Best Welding Rod For Cast Iron (Reviews & Buying Guide 2021)

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Welding cast iron is among the most difficult welding process. A wrong miscalculation can completely damage the broken parts, even more, the final weld may appear sturdy and good but it is internally weak. Therefore, choosing the best welding rod for cast iron is of great necessity than anything else. When welding cast iron you should be keen on following the guidelines and set rules. This is necessary because you will need final welds that are internally strong and have no cracks to serve the intended purpose.

So, what is the best welding rod for cast iron? Don’t forget that having the best electrode recommended for welding cast iron is also necessary. One of the best rod for welding cast iron is Weldcote Nickel 99 Cast Iron Welding Electrode Repair 1/8" 1 Lb. This electrode is best for all-position welding, especially where machinability is required.

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Product Image
Top Pick
Weldcote Nickel 99 Cast Iron Welding Electrode Repair 1/8" 1 Lb.
US Forge 52332 Nickel Free Cast Iron Electrode
WeldingCity 5-pcs Cast Iron Repair Stick Welding Electrode Rods ENi-C1 (Nickel-99...
Weldcote Nickel 55 Cast Iron Welding Electrode Repair 1/8" 1 Lb.
Hot Max 23066 3/32-Inch Cast Iron 55-Percent Nickel 1# ARC Welding Electrodes
Installation Method[Arc Welding]
Arc-welding
Arc-welding
TIG
Arc-welding
Arc-welding
Tensile strength[84,000 PSI]
70,00Psi
80,000psi
81,000psi
70,00psi
70,00psi
Size-rod diameter [1/8"]
1/8"
1/8"
1/8"
1/8"
1/8"
Polarity [DCEP/AC]
AC
AC
AC
AC
AC
Amperage[45-75A]
75A
50-75A
45-75A
80A
45- 75A
Material[Nickel]
Nickel
Nickel
Nickel
Nickel
Nickel
Item Weight
1.09 pounds
8-8 ounces
8 ounces​
1.09 pounds​
1 pound
Prime Status
-
-
Top Pick
Product Image
Weldcote Nickel 99 Cast Iron Welding Electrode Repair 1/8" 1 Lb.
Installation Method[Arc Welding]
Arc-welding
Tensile strength[84,000 PSI]
70,00Psi
Size-rod diameter [1/8"]
1/8"
Polarity [DCEP/AC]
AC
Amperage[45-75A]
75A
Material[Nickel]
Nickel
Item Weight
1.09 pounds
Prime Status
Available
Product Image
US Forge 52332 Nickel Free Cast Iron Electrode
Installation Method[Arc Welding]
Arc-welding
Tensile strength[84,000 PSI]
80,000psi
Size-rod diameter [1/8"]
1/8"
Polarity [DCEP/AC]
AC
Amperage[45-75A]
50-75A
Material[Nickel]
Nickel
Item Weight
8-8 ounces
Prime Status
Available
Product Image
WeldingCity 5-pcs Cast Iron Repair Stick Welding Electrode Rods ENi-C1 (Nickel-99...
Installation Method[Arc Welding]
TIG
Tensile strength[84,000 PSI]
81,000psi
Size-rod diameter [1/8"]
1/8"
Polarity [DCEP/AC]
AC
Amperage[45-75A]
45-75A
Material[Nickel]
Nickel
Item Weight
8 ounces​
Prime Status
-
Available
Product Image
Weldcote Nickel 55 Cast Iron Welding Electrode Repair 1/8" 1 Lb.
Installation Method[Arc Welding]
Arc-welding
Tensile strength[84,000 PSI]
70,00psi
Size-rod diameter [1/8"]
1/8"
Polarity [DCEP/AC]
AC
Amperage[45-75A]
80A
Material[Nickel]
Nickel
Item Weight
1.09 pounds​
Prime Status
-
Available
Product Image
Hot Max 23066 3/32-Inch Cast Iron 55-Percent Nickel 1# ARC Welding Electrodes
Installation Method[Arc Welding]
Arc-welding
Tensile strength[84,000 PSI]
70,00psi
Size-rod diameter [1/8"]
1/8"
Polarity [DCEP/AC]
AC
Amperage[45-75A]
45- 75A
Material[Nickel]
Nickel
Item Weight
1 pound
Prime Status
Available

What Are The Best Welding Rod For Cast Iron?

