Due to cast iron’s high carbon content and inherent brittleness, welding this material presents unique challenges. ANSI/AWS D11.89 (R2006): Guide for Welding Iron Castings provides comprehensive guidelines for the welding of iron castings.
Weldability of Cast Iron
Cast iron is considerably less weldable than steel. Since cast iron contains much more carbon and silicon than steel, it is less ductile and more metallurgically deformed when welded. There have been, however, many successful cast-iron repair welds performed. This process requires specialized techniques like preheating (using low heat input), slow cooling, using specific nickel-based filler rods, and applying peening to the weld bead to reduce stress and prevent cracking.
The degree of brittleness and likelihood of cracking of the welded material depends on the type of casting, the heat treatment, and the welding procedure. AWS D11.2-89_R2006 recommends the steps of welding procedures and requirements for the quality of welds.
What Is ANSI/AWS D11.89 (R2006)?
AWS D11.2-89_R2006 serves as a guide for welding iron castings, covering the metallurgy of cast iron, various welding processes (gas, arc, surfacing), joint design considerations, heat treatment, and procedures for qualifying welding operators and welders, as well as quality control practices and safety. The standard helps inspectors and welders evaluate weld quality in a consistent and standardized way and includes:
- Criteria for acceptance/rejection
- Surface conditions
- Weld size
- Discontinuities (e.g., cracks, porosity, undercut, overlap, etc.)
- Inspection tools and methods
- Photographic examples of welds
This standard presents 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 are given for its application in specific cases. A provision is made for qualification of welding procedures and welders when necessary; quality control practice is also included.
Objective of ANSI/AWS D11.89 (R2006)
The objective of AWS D11.2-89_R2006 is to provide instructions on the processes, procedures, qualifications, and quality control necessary for welding various types of cast iron. Ultimately, by thoroughly examining welds at various stages of the industrial fabrication process, inspectors and welders can identify and mitigate potential defects or flaws that could compromise the quality and performance of the final product.
By following the procedures and acceptance criteria outlined in this standard, inspectors can systematically identify surface discontinuities, evaluate weld quality, and assure that repairs or modifications meet industry best practices.
AWS D11.2-89_R2006 is developed by the American Welding Society (AWS).
Please direct any technical questions relating to this American National Standard to the developer. You can find the contact information for all standard developing organizations (SDOs) here: Who to Contact for Standards Related Questions.
ANSI/AWS D11.89 (R2006): Guide for Welding Iron Castings is available on the ANSI Webstore.