How to do cast steel welding

Written by alexis rohlin
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How to do cast steel welding
Split cast steel can be welded back together. (welding image by Kaarel from

Cast steel tends to crack and wear down when overexposed to high amounts of heat. Cast steel welding is a bit more difficult than other types of welding repairs because not all items made out of cast steel are created the same way. Welding cracked cast steel takes patience and diligence.

Skill level:

Things you need

  • Metal grinder
  • Sand Paper
  • Nickel-type stick electrode for single pass high dilution welds
  • MIG Welder and filler metal
  • Peeling and shearing bevel
  • Drill
  • Tap
  • Threaded steel studs

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  1. 1

    Clean the metal where it has cracked with a metal grinder, going 1/2 inch past the area where you are going to weld until it is bright and shiny.

  2. 2

    Bevel the surfaces of the edges of the crack that is to be repaired with a peeling and shearing bevel.

    Drill with a tap attachment threaded holes into the edge of the crack that are going to be welded back together. The holes should face toward the main body of each cast steel piece.

  3. 3

    Insert steel studs into the threaded holes, making sure to leave 1/4 inch of the stud above the surface. Weld the studs into place by heating them and their surrounding metal with the MIG welder until it has melted. Add molten weld metal if necessary to secure the studs into place.

  4. 4

    Place the setting on the MIG Welder to low current. Run a bead of molten metal around the bottom edge. Start by welding in small 1 inch circles to prevent build-up of residual stresses. Add weld metal in progressively narrowing circles until the hole is closed at the bottom. Start adding metal, one layer at a time, until the hole is filled, taking care to make every layer fused to the one below it.

Tips and warnings

  • If a crack or hole goes all the way through a section, fit a small piece of steel into the centre of the crack before welding each side shut. Heat the crack from both ends with the MIG torch. The steel insert should completely melt and fill up the remaining part of the crack.
  • Working with molten metal and open flames is hazardous. Take precautions and wear the appropriate safety gear, such as a welding mask, safety goggles, and protective gloves whenever you weld to protect your skin, eyes, and lungs from damage.

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