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Cast iron welding - today and in the future

Castolin welding alloys developed for cast iron • are certified by Lloyd’s Register • are used worldwide in foundries and repair shops • are ideal for maintenance and repair, manufacturing and fabrication applications

CAST IRON WELDING

Your partner in industry

LLOYD’S REGISTER CERTIFICATION After a thorough inspection, Lloyd’s Register certified the Castolin welding alloys EutecTrode 2-24, EutecTrode 2-26D, EutecTrode XHD 2230 and EnDoTec DO*23, as well as our manufacturing facility in Dublin, Ireland.

With this certification, Castolin is one of the few companies whose welding alloys for cast iron are listed in the “Supplementary List of Welding Consumables” of Lloyd’s Register.

They are particularly suitable for foundries and repair shops that weld cast iron parts which are subject to monitoring by Lloyd’s Register. These arc welding alloys are also important for companies that carry out procedural tests according to the LR “Rules of Shipment”.

Thus consistent quality is ensured by the annual inspection by Lloyd’s Register and the auditing according to the DIN EN 9001 quality standard.

EutecTrode 2-26 D Applications Hot welding cast iron with similar metal applications in manufacturing, fabrication and repair of nodular iron castings (Spheroidal Graphite) as well as grey flake iron castings (GJL). Repairing casting defects, blowholes, porosity etc. e.g.: turbine housings, motor and gearbox housings, fitting housings, rotor hubs and gearbox housings of wind turbines

Weld metal (heat treated)

Values determined on pure weld metal

Yield stress Rp0.2

[MPa]

325

Tensile strength Rm

[MPa]

435

Elongation at break A5 [%]

12

Diameter

[mm]

4,0; 6,0

DIN EN ISO 1071: AWS A5.15:

E C FeC-GF 1 ECl

Classification and certification according to Lloyd’s Register: er *** - 1

EutecTrode 2-24 Applications Cold welding cast iron with dissimilar metal applications for joining and surfacing of grey flake and malleable cast irons.

Also for joining bronze alloys to cast iron. e.g.: Machine tool slides, bearings, crankshaft housings, cable drums, slide rails, rack and chain wheels, turbine blades, gaskets, valve seats and the housings of electric motors

Weld metal

Values determined on pure weld metal

Yield stress Rp0.2

[MPa]

375

Tensile strength Rm

[MPa]

480

Elongation at break A5 [%]

7

Diameter

[mm]

2,5; 3,2; 4,0

DIN EN ISO 1071: AWS A5.15:

E C Ni-Cl 1 ENi-Cl

Classification and certification according to Lloyd’s Register: fs *** - 20 Stronger with Castolin Eutectic

EutecTrode XHD 2230 Applications Cold welding cast iron with dissimilar metal applications for joining and surfacing castings with nodular or grey flake graphite and malleable cast iron. Also for joining cast iron to steel or cast steel and for production welding of castings. e.g.: welding of connections, outlets and wall flanges on pipes made from ductile cast iron to cast iron and steel for piping for the public gas and water supply

Weld metal

DIN EN ISO 1071: AWS A5.15:

Values determined on pure weld metal

Yield stress Rp0.2

[MPa]

345

Tensile strength Rm

[MPa]

450

Elongation at break A5 [%]

13.5

Diameter

[mm]

2,5; 3,2; 4,0

E C NiFe-1 3 ENiFe-Cl

Classification and certification according to Lloyd’s Register: er *** - 20

EnDOtec DO*23 Applications Cold welding cast iron with dissimilar metal applications for joining and surfacing castings with nodular or grey flake graphite and malleable cast iron. Also for joining cast iron to different steel grades. e.g.: Large fittings, machine tool slides, bearings, slide rails, gears, turbine blades and housings, crankshaft housings and valve seats.

Weld metal

DIN EN ISO 1071: W. No.:

Values determined on pure weld metal

Yield stress Rp0.2

[MPa]

345

Tensile strength Rm

[MPa]

500

Elongation at break A5 [%]

12

Diameter

1,2

[mm]

Product description

Classification and certification according to Lloyd’s Register: es *** - 20

Specification

Certificate number

E C FeC-GF 1 EutecTrode 2-24 DIN EN ISO 1071: E C Ni-Cl 1 EutecTrode XHD 2230 DIN EN ISO 1071: E C NiFe-1 3 EnDOtec DO*23 DIN EN ISO 1071: T C NiFe-2 M EutecTrode 2-26 D

DIN EN ISO 1071:

T C NiFe-2 M ~ 2.4560

Classification according to LR

DUB1000051/4

er***-1

DUB1000051/1

fs***-20

DUB1000051/2

er***-20

DUB1000051/3

es***-20

Stronger with Castolin Eutectic

LLOYDS REGISTER CERTIFICATION

Cold welding cast iron - dissimilar metals

Hot welding cast iron - similar metals

The cold welding cast iron procedure requires no preheat and a dissimilar metal welding alloy. The casting should be hand-warm and free from moisture or condensate in the area of the welding zone. It is welded using the stringer bead technique plus peening.

The hot welding cast iron procedure requires slow preheating of the complete casting to between 550°C and 700°C after a suitable welding zone preparation. Then a post weld heat treatment (PWHT) according to the base metal, is applied.

The cold welding procedure is always recommended when: • warping or a distortion of the parts and components to be processed is not acceptable • the casting cannot be preheated due to its size or geometry • preheating equipment is unsuitable or not available

The hot welding procedure is always recommended when: • the mechanical properties, machinability or colour of the weld deposit must closely correspond to those of the casting • the cast workpiece can be positioned and welded while it is located in a gas-fired or electrical brick furnace • Warping, distortion or surface oxidation can be accepted up to a certain degree

Application example: EnDOtec DO*23 The die made from alloyed cast iron GG 25 CrMo is used for the cold drawing of body parts in the automotive production industry. Critical areas are exposed to metallic friction, and must be regularly refurbished in order to guarantee the dimensional accuracy of the cold-drawn parts. Highly processable, ductile welding layers are applied with the EnDOtec DO*23 flux-cored electrode with a low heat input. This fast welding procedure can be used several times on one and the same die.

Micrograph of a hot cast iron weld

Base metal

Yo u r

partner

Transition zone

for

protection,

Weld metal

repair

and

assembly

The information provided about our products and procedures is based on the latest state-of-the-art, as well as on the findings of our Research Department and our operational experience. We reserve the right to make changes in the interest of technical progress. Our General Terms and Conditions of Business (AGB) will apply.

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