Here are some of the best welding rod for cast iron we found:

1.Weldcote Nickel 99 Cast Iron Welding Electrode Repair 1/8" 1 Lb

Salient Feature

  • Installation Method: Arc-welding
  • Tensile strength: 70,00Psi
  • Size-rod diameter: 1/8"
  • Polarity : AC
  • Amperage: 75A
  • Material: Nickel
  • Item Weight: 1.09 pounds

This welding electrode is specifically designed to weld stainless steel, mild steel and joining gray iron to themselves. It is mostly preferred when repairing iron castings. The final welds from these rods are very machine able. During the welding temperatures of above 350F are highly recommended.

This rod has a diameter of 1/8, weighs 1.09 pounds and is best used for welding all-position sections of cast iron especially thin ones specifically when the great level of machinability is needed. Final welds can be easily tapped, milled, drilled shaped and are soft. This is due to its 99% Nickel core wire which also makes the color match with cast iron. The 99% Nickel in this rod is ideal especially when repairing porous or cracked iron castings or to join dissimilar metals like carbon steels and low alloy they can also join iron castings to themselves.

Pros

  • Best for all-position welding especially where high level of machinability is needed.
  • The final weld is soft and can be tapped, milled, drilled or milled.
  • Best especially when repairing porous castings and cracked ones.

Cons

  • 99% Nickel electrode is expensive when compared to other cast iron welding electrodes.
  • The weld deposits created by 99% Nickel rod tend to have lower ductility and strength than those of 55% Nickel rod.

2. US Forge 52332 Nickel Free Cast Iron Electrode

Salient Feature

  • Installation Method: Arc-welding
  • Tensile strength: 80,000psi
  • Size-rod diameter: 1/8"
  • Polarity: AC
  • Amperage: 50-75A
  • Material: Nickel
  • Item Weight: 8-8 ounces

Many confuse this electrode to be made of Nickel but in the real sense, this rod is Nickel free. It is also an all-position rod but its deposits are non-machinable. It is characterized with fast freeze a feature the enables it to weld successfully nickel alloys and join the cast iron to steel which sometimes is a nightmare to many welders even the most experienced ones. This welding rod is widely applied in shaft building, machine parts and general-purpose fabrications.

Pros

  • It is a cheaper electrode that welds cast iron with ease.
  • It is the best welding rod used to join steel to cast iron which is sometimes problematic.
  • Successfully applied when alloys of Nickel fail to join.

Cons

  • They are Nickel free rods, not Nickel rods hence not the best option for cast iron.

3. WeldingCity 5-pcs Cast Iron Repair Stick Welding Electrode 3/32"x12" Rod Nickel99 Ni99 ENi-C1

Salient Feature

  • Installation Method: TIG
  • Tensile strength: 81,000psi
  • Size-rod diameter: 1/8"
  • Polarity: AC
  • Amperage: 45-75A
  • Material: Nickel
  • Item Weight: 8 ounces

This electrode like other welding electrodes it is also ideal for all-position sections of cast iron especially thin ones specifically when great level of machinability is needed. It produces welds that are easily moulded, milled, tapped and drilled. This is due to its inner wire which is 99% Nickel. This feature also aids in the production of soft welds.

This electrode additionally even when welding with poor quality cast iron containing contaminants and high levels of phosphorous it produces deposits that are sturdy, ductile and soft.

This rod is also widely applied for all-position welding especially when welding wrought alloys, mild steel, stainless steel alloys with high Nickel or when surfacing and joining cast iron, ductile iron to itself or malleable iron.

Pros

  • This welding rod delivers high quality, pliable final deposits.
  • Its 99% Nickel is appropriate where most extreme machinability is required.
  • The final weld is soft and can be tapped, milled, drilled or milled.

Cons

  • These rods are a bit difficult to weld with.

4. Weldcote Nickel 55 Cast Iron Welding Electrode Repair 1/8" 1 Lb.

Salient Feature

  • Installation Method: Arc-welding
  • Tensile strength: 70,00psi
  • Size-rod diameter: 1/8"
  • Polarity: AC
  • Amperage: 80A
  • Material: Nickel
  • Item Weight: 1.09 pounds

Weldcote Nickel55 electrode is widely applied for all-position welding especially when welding wrought alloys, mild steel, stainless steel alloys with high Nickel or when surfacing and joining cast iron, ductile iron to itself or malleable iron.

