Why Cast Iron is a tricky material to weld?

Cast Iron is a wide range of casting material which contains 1.7-4.5% C with other alloying elements. This
is very important engineering metal which finds many modern applications around us. However,
successful welding of Cast Iron is always remained a challenge to a welding engineer. In this brief article,
attempt to understand weld cracking mechanism & to summarize prevailing good engineering practices
is made.

Types of Cast Iron:

1. White cast Iron – Due to lesser Si content, C doesn’t precipitate as graphite. Instead forms Fe3C
and other carbide, which makes this form extremely brittle and least weldable.
2. Gray cast iron – Most common form of C.I. Posses higher compressive strength than tensile
strength. Posses higher weldability than white cast iron
3. Ductile/ nodular cast iron – Similar to Gray cast iron but addition to elements like Mg or Cerium
inoculates graphite nuclei which precipitates excess carbon in the form of graphite
4. Malleable cast iron – This is heat treated form of white cast iron. First phase associated with
heating above AC3 (927°C) for enough time till all carbide dissolves and carbon goes back into
matrix. In second phase if this heated C.I. is very slowly cooled (3°C/Hr. to 17°C/Hr.) to room
temperature, it will result in ferritic malleable cast iron. If C.I. is rapidly cooled from 815-870°C to
room temperature either by air or oil quenching it will form pearlitic malleable cast Iron.
5. Compacted/ vermiculated cast iron – Similar to Ductile C.I. except, controlled addition of Mg to
shape control graphite.

Three zones in which cracking may occur in C.I.:

Weld metal: When molten weld metal is rapidly cooled, carbon is not rejected in the form of graphite
instead forms hard and brittle Fe3C, which will lead to cracking. To improve this, selection of suitable filler
metal which carbide forming elements, use of low dilution welding technique and appropriate PWHT is
necessary.

Partially Melted Zone: The partially melted region is like liquid eutectic cast iron, which solidifies as white
iron because of the rapid cooling that take place during welding. In PMZ, mixture of martensite, austenite,
ledeburite and flakes of graphite is expected. To prevent this, peak temperature during welding & time at
such temperature need to be avoided by controlling heat input, preheat and inter pass temperature.

HAZ: Temperature in HAZ is not enough to cause carbide problem but on rapid cooling matrix can be
transformed to hard martensite which again lead to cracking. To prevent martensite formation, slow
cooling and PWHT can be advocated.

In nutshell, following are the key steps to weld C.I. successfully:

1. Selection of appropriate preheat and inter pass temperature. AWS D11.2 can be referred for
same.
2. Selection of appropriate filler wire: either Iron based, or Nickel based. SS filler wire seldom used.
AWS A5.15 can be referred for same.
3. Do not melt casting more than required.
4. Whenever possible, deposit weld beads in even number, minimum 2.
5. Avoid all arc strikes.
6. Use smaller arc length possible.
7. Peening is very effective technique to reduce crack tendency.
8. Back step technique shall be used for evenly heat distribution (within smaller area).