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I've done a bunch of cast iron repairs and the best I've found is welding it with oxy fuel. They make square filler rods and cans of flux that you have to dip the rods in. Its an older method but it...

Something is up with your gas. You have a leak somewhere or you have a bad tank of gas.
A leak is Way more likely than bad gas.
Soap bubble all of your connections, then check for proper seating...

Just go to the liquor store and get a jug or 2 of everclear. Bout as pure ethyl alcohol as one can get and itll work as good as 90% isoproypal/ denatured alcohol.
+ its safe enough to drink...
...

Never tried it my self. All I know is DO NOT use the phosphoric acid that comes with most common units like surfox or tigbrush.
The phosphoric acid attacks aluminium pretty badly.

Tip TIG adds a motion to the wire, the whole feeding unit jiggles back and forth.
Still a nifty process that I wish I could get a chance to try out...
Hot wire tig is a "normal" process compared...

268896
You can use a normal mig welder just fine, throw the ground clamp for the mig inside an old welding glove for safety and have at it. Start at the slow end of the WFS dial, and creep up until...

I like the idea of using lift arc to start stick rods, never thought of that one...

Starting the arc with scratch/lift isnt the problem, trying to stop it cleanly is. One method i've read about...

For the record, the pictures of parts I've taken have been cleared with either the customers or are done in such a way that its impossible to tell anything valuable/critical about them.
I have...

Thank you all for the input, I'm going to go with a portfolio brought along to an interview (if I get one). Any pictures I would include would be of parts I've worked on and would include the back...

Hi all,
I'm looking for advise from you shop owner types, Would you look at pictures included with a resume?
I want to leave the shop I'm currently in because its pretty much heading down the...

Yeah, they will. It Sucks.
Learned that one the fun way... Nothing like watching a big patch of your skin come off when you are trying to cool it down with cold water......

I'll second the checking the ground. Grounding issues can seem a lot like feed issues. If its a spring clamp kinda ground make sure it has tension. I solved a bunch of issues at work by replacing...

If you're gonna get a lincoln go for the 350 mp. Still single phase but can kick out 350 amps. + fancy pulse modes if one desires. It can also run as a DC tig and stick without much fuss

Not that it will help you with zinc/aluminium castings, but using oxyfuel with square cast iron rods and flux has worked the best for me with the castings I've had to repair. I have had it work on...

Get the tungsten out further for the fillet welds. Rest the cup on the joint, and drop the tungsten out till its almost touching the joint. You can almost slide the cup along but Im not a fan due to...

Soap bubbles work just as well as waving a lit flame around the lines to check for leaks of flammable gas...
A few drops of dish soap in a 12 oz plastic soda bottle works wonders.

For the record, Dye penetrant kits are fairly cheap, easy enough to use, and will show you where the crack ends on any metal vs just steels with magnets and powder.
Just be careful if non-metals...

*disclaimer* Not a machinist.
I'm just a welder, but I work on a bunch of parts that start as waterjeted blanks and end up machined after. Some are 1"-2" thick done in house. I have seen 1/16...

Get a gas lens, It helps. A Lot. It's worth the extra cost in argon/up front for the kit.
Being able to get your tungsten out closer to the weld will let you move faster which will result in less...

If you're not going to weld it, epoxy it.
IF you have even the slightest doubt and think that you *Might* want it welded at some point, get it welded Before you put any goop in it. Your welder will...

Is he working in a shop or outside?

The best way to Weld cast iron from my experience is to use Oxy/Acetylene with the old square rods and a can of flux. You have to heat the rod, dip it in the can, weld for 1/2" to 1" then dunk it in...

Glad the spammer dug this thread up tho, thats a funny list that is wayyyy too accurate

I would hope the HF could overcome, but if not, scratch start it is. It's especially vicious with the new inverters... They hurt when you forget the ground and the HF goes through you. Not like the...

I have a baldor at the moment. The 1/1/1/1 rating is the best thing ever and using anything else is annoying. + the blue tint to the baldor is awesome.
The only other helmet I want at the moment is...