore! (Wish they did!)

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Old 04-25-2007, 02:31 PM
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Just cut the losses and braze it now and hope it holds..Perhaps you can make a new part for that old saw..Just a thought..

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Old 04-25-2007, 02:42 PM
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Your right in Nicad won't like the braze,I would rebevel part,make a jig and clamp it exactly how you want it then rebraze it.. ,let the cast cool slowly.
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Old 04-25-2007, 02:52 PM
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Nicad rod? I assume you are talking about a Nickel rod such as a NI 55 (Nickel iron) or NI 99. In order to use the Nickel rod you will have to grind off the bronze left over from the brazing but IMO just brazing it back would be a better option, that stuff is a lot stronger than most people think. How strong this repair will be depends more on the type of iron more so than than the weld, assuming a good weld, but with brazing you are far less likely to encounter problems and most likely will end up with a stronger repair.
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Old 04-25-2007, 03:02 PM
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Yes NI 99 rod. I was thinking that by welding with this rod I would get a stronger attachment then if I brazed it.
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Old 04-25-2007, 03:11 PM
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Probably the brazing would be the strongest, depends on the factors involved. Actually a NI 55 rod would be a better choice than the 99 in this case as the softer 99's only real advantage is that it's machinable plus the 99 is painfully expensive if you have to buy much of it.
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Old 04-25-2007, 03:17 PM
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I have the NI 99 sitting on my work bench now, so that's a "give-me". I don't think I can grind away the brazed section as I had beveled it near all the way thru and its about 1/8 to 5/16 up from the edge I want to weld. ...sounding like I should "think" brazing here!!?
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Old 04-25-2007, 03:26 PM
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The nickel rod and the bronze are not compatible so that could be a problem but IMO the bronze brazing rod is the way to go anyway.
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Old 04-25-2007, 04:01 PM
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the real key is the pre and post heating.
allowing cast to cool to quickly will cause movement and cracking.
it takes time and patience to repair cast . but it can be done ...
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