WELDING OF FLAKE

AND SPHEROIDAL
GRAPHITE NI-RESIST
CASTINGS
A PRACTICAL GUIDE TO THE USE
OF NICKEL-CONTAINING ALLOYS
NO 4421

Distributed by
Produced by NICKEL
INCO INSTITUTE
WELDING OF FLAKE AND SPHEROIDAL
GRAPHITE NI-RESIST CASTINGS

A PRACTICAL GUIDE TO THE USE

OF NICKEL-CONTAINING ALLOYS
NO 4421

Originally, this handbook was published in 1976 by INCO,

The International Nickel Company Inc. Today this company is
part of Vale S.A.
The Nickel Institute republished the handbook in 2021. Despite
the age of this publication the information herein is considered
to be generally valid.
Material presented in the handbook has been prepared for
the general information of the reader and should not be used
or relied on for specific applications without first securing
competent advice.
The Nickel Institute, INCO, their members, staff and consultants
do not represent or warrant its suitability for any general or
specific use and assume no liability or responsibility of any kind
in connection with the information herein.

Nickel Institute
communications@nickelinstitute.org
www.nickelinstitute.org
The welding of flake and
spheroidal graphite Ni-Resist castings
Details of the engineering properties of the
various grades of Ni-Resist cast irons are
contained in the lnco publication 2574, 'Ni-
Resists and ductile Ni-Resists - engineering
properties'. The chemical compositions for
The weldability of Ni-Resist castings
The flake graphite grades of Ni-Resist cast
iron are all capable of being welded
satisfactorily provided that the sulphur and
phosphorus contents are carefully controlled,
seepage 5.
Until recently, satisfactory welds in SO
Ni-Resist have not been easily obtained but
the position has now improved and can be
summarised as follows:
• SO Ni-Resist type D-2, subject to
compositional control and a niobium
addition, can be repair welded. This has
Welding practice
Welding processes and consumables
Most welding will be concerned with the
reclamation of castings. For this purpose, the
processes available are usually limited to
manual arc welding with flux-coated ·
electrodes and the occasional use of oxy-
acetylene welding.
Mild steel electrodes cannot be used for
the Ni-Resist irons because, as with ordinary
grey irons, a brittle weld will result from
carbon pick-up. Moreover, the weld would
have inferior resistance to corrosion and
heat. Flux-coated electrodes depositing weld
metals of compositions matching those of the
castings are not available commercially.
However, the widely available, high-carbon
55 per cent nickel-iron electrodes used for
the reclamation and repair of ordinary grey
and SO iron castings can give excellent
results, and the majority will be found
suitable for welding the flake graphite Ni-
Resist irons. Although perfectly suitable for
other applications, not all of these electrodes
deposit weld metals which will match the
impact toughness of the most widely used
SO Ni-Resist irons, although, in most
instances, the weldments are at least as
strong in tension. The electrode chosen
should be carefully evaluated by the user to
ensure that it gives good operability,
the different grades are reproduced in Table 1
but for optimum weldability it has been
found necessary to control compositions to
closer limits than the ranges given. A general
statement on the weldability of each grade is
been adequately proven with commercial
castings made in the modified com-
position, particularly in West Germany.
Furthermore, it has been demonstrated
that fabrication by welding is possible and
capable of development.
e SO Ni-Resist types D-2B, D-3, D-4 and
D-5B are reasonably weldable subject to
compositional limitations and control of
welding parameters such as pre-heat and
interpass temperatures.
e SO Ni-Resist types D-2C, D-2M, D-3A
adequate freedom from slag inclusions,
acceptable weld metal soundness and, if
relevant, satisfactory toughness and
machinability. The manufacturers' instruc-
tions for storage, drying, baking and using ·
the electrodes should be closely followed.
Weld preparations and procedures
Preparations for welding arc basically
similar to those needed for grey and SO iron.
Surface contaminants such as slag, sand,
casting skin, corrosion products, paint, oil
and grease must be removed to ensure that
they will not affect welding quality. Defective
regions in the casting are removed by
machining, chipping or grinding down to
sound base metal and, as with all austenitic
cast irons, care must be taken to ensure that
part of the defect is not concealed by metal
flowed-over by the process. Arc-gouging is
not recommended. If possible, the soundness
of the preparation should be checked with
dye-penetrant, as described in BS 4416 and
the penetrant should be removed before
welding. Welding is facilitated by using wider
preparations than would be used for mild
steel, and examples are shown in Figure 1.
When using certain electrodes of the nickel-
iron-carbon type, even wider preparations
may be necessary to diminish the formation
of slag stringers near the fusion boundary,
especially if welding without preheat and at
low interpass temperatures.
given below but, to date, most practical
experience has been obtained with the more
commonly used grades designated in ASTM
A436 and A439 as types 1, 2 and D-2.
and D-5 are difficult to weld and welding
should be restricted to shallow reclam-
ation welding in non-critical parts of the
casting.
For details of the metallurgical
considerations of welding Ni-Resist castings
and restrictions on composition see pages
5-6. Expert guidance should be sought if the
presence, location or size of the proposed
weldment is likely to be critical in relation to
the conditions to be encountered in service.
In preparing the weld, adequate access for
the welding operation should be assured.
Welding downhand is preferable because
positional welding with certain nickel-iron
electrodes is difficult; although satisfactory
positional welds with some makes of
electrode, at diminished welding currents,
have been reported.
In arc-welding all the flake graphite Ni-
Resist irons and SO type D-4 iron,
preheating to 300-350°C is important and
interpass temperatures must also be in that
range. When necessary, local or entire
heating of the casting may be needed to
ensure that the weld is not subject to unduly
high tensile stresses during cooling. Ideally,
the welding operations should be completed
without intermediate cooling; in this respect
the requirements are rather less critical than
when welding the ordinary grey irons.
The other grades of SO Ni-Resist are
usually arc welded without preheat and at
low interpass temperatures; 'buttering' the
weld preparations helps to avoid heat-
affected-zone cracks, see Figure lB. Prior
heating of the casting or weld preparation is
helpful in the elimination of residual volatile
matter such as oil, penetrant and moisture
which could affect weld metal soundness, but
the casting should be cooled to room
temperature before welding.
Metal wash is improved by moderate
weave and, in extensive welds, the tendency
Table 1 ISO and Related National Specifications of NI-Resist Austenltlc Cast Irons