Its inner wire of 45% iron and 55% Nickel creates final welds that have a lower shrinkage stress and heat-affected areas have a lower possibility of cracking. This electrode additionally even when welding with poor quality cast iron containing contaminants and high levels of phosphorous it produces deposits that are sturdy, ductile and soft.

Weldcote Nickel 55 is best suited when welding motor block sections, frames, machine parts, housings, constructing worn sections and defective castings. The resultant welds are machinable and the colour mostly matches with that of cast iron.

Pros

  • Its 55n% Nickel is appropriate where machinability is required.
  • Creates final welds that have a lower shrinkage stress.
  • Even with poor quality cast iron, it produces welds that are ductile and strong.

Cons

  • It is relatively expensive because of its 55% Nickel.

5. Hot Max 23066 3/32-Inch Cast Iron 55-Percent Nickel 1# ARC Welding Electrodes

Salient Feature

  • Installation Method: Arc-welding
  • Tensile strength: 70,00psi
  • Size-rod diameter: 1/8"
  • Polarity: AC
  • Amperage: 45- 75A
  • Material: Nickel
  • Item Weight: 1 pound

This welding electrode is used with arc-welding. Hot Max 55 is an all-position welding rod which is designed to weld almost all grades of cast iron. It is most ideal when it comes to building up areas that are worn out. This rod additionally is applied where machinability is required. It has a tensile power of 70,000 PSI and its advised machine polarity is either AC or DC-(DCEN)

Pros

  • Appropriate where machinability is needed.
  • It is versatile since it can weld almost all types of cast iron.
  • It is best especially when repairing iron castings.

Cons

  • Its 55% Nickel is not the best option for welding cast iron.

Click Here To See The Best Wire For MIG Welding Mild Steel

How to weld cast iron with nickel rod

Welding cast iron has some challenges but when effectively in-house welded it can save some bucks and time for you. When not effectively welded it can result to damages like cracking and weak inner joints. It is wise to look for an experienced welder if the parts involved are critical and needs special attention. Below is a summary of the cast iron welding process.

Identify the Alloy

There are two types of alloys:

Grey cast iron

The most common type of cast iron is the Grey cast iron. During the assembling process, the carbon encourages out into graphite chips either as ferrite crystalline or pearlite microstructure. When compared to white cast iron it is more weldable and flexible. Be that as it may, it despite everything it represents a test to planned welders as the graphite segments inside the gray cast iron can easily enter the weld tarn to cause weld metal embrittlement.

White cast iron

This form of iron holds the carbon as iron carbide minus encouraging it out as graphite. It is very hard and brittle due to its cementite crystalline microstructure. White cast iron is commonly viewed as hard to weld.

Clean the Casting

Despite the amalgam, all iron casts should be appropriately arranged before welding. While setting up the iron casts for welding, it is critical to expel every single surface material to make the casting clean in the place of weld.

Pre-heat

When under stress cast iron is vulnerable to cracking, however, this can be prevented by pre-warming the iron castings before the real welding process commences.

Choose the Welding Process

When you've decided on the type or grade of cast iron you are going to weld, the subsequent stage is picking the welding process you will utilize to weld it. You can weld cast iron with each welding procedure, if you utilize the correct filler material and welding strategy. It's principally founded on a welder’s taste, however, there are a couple of elements to consider. The most recommended welding process when it comes to cast iron is arc welding.

The welding process

Alloy rods made of Nickel are the most well known for welding cast iron. As per many experienced welders, welds from nickel-iron are more grounded with lower chances of thermal expansion, lessening welding difficulties and increasing opposition from splitting.

Fusion between the welds is created by passing an electric arc in between welding areas and the electrode causing the metals to melt. The circular segment ought to be aimed at the weld pool, as opposed to at the base metal because this will limit weakening. It is prescribed to utilize the most minimal current setting affirmed by the producer to limit heat pressure. Preheat pieces to at any rate 250°F preceding welds with copper or cast iron rods. Nickel anodes can be utilized minus necessarily preheating.

Why Cast Iron welding is problematic. What is the easiest way to weld cast iron?

