ThePipingMart Blog Metals How to Weld Cast Iron with Nickel Rods – A Step-By-Step Guide

How to Weld Cast Iron with Nickel Rods – A Step-By-Step Guide

How to Weld Cast Iron with Nickel Rods

When it comes to welding cast iron, nickel rods are the preferred choice. Nickel rods provide a ductile weld that is both strong and durable. But how exactly do you weld cast iron with nickel rods? Let’s take a look at the steps needed for successful welding.

Step 1: Prepare the Cast Iron Surface

In order to get an optimal weld, it is important to prepare the surface of the cast iron before welding. Make sure that you clean off any dust, dirt, or debris from the surface using a wire brush or abrasive cloth. It is also important to remove any rust from the area that you are going to be welding by using either sandpaper or steel wool. Once you have done this, make sure that you use an acetone-based cleaner to wipe down the cast iron and remove any traces of oil or grease.

Step 2: Selecting Your Rod

When selecting your rod, it is important to choose one that is designed specifically for welding cast iron. Nickel alloy rods come in various sizes depending on what thickness of the material you will be working with; thicker materials require larger rods, while thinner materials can use smaller ones. Regardless of which size rod you select, make sure that it has a flux coating in order to protect your weld from oxidation as it cools down.

Step 3: Set Up Your Welder

Once you have selected your rod and prepared your work area, it’s time to set up your welder so that you can begin welding. Start by setting the current on your welder according to the manufacturer’s instructions; most settings range between 60 and 90 amps when working with nickel rods on cast iron surfaces. Next, select a speed setting based on how thick your material is; thinner material requires slower speeds, while thicker material needs faster speeds in order for proper melting of metals and penetration into them. Finally, make sure that your ground clamp is securely attached before beginning your weld job.


Welding cast iron with nickel rods requires careful preparation and attention to detail in order for the best results. By following these steps—preparing your cast iron surface, selecting the right size rod for your project, and setting up your welder correctly—you can achieve a strong and durable weld on any cast iron surface. Good luck!

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