ANSI/AWS D11.2-89 (R2006)An American National Standard

Guide for WeldingIron Castings

550 N.W. LeJeune Road, Miami, FL 33126

ANSI/AWS D11.2-89 (R2006)An American National Standard

Approved by theAmerican National Standards Institute

July 14, 1988

Guide for

Welding Iron Castings

Prepared by theAmerican Welding Society (AWS) D11 Committee on Welding Iron Castings

Under the Direction of theAWS Technical Activities Committee

Approved by theAWS Board of Directors, March 3, 1988

AbstractThis standard presents briefly the history and metallurgy of cast iron and the welding processes applicable to it.

A newly developed weldability test is described in detail and instructions given for its application in specific cases.

Provision is made for qualification of welding procedures and welders when necessary; quality control practice is alsoincluded.

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Table of Contents

Page No.

Personnel (Reaffirmation) ............................................................................................................................................vPersonnel (Original) ..................................................................................................................................................viiForeword .....................................................................................................................................................................ixList of Tables ............................................................................................................................................................ xiiiList of Figures............................................................................................................................................................xiv

1. Scope and History................................................................................................................................................11.1 Scope............................................................................................................................................................11.2 History .........................................................................................................................................................1

2. Cast Iron — Its Metallurgy and Weldability....................................................................................................12.1 Metallurgy....................................................................................................................................................12.2 Difficulties in Welding Iron Castings..........................................................................................................42.3 AWS Weldability Test Program..................................................................................................................62.4 Preweld Testing for Weldability................................................................................................................11

3. General Considerations When Welding Iron Castings .................................................................................143.1 Base Metal Preparation..............................................................................................................................143.2 Joint Design ...............................................................................................................................................153.3 Heat Input ..................................................................................................................................................173.4 Preheat .......................................................................................................................................................173.5 Electrode Manipulation .............................................................................................................................203.6 Peening ......................................................................................................................................................213.7 Cooling ......................................................................................................................................................213.8 Postweld Heat Treatment...........................................................................................................................21

4. Gas Processes .....................................................................................................................................................234.1 Oxyfuel Welding (OFW)...........................................................................................................................234.2 Flame Spraying of Gray Iron (FLSP) ........................................................................................................274.3 Braze Welding ...........................................................................................................................................27

5. Arc Welding Processes......................................................................................................................................305.1 General.......................................................................................................................................................305.2 Shielded Metal Arc Welding (SMAW) .....................................................................................................305.3 Gas Metal Arc Welding (GMAW) ............................................................................................................355.4 Flux Cored Arc Welding (FCAW) ............................................................................................................375.5 Gas Tungsten Arc Welding (GTAW)........................................................................................................415.6 Submerged Arc Welding (SAW)...............................................................................................................44

6. Surfacing and Overlaying.................................................................................................................................456.1 Processes....................................................................................................................................................456.2 Thermal Spraying ......................................................................................................................................456.3 Other Processes..........................................................................................................................................476.4 Surfacing Materials....................................................................................................................................486.5 Technique ..................................................................................................................................................50

7. Applications .......................................................................................................................................................507.1 Casting Defect Repair................................................................................................................................507.2 Repair of Machining Defects.....................................................................................................................51

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7.3 Repair of Castings After Service ...............................................................................................................517.4 Fabrication .................................................................................................................................................51

8. Welding Procedure and Performance Qualification......................................................................................518.1 General.......................................................................................................................................................518.2 Welding Procedure Qualification ..............................................................................................................528.3 Welding and Welding Operator Performance Qualification .....................................................................52

9. Quality Control..................................................................................................................................................529.1 General.......................................................................................................................................................529.2 Quality Control Practices and Procedures .................................................................................................529.3 Acceptance Criteria ...................................................................................................................................54

10. Safety and Health ..............................................................................................................................................5410.1 Fumes and Gases .......................................................................................................................................5410.2 Radiation....................................................................................................................................................5510.3 Electric Shock............................................................................................................................................5510.4 Fire Prevention...........................................................................................................................................5510.5 Explosion ...................................................................................................................................................5510.6 Burns..........................................................................................................................................................5510.7 Further Information ...................................................................................................................................55

Appendix A — Weldability Test .............................................................................................................................51A1. Introduction................................................................................................................................................57A2. Equipment Required ..................................................................................................................................57A3. Welding Conditions ...................................................................................................................................58A4. Test Procedure ...........................................................................................................................................59

Appendix B — Applications ....................................................................................................................................63

Appendix C — Welding Procedure and Performance Qualification ..................................................................83C1. General.......................................................................................................................................................83C2. Welding Procedure Qualification ..............................................................................................................83C3. Inspection Results Required ......................................................................................................................95C4. Welding and Welding Operator Performance Qualification .....................................................................97

Appendix D — Recommended System for Classification of Welds in Iron Castings,Appendix D — and Associated Quality Levels ....................................................................................................105

D1. Classification of Welds in Iron Castings .................................................................................................105D2. Test Requirements ...................................................................................................................................105

Appendix E — ASME Code Cases........................................................................................................................109E1. Case 1867.................................................................................................................................................109E2. Case 1939.................................................................................................................................................109

Appendix F — Safety and Health .........................................................................................................................111

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List of Tables

Table Page No.

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List of FiguresFigure Page No.

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Figure Page No.

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Guide forWelding Iron Castings