Braze Repair on a Broken Casting Part 1

so here's my next repair job we're going to get started on this is part of a as part of a pump and this housing has been has been repaired once before it's done been busted and repaired and now it's cracked again and broken out and customer said that they have had a difficult time trying to find this part they cannot find it can't replace it s is there any way that I can fix it our only other option is if we can't fix this is to actually make one so we're trying to avoid having to make one so I think that I can provide a suitable repair on this so that's what we're going to shoot for you can see there's the well that's cracked in the same place basically except it's come on across there you can see the gap there where it's busted and pulled out a couple we got a piece there that we're going to have to weld in there so what we'll do is this is a ring that I've been machining on that we're going to use as a backup on here that was a piece of ten by fourteen mechanical tubing that was just a there was a thin piece left and I've got it faced and turned artboard chasse where it'll it'll register he'll register on there all right and I'm going to drill a hole pattern enough so that it will bolt up to that flange and it'll line up all the little line up all the pieces there too you know this section here everything will line up and I'll have to grind this off grind all that away and we're going to we're going to braise this and I'll braise it back together and I'll probably do some being on this side as well and braze all this in after this other side's braised and then set this up and actually face this and turn that register back on there we'll also have to do a little bit of being here and make sure that these cracks are braised up as well it's a pretty extensive repair that I think we can tackle it so let's go get started on I've got the ring finished machine in the holes drilled and one of these holes leave us this one right here this hole right here is on a different the it's on a different divisional it's off the true bolt circle for this one hole is off there's probably a reason why they did that depends on where it it goes into the housing maybe they had to move it to one side or the other so I left this hole while this is no big deal but all the other ones line up on a tree bolt circle all right and then what this will allow me to do is hold this nice and flat and everything together once I'm ready to do my welding let me use some bolts and nuts like this pull everything up snug and that will do our grazing on the one side there we'll do all we're brazing here so it's possible that once I get this ground here everything ground relieving ready to braise I might have to go in on the steel and relieve that corner a little bit so that the brass doesn't go down and try to stick to it I'm not sure yet we'll figure that out once we get to it so next step is this all right we're going to go ahead and get this ground apart and most of this is already cracked there's one section right here that is still connected so I'm going to come in here with the cutoff wheel and go ahead and cut that let's see yeah right in here right across here I might have to grind a little bit out with a grinding wheel but we'll get that off and we'll just kind of knock this piece off and then we'll start our our other grinding to remove all this nickel from here get right here a little bit all right so I got a lot of ground and ahead of me and we'll get all this we'll get all this weld that's been on here we'll get all that removed and out of the way it'd kind of be kind of beat out I'm going to put a V along this edge here also I'm going to try to leave just enough there for maybe it the lineup I don't know yet but I'm wanting to try to be out the inside of it also put some weld on the inside there as well so I'll show you a little bit along the way though okay you there's a little bit of the fitment that we pre started on it getting one side ground and you can see where I need to come in here now and remove this weld bead that was put on there before and then all this will be filled up with with brass when we braise it just like here we'll fill all this in right there and probably have to just go back in there and and drill those holes back out this piece is going to be a little bit more challenge on this end we need to actually grind this one off see where it's crack there it actually made a new crack out here where it broke so we'll take that apart and grind all that we'll have you know be a holding a little piece right there that'll get filled in okay I think I got most the grinding done that I want to do everything beat out the the crack was a little deceiving on the weight the how it cracked you know I did this grinding right here didn't realize the crack actually run up underneath there underneath that flange so I had to do a little more grinding on both sides of this here and here but I'm definitely glad that I made that ring so we'll use that to our advantage and get it bolted on here and then these should just float right there where they need to bulk up to and we've also got another little piece right here that we've got to get fitted in there and I'll have to use a C clamp to hold that in place but everything will be pulled up flat against the the machine side right there and we'll just fill all that in with brazing rod okay fill all this in on the the holes on the end just weld it all up nice and solid and then we'll go back in there and line them holes up and drill down now before I go raising this all I'm also going to be plastics entire piece make sure it's the dry and clean there's no paint or anything on it and this piece here I'll make sure it's clean to it no oil still on it from the machine I'm just going to get a couple these bolts in here and then I'm gonna check them other parts there okay just got them all finger tight pulled up okay and that will see put my there there needs more bolts all right that's lining up pretty good there like a little jigsaw puzzle that one I'll have to use a clamp here there it is so I'm gonna move back inside with everything and get this bead blasted clean and get set up for brazing all right we got it all bolted together where I need it so we're going to do do a preheat got my one set of torches set up for heating using the meddling we're going to get preheated get it nice and hot and then I'm going to switch over to the to the other rig and we'll we'll braze it my brazing rod ready so let's go for the horse okay we got it preheated this is a 350 temp stick and it's melting pretty fast on there so we should be maybe around 400 or so clean the the ground area again where we're going to braise it with a wire wheel and we're ready to go but I think I got her raised in there pretty well for now what I'm going to do is go ahead and take these two bolts off and fill in these in these in uh grind outs there get those finished up all right we've got a pretty well down here and think I'm good taking bolts off and drop the ring see if we need to fill in the top or anything on the back my man's there pretty good all right we got both the ends oh no something what's next here I'm going to go ahead and get the little grinder with the carbide burn and be out the little cracks there and go ahead and fill those in and I'm going to run one bead all the way down to this little crack here where it didn't fully filled within and then after that we'll build a let it cool down and we'll set this up in the way then the machine this off clean it up you I think we got Oliver brazing done now we got our beat all the way across that back fill in that crack there we're going to let it cool it'll go to label it I think it did pretty good once I dress it up a little bit you know clean the flux off and a couple of little droops there I think it'll be it look pretty good

Channel: Abom79

Views: 321,900

Rating: 4.9227452 out of 5

Keywords: abom79, braze, brazing, braze weld, welding, oxyfuel, oxyfuel welding, torch, torch welding, heating, preheat, rosebud, pump, pump housing, repair, cast iron, welding cast iron, brazing cast iron, machining, machine shop, job shop, repair shop, metal repair, grinding

Id: wN3-4rN0n4E

Length: 24min 3sec (1443 seconds)

Published: Sat Jan 23 2016