The key factor behind why welding cast iron can be difficult is the high carbon content. All through the welding procedure, this carbon moves into the metal being welded or it can move to the adjacent weld metal that is heat affected, causing raised brittleness/hardness. This is the reason behind post welding cracks in cast iron.

Arc Welding is the most recommended welding process that works best with cast iron, provided the right welding electrodes are utilized. Cast iron Welding Rods have an uncommon Graphite rich motion, this graphite artificially ties up the Carbon in the Cast Iron, restricting relocation into the weld metal and warmth influenced zone.

How to Choose the best welding rod for cast iron?

Several types of filler wires and rods can weld cast iron appropriately. The vast majority of the ones accessible that haven't been planned explicitly for iron metal cool too rapidly and cause pressure splits, or don't intertwine appropriately with the cast iron. Below is a list of the best to use when it comes to cast iron.

Rich nickel content

This is the best kind of rod or wire, as it's machinable and soft. It does not cool too rapidly and it matches with the color of cast iron. The only setback is that these are the most costly electrodes and aren't appropriate for welding thick segments.

55% nickel, 45% iron mix

This is a progressively reasonable cost and looks equivalent to cast iron when welded. It delivers a machinable weld, even though it's a lot harder than the 99% nickel welds. It has a lot of lower weld shrinkage than most iron poles, which means it limits breaking.

Iron

his sort costs less and produces an alternate shaded weld than the cast iron. It is considerably more testing to use as it has higher shrinkage properties. It's likewise not machinable, as it solidifies during the welding procedure, however, it very well may be ground back.

Stainless steel

Cast iron melded with austenite treated steel doesn't solidify and change properties such a great amount with iron consumables. The treated steel does extend and contract essentially during the warming and cooling of the welding procedure, so it's trying to utilize. Be that as it may, it's utilized to weld cast iron and delivers a machinable surface.

Brazing bronze

You can oxy-acetylene braze or utilize the poles with a TIG welder. It's a decent method to give a solid hold in a break or between two parts requiring joining, while not causing splitting and a difference in the cast iron properties.

Conclusion

Welding cast iron has proved to be problematic. It calls for utilization of the best welding rod for cast iron, in this case, a rod with 99% Nickel. Meticulous preparation and a lot of care during preheating, welding and cooling processes. In any case, it's a metal that is regularly welded and can deliver a solid segment that will last similarly just as a cast item without welds. Be sure to follow all the fundamental advances, and you will create the finishes you require for your next cast iron venture. If you take any easy routes, the weld will in all likelihood split, or be inside feeble and may not keep going long.

If you have a problem with getting the best welding rod for cast iron or other welding-related products our website will be of much importance when it comes to welding matters.

FAQ

Can You Use 7018 On Cast Iron?

Yes, you can use 7018 electrodes on cast iron. Even though it can be used on cast iron to make it work it calls for much of preheating, slow cooling, and peening. The same precautions apply and it needs you to thoroughly clean the weld metals first.

Can Cast Iron Be Welded Together?

Welding cast iron pieces together is possible but it has proved to be a difficult process. In most instances, welding on cast iron is ideal when it comes to repairs on castings but not joining cast iron to other members.

What Is The Easiest Welding Rod To Use?

The easiest welding electrode to use to weld cast iron is 99% Nickel. The only challenge is that 99% of Nickel is expensive but it works best for cast iron.

Why Do You Preheat Cast Iron Before Welding?

Preheating cast iron before welding is usually done to slow down the rate of cooling the welds and the area around the welds. If possible heating the entire cast is recommended. To slow the cooling rate the casting can be wrapped using a blanket or be buried in dry sand.

What Is The Difference Between 6013 And 7018 Welding Rods?

Both electrodes are mild steel but their coating differs. The coating on 6013 is high titanium potassium while the 7018 coating is low hydrogen potassium. Also, 7018 has higher tensile strength and yield than 6013.

Can You Weld Cast Iron With 6011 Rods?

6011 electrodes can be used on cast iron because it is like putting mild steel in the welds.

Can You Weld Cast Iron With Mild Steel Rods?

Steel rods can be welded to cast iron though ductile iron and Gray iron will behave differently. Regardless of all this, the most important thing is a sturdy weld that will serve for some time.

Last Updated on May 24, 2021 by weldinghubs

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