ISO 2892-1973 (E) RELATEDSPECIFICATIONS

FLAKE GRAPHITE NI-RESISTS USA U.K. FRANCE GERMANY

COMPOSITION PERCENT MECHANICAL PROPERTIES(minimum)

p T.S. Elong. (A) Mean impact value ASTM BSI (1) AFNOR DIN 1694 .· DIN 17007
GRADE C SI Mn Ni Cr Cu 0.2%proof
max stress (Rm) Lo=5.65 Charpy U-notch A436-72 3468 (1974) NF-A32-301
max (1972)
(Rp0.2) JSo V-notch (Mesnager) Grade Grade Grade WerlcstoffNr.
N/mm 2 N/mm2 % J J Type

L-NiCuCr 15 6 2 3.0 1.0- 0.5- 13.5- 1.0- 5.5- - - 170 - - - 1 L-NiCuCr 15 6 2 L-NUC 15 6 2 GGL-
NICuCr 15 6 2 0.6655
2.8 1.5 17.5 2.5 7.5
L-NiCuCr 15 6 3 3.0 1.0- 0.5- 13.5- 2.5- 5.5- - - 190 - - - 1b L-NiCuCr 15 6 3 L-NUC 15 6 3 GGL-
NICuCr 15 63 0.6656
2.8 1.5 17.5 3.5 7.5
L-NiCr202 3.0 1.0- 0.5- 18.0- 1.0- 0.5 - - 170 - - - 2 L-NiCuCr 20 2 L-NC202 GGL-
NICr202 0.6660
2.8 1.5 22.0 2.5 max
L-NiCr20 3 3.0 1.0- 0.5- 18.0- 2.5- 0.5 - - 190 - - - 2b L-NiCr20 3 L-NC20 3 GGL-
NICr203 0.6661
2.8 1.5 22.0 3.5 max
L-NiCr30 3 2.5 1.0- 0.5- 28.0- 2.5- 0.5 - - 190 - - - 3 L-NiCr303 L-NC303 GGL-
NICr303 0.6676
2.0 1.5 32.0 3.5 max
L-NiSiCr 30 5 5 2.5 5.0-
6.0
0.5-
1.5
29.0-
32.0
4.5- 0.5
5.5 max
- - 170 - - - 4 L-NISiCr 30 5 5 L-NSC30 5 5 GGL-
NISICr3055 0.6680

