INTRODUCTION

Aufhauser NickelRod 99 is designed for welding of gray iron castings to themselves as well as joining them to mild steels or stainless steels. It is also used extensively to repair castings. The welds are quite machinable. A preheat and interpass temperature of not less than 350°F (175°C) is required during welding.

GENERAL INFORMATION

Chemical Composition

Carbon	Manganese	Silicon	Iron	Copper	Nickel	Sulfur	Phosphorus
0.85	0.5-2.5	1.73	4.2	1.5	91.50	0.005	0.025

Note: All values are maximum percentage, unless shown in range.

NICKELROD 99 & 55 COMPARISON

	NickelRod 99	NickelRod 55
General Description	High nickel, extruded electrode for production and repair of cast iron. Fabrication and repair. Pump housings, valves, castings, cast and malleable fittings.	Lower nickel content electrode for production, salvage and repair of all cast irons. Fabrication and repair. Pump housings, valves, cast and malleable fittings.
Weld Deposit	Good machinability. Very hard weld deposit, predominantly nickