> Ken,
> Could you post who the shop is, where they
> are and what type of process and expertise
> they have. If this is technology, old or
> new, then everyone who may need it at some
> point should have the information.

> Thanks
The work on the cylinders is going to be done at the Sherman Iron Works in Sherman,Texas. they have been in business for more than 100 years and have done this type of cast iron welding before,most recently on oil field equipment.

kbcotton@flash.net

> If I might add;
> Are you positive that you are dealing with
> cast iron?
> There are several grades of Cast Iron used
> for castings, each having a different
> analysis dictating the filler material to be
> used. Preheat and postheat temperatures for
> this type of weld are critical to maintain
> integrity. I am not one, but a welding
> engineer can help insure the job is done
> right.

We have had the metal analyzed,and it is cast iron,for sure! We had to make certain for obvious reasons what we were dealing with,and who could handle a job like this.

kbcotton@flash.net

I hope you don't mind the questions but a long nose and a Metallurgy Degree prompts me. It's unrelated but the "alloy" boiler problems could have been avoided if the right questions were asked.

When you had your sample analysed did you get "all" the normal elements run or just the carbon? Mn, Ni, Cr, Mo, Cu will better define the material for the filler material and heat treating for the engineers.

Cast iron is basically "dirty" steel with the carbon precipitating out as "goobers" as the casting cools. The different alloying elements and even some rare earths are used to modify the carbon structure in an attempt to decrease the size and improve the distribution of the goobers. The bigger the goobers, the harder it is to weld.

Generally large castings are left in the sand molds for up to a week to allow the castings to age and relieve residual stresses. This is the process you are going to have to simulate for a good weld. The preheat will eliminate micro cracks in the welding zone that will weaken the weld and cause early failure.


lamontdc@adelphia.net

The place at Sherman is the old Washington Iron works. The made a few stationary engines back in the old days, and definately have the expertise. if needed, I wouldn't doubt that they couldn't make you a half saddle. I believe that they also did work for the several RRs that had shops in Sherman and Denison.

PS I have a good neighbor and old iron enthusiast(James Randles, jrtoyco@hotmail.com) that would probably cut you a good rate on hauling the saddle on his 18wheel low boy. we just live 20 miles south of Sherman. Let us know when you're coming this way, or if you need hauling. If nothing else, we'll all get together and I'll introduce you to the All You Can Eat glories of "The Rib" BBQ. come see us.

> The place at Sherman is the old Washington
> Iron works. The made a few stationary
> engines back in the old days, and definately
> have the expertise. if needed, I wouldn't
> doubt that they couldn't make you a half
> saddle. I believe that they also did work
> for the several RRs that had shops in
> Sherman and Denison.

> PS I have a good neighbor and old iron
> enthusiast(James Randles,
> jrtoyco@hotmail.com) that would probably cut
> you a good rate on hauling the saddle on his
> 18wheel low boy. we just live 20 miles south
> of Sherman. Let us know when you're coming
> this way, or if you need hauling. If nothing
> else, we'll all get together and I'll
> introduce you to the All You Can Eat glories
> of "The Rib" BBQ. come see us.
Jim:
Thanks for the information and the offer! I will forward it to the persons in charge and hopefully they will contact you as soon as possible!

kbcotton@flash.net