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PHILCAST Ni

AWS Specification: E NiCl

JIS Specification: DFCNi

Other Specification : DIN 8573 : (Eni BG 1)

I. APPLICATIONS:

Repair, reclamation and build-up of cast iron parts, grey cast iron and malleable (blackheat iron) such as auto blocks and heads, cylinder walls, motor exhaust ports, impeller rings, valve seats, cast iron dies, defective castings, gear box housings, pump castings, machine parts, frames, correcting machining errors, joining steel to cast iron, etc.

II. DESCRIPTION:

Shielded Metal Arc Welding electrode used primarily for the reclamation and repair of casting defects, machining errors, shrinkage cavities, gas blow holes and voids resulting from defect excavation of grey iron castings. The electrode is manufactured using a pure nickel core wire and gives a fully machinable weld deposit.

PHILCAST Ni has been specifically designed to produce a very fluid molten pool with good wetting properties making it particularly suitable for the filing of casting defects. An all positional electrode suitable for use with both AC (minimum OCV of 50V) and DC+. Deposit is free from hard zones, cracks and porosity. Low current requirements. Tensile strength and ductility adequate for cast iron.

III. NOTES ON USAGE:

Use  AC or DC+ current. Prior to welding remove all traces of rust, oil, paint, sand inclusions and scale. Use dye penetrant NDT to establish that there are no remaining cracks in shrinkage cavities or blow holes. These defects should be prepared carefully to provide good access for the electrode and to ensure that all contamination is completely removed. Use PHILARC PA-GR gouging/cutting electrodes for the removal of defects and the preparation of the cracked area.

Repairs can be made with or without preheat, this depends upon component size and thickness. For large sections preheating in the region 250ºC-300ºC will facilitate improved machinability of the weld repair. The molten pool exhibits good fluidity which allows the operator to direct the electrode readily into corners whilst filling shrinkage cavities. The slag properties are such that the “slag-over-slag” technique can be applied whilst filling deep blowholes and excavations. Joints or cracks should be grooved if parts are more that 5.0 mm thick till root is 3.25 mm to 5.0mm thick. Use lowest current practical, depositing short intermittent beads about 25mm to 5.0mm. Remove all traces of slag remnants before applying the next bead. Proceed slowly so that the work does not become too hot.

When preheating is required, the whole piece should be kept at a temperature of at least 260ºC. Do not pre-heat only a small part of the job, but keep the whole piece hot. For every heavy castings it is best to cool in sand, asbestos or mica.

     For building up large and deep grooves, the most economical procedure is to use PHILARC PA-52 up to 3.25 mm of the surface to be machined and then finish off with a number Ni.

IV. TYPICAL CHEMICAL COMPOSITION OF WELD METAL (%):

V. TYPICAL MECHANICAL PROPERTIES OF WELD METAL:

VI. WELDING POSITIONS: FLAT, FILLET, VERTICAL UP, HORIZONTAL, OVERHEAD

VII. SIZES AVAILABLE AND RECOMMENDED CURRENTS (AC or DC + ):