Cast sump repair

[snowcat]

Having trouble with a very large Cast Sump circa 50KGs , Do all the normal Nickle filler, penning and working cold, but its stress cracking at the Haz...

I think ambient temperatures are not helping at the moment, and I may have to (sneek) it into the kitchen overnight, would preheat help with this one item or is there any other ways of stress relieving in local areas...

 

[Woody.v8]

Having trouble with a very large Cast Sump circa 50KGs , Do all the normal Nickle filler, penning and working cold, but its stress cracking at the Haz...

I think ambient temperatures are not helping at the moment, and I may have to (sneek) it into the kitchen overnight, would preheat help with this one item or is there any other ways of stress relieving in local areas...

Can you not braze it up ?

 

[snowcat]

Possibly braze although the crack although fresh has got a fair bit of oil contamination..

First casting Iv ever had cause issues.

 

[Drains]

I'm not surprised you're having trouble if you're welding at freezing point. Probably worth giving it a tickle with a propane torch or something to get it up to hand-warm before welding. That or start stapling it...

I heard some story years ago about a big cracked casting. They got a man in, a little Indian bloke with a suitcase. He had all his kit in the suitcase - hand drill, drill bits, material for staples etc. He worked away drilling holes and hammering in the staples to draw the job together. Once finished, not a leak in sight.
I've seen photos of stapled jobs too - the staples tapered to plug the holes and draw the sides together at the same time.

 

[nickk]

I'm not surprised you're having trouble if you're welding at freezing point. Probably worth giving it a tickle with a propane torch or something to get it up to hand-warm before welding. That or start stapling it...

I heard some story years ago about a big cracked casting. They got a man in, a little Indian bloke with a suitcase. He had all his kit in the suitcase - hand drill, drill bits, material for staples etc. He worked away drilling holes and hammering in the staples to draw the job together. Once finished, not a leak in sight.
I've seen photos of stapled jobs too - the staples tapered to plug the holes and draw the sides together at the same time.

A bit of pre-heat will burn away the oil contamination out too.

 

[Wedg1e]

One of my clients in Coventry used to cast the sump pans for the 6.75L Rolls-Royce V8; they had no end of problems with porosity on the flat area towards one end of the pan. It was the almost full-time job of one man to grind out the area and weld it back up...

 

[snowcat]

Well I know when I'm beet, attempted this warm, same thing continual cracking and not even in the haz all directions proper stress fractures, even tickling the cracks caused more cracking some up to 50mm in opposing dirrections..

I have a feeling that both the shape and 5000hrs of temperature cycles has made this material impossible to weld....

Unless someone has a fantastic idea I shall be phoning the dealer to ask if he wants it my scrap bin or his......

 

[madkayaker]

Chemical metal?

 

[snowcat]

Chemical metal?

If it was mine Id take a chance I think the hairline cracks may even just paint tight, however Its for a Main dealer I do quite allot of work for, rather they just renew than have it bite a month down the line

 

[Tino]

Unless someone has a fantastic idea I shall be phoning the dealer to ask if he wants it my scrap bin or his......

Best way. My heart always sinks when someone wants something cast welded. I've had the same problems in the past. I hate to be defeated but some times its just not possible. Tried every trick I could on a cast dif housing once, even brazing caused more cracking.