L-Ni 35 2.4 1.0- 0.5- 34.0- 0.2 0.5 - - 120 - - - 5 L-Ni 35 L-N 35 GGL-
N135 0.6683
2.0 1.5 36.0 max max
ASTM A 439-71
SPHEROIDALGRAPHITE(DUCTILE)NI-RESISTS Tvoe
210 370 7 13 16 D-2 S-NiCr202 S-NC202 GGG- (2)
S-NiCr 20 2 3.0 1.5- 0.5- 18.0- 1.0- 0.5 0.08
N1Cr202 0.7660
3.0 1.5 22.0 2.5 max
S-NiCr 20 3 3.0 1.5- 0.5- 18.0- 2.5- 0.5 0.08 210 390 7 - - D-2B S-NiCr20 3 S-NC20 3 GGG-
NiCr203 0.7661
3.0 1.5 22.0 3.5 max
0.5 0.5 0.08 170 370 20 20 24 D-2C S-Ni22 S-N22 GGG-
S-Ni 22 3.0 1.0- 1.5- 21.0- 0.7670
24.0 max max N122
3.0 2.5
22.0- 0.2 0.5 0.08 210 440 25 24 28 (ASTMA571-71 S-NiMn 234 S-NM234 GGG-
S-NiMn 23 4 2.6 1.5- 4.0-
NIMn234 0.7673
2.5 4.5 24.0 max max Type D-2M)
S-NiCr30 1 2.6 1.5- 0.5- 28.0- 1.0- 0.5 0.08 210 370 13 - - D-3A S-NiCr30 1 S-NC301 GGG-
NICr301 0.7677
3.0 1.5 32.0 1.5 max
S-NiCr303 2.6 1.5- 0.5- 28.0- 2.5- 0.5 0.08 210 370 7 - - D-3 S-NiCr303 S-NC303 GGG-
N1Cr303 0.7676
3.0 1.5 32.0 3.5 max
S-NiSiCr 30 5 5 2.6 5.0- 0.5- 28.0- 4.5- 0.5 0.08 240 390 - - - D-4 S-NiSiCr 30 5 5 S-NSC305 5 GGG-
NIS1Cr305 5 0.7680
6.0 1.5 32.0 5.5 max
S-Ni 35 2.4 1.5- 0.5- 34.0- 0.2 0.5 0.08 210 370 20 - - D-5 S-Ni 35 S-N 35 GGG-
Nl35 0.7683
3.0 1.5 36.0 max max
S-NiCr35 3 2.4 1.5- 0.5- 34.0- 2.0- 0.5 0.08 210 370 7 - - D-5B S-NiCr35 3 S-NC35 3 GGG-
NICr353 0.7685
3.0 1.5 36.0 3.0 max

( 1) The BSI specification requirements are the same as those In the ISO 2892 Standard
(2) DIN 1694 is being revised to Include a weldable grade viz. GGG-NICrNb 20 2. Werkstoff Nr. 0.7659
 A B
Preparation and welding procedure for a shallow
defect.
Figure 1 Some examples of prepara-
tion and welding procedure on
defective castings.
Root face: nil to 1.5mm
Root gap: 1.5mm
Figure 2 Preferred types of joint
design for metal-arc welds.
to distortion can be diminished by
intermittent or balanced weld runs. The weld
deposits should not be peened. Adequate
removal of slag before restrike and complete
interpass slag removal are important to the
production of sound weld deposits. Slag
globules and stringers near the weld fusion
boundary can induce heat-affected-zone
cracks in Ni-Resist castings that have
marginal weldability, as can other welding
defects such as undercut and grossly
irregular penetration of the weld bead into
the casting.
55 per cent nickel-iron electrodes may be
Metallurgical considerations
The flake graphite Ni-Resist irons are
slightly tougher and more ductile than
ordinary grey cast irons and despite their
higher expansion coefficients and lower
thermal conductivity, have proved to be
rather more tolerant to stresses induced by
expansion and contraction during welding.
The austenitic matrix implies less tolerance
for impurity elements such as phosphorus
and sulphur. To avoid hot-cracking in the
Preparation and welding procedure for deep seated defect.
Note the buttering layer.
Root face: 1.5-2.Smm
Root gap: 2.5-3mm
used to join the Ni-Resist irons to mild steel,
to certain stainless steels and to some high-
nickel alloys. The iron should be prepared
and joined as if being welded to like material,
see Figure 2.
Post-weld heat treatment
The coefficients·of thermal expansion of the
high-carbon, SS per cent nickel-iron weld
metals are less than those of the Ni-Resist
irons so th~ localised stresses are re-
imposed on the weldments after heat
treatment. A stress-relieving heat treatment
at 650°C after extensive welding operations
heat-affected zones it is strongly
~mmended that castings should not
contain more than about 0.04 per cent each
of phosphorus and sulphur and, preferably,
less than 0.03 per cent.
The greatly enhanced ductility and
toughness of the spheroidal graphite
Ni-Resist irons might suggest weldability
superior to that of the austenitic flake
graphite irons but, in practice, this is not
C
Preparation and welding procedure for comer defect.
Casting preferably to be positioned for downhand
welding.
,r30•--;
\ I
~----~ I I
,-------.,.
Root face: 1.5-2.Smm
Root gap: 2.5-3mm
may be beneficial in redistribution of the
stresses and so improve dimensional stability
during machining or in service. Also, post-
weld annealing at 980-1035°C may be used
if it is necessary to improve the toughness
and ductility of the weldments. When heat
treating welded Ni-Resist castings which
have low ductility and toughness at ambient
temperature and which have also been
subjected to high preheat and interpass
temperatures, consideration should be given
to transferring the casting directly to the heat
treatment furnace immediately on comple-
tion of the weldment.
necessarily so. The presence of the
magnesium for the spheroidisation of the
graphite decreases the ductility at welding
temperatures and cracks (up to 3 mm long)
tend to form in the heat-affected zone in a
direction normal to the weld fusion
boundary. The danger can be lessened by
modifying or controlling the compositions of
the irons but, even then, welding operations
on certain of the SG Ni-Resist irons (see
below) should be limited to shallow In view of the common usage of the SG Ni-Resist types U-4 and U-4A
reclamation welds. It is wiser, however, to ASTM type numbers for the Ni-Resist irons
Because of their high chromium contents.
ask the customer to accept superficial and to avoid confusion with other grades it is
these irons are not usually prone to tht
casting defects rather than take the risk of suggested that the niobium-containing
formation of cracks in the heat affected zone.
producing weld cracks simply for the sake of modified D-2 grade is referred to as D-2W.
However, unless the preheat and interpasf
improving the external appearance of the In West Germany, following the successful
temperatures exceed 300°C, large cok
casting. In general, the tendency to form use of this alloy, DIN 1694 is to be revised
fissures may occur near welds made in the
such cracks diminishes with increase in the to include niobium-modified SG Ni-Resist
type D-4 iron, because of its low ductility a,
chromium content of the iron. designated GGG-NiCrNb 20 2.
near-ambient temperatures. Resistance tc
Brittle martensitic microstructures are not Buttering of the weld preparation is
crack formation and propagation if
usually encountered adjacent to welds in recommended, particularly in sections
improved by ensuring that the graphite ii
flake graphite and SG Ni-Resist irons, but thicker than 15 mm and/or if the castings are
fully spheroidised; also, restriction of tht
the amount of carbide may increase. To to be stress relieved or annealed after
magnesium and phosphorus contents tc
maintain optimum toughness in SG Ni- welding. maxima of 0.05 per cent and 0.035 per cent
Resist weldments the width of the heat- respectively, is recommended. Under thes<
affected zone should, in general, be restricted conditions the addition of niobium i:
by using low preheat and interpass SG Ni-Resist type 0-2B probably unnecessary.
temperatures and low weld heat inputs. The In this higher-chromium grade it has been A lower chromium (2-4%) version oftyp,
exception to this practice is the SG Ni-Resist established that the tendency for crack D-4, known as D-4A t, with controlle<
type D-4 where preheat and high interpass formation adjacent to the weld is less likely phosphorus and magnesium content, ha
temperatures may be necessary to avoid cold to occur. Nevertheless, it has also been been welded successfully without prehea
cracking. shown in test castings that improved and at low interpass temperatures because o
Post-weld annealing at 980-1035°C of all weldability and crack-free welds can be its higher ductility, but high preheat anc
Ni-Resist irons can be used to improve obtained when the composition is controlled interpass temperatures may be necessary i
toughness and ductility by spheroidising the with respect to phosphorus and magnesium, cold cracking is encountered. Unlike typ
carbides in the heat affected zone and in the combined with the addition of niobium as in D-4, an addition of niobium to type D-4i
bulk of the casting. Ni-Resist type D-2. A preferred composition is likely to be beneficial.
In some instances, minor repair welds range for type D-2B is:
have been made successfully in small Total carbon 3.0 max. The effect of niobium on the
castings by using very high preheat and Silicon 1.5-2.5 properties of Ni-Resist irons
interpass temperatures and high heat-inputs, Manganese 1.0-1.5 Tensile and impact properties at roor
e.g. in oxy-acetylene welding, such that the Chromium 2.7-3.3 temperature of both cast and cast-anc
concentration of welding stresses is low and Nickel 18.0-22.0 welded Ni-Resist D-2W have been measure
the low cooling rates limit the formation of Magnesium 0.05 max. and found to be well within the requiremem
excess carbides in the heat affected zone. Phosphorus 0.040max. specified for type D-2. Some loss of ductilit
Niobium 0.12---0.17 and impact values occurred when tests wer
Iron balance made using certain welding materials'
Niobium-modified SG Ni-Resist
type 0-2 This preferred composition may be Similar tests on other types of niobiurr
The tendency to cracking in the heat-affected conveniently referred to as D-2BW. containing Ni-Resist have not yet bee
zone of this iron is greatly diminished or made.
eliminated by making small additions of SG Ni-Resist types 0-3 and 0-5B The high-temperature properties of tl
niobium together with closer control of the The tendency to crack formation adjacent to niobium-containing Ni-Resist irons have n,
composition than is necessary to satisfy the the weld is also diminished by the higher been measured. If these irons are to be use
specification requirements of SG Ni-Resist chromium contents of these irons and similar for high-temperature applications it
type D-2. A practical composition range is control of the levels of phosphorus and recommended that the properties and we
as follows: behaviour are examined in relation to tl
magnesium plus an addition of niobium, as service temperature.
Total carbon 3.0max. recommended for the type D-2 iron, may be
Silicon 1.7-2.2 beneficial.
Manganese 1.0-1.5 Magnetic properties of welded
Chromium 2.0-2.5 Ni-Resist irons
Nickel 18-22 SG Ni-Resist types 0-2C, 0-2M, The 55 per cent nickel-ironelectrode may I
Magnesium 0.05 max. 0-3Aand 0-5 unsuitable for applications where no
Phosphorus 0.040max. Cracking in the heat-affected zone of welds magnetic properties are important because ·
Niobium 0.12---0.17 made in the low-chromium irons types D-2C the magnetic properties of the weld depos
Iron balance and D-2M is reduced by severely limitingthe
phosphorus, silicon and magnesium contents
It is preferred that the phosphorus and of the castings and by making additions of
lead contents be restricted to 0.035 max. and up to about 0.3 per cent niobium, but
0.003 per cent respectively. However, compositional ranges that provide
specification by means of chemical satisfactory weldability have not been found.
composition alone may be unduly restrictive Accordingly, it is recommended that welding
in that advantage cannot be taken of the full operations should be restricted to supervised,
scope afforded by other weldability shallow, reclamation in non-critical regions
relationships•; and weldable castings could of castings. Similar considerations probably
be rejected unnecessarily. will apply to irons of the D-3A and D-5
types since variation of nickel content in the
range 18-36 per cent has been found to have
"This is fully described in the paper by N. Stephenson
"Improving the weldability of SG Ni-Resist type D-2 iron'. lntn.
no significant influence on the susceptibility tD-4A is a development of type D-4 which has imprc·
toughness, ductility and machinability and may be include,
Conf. on Weldin• ofCastinu. Bradford. Sept. 1976. to weld cracking. National Specifications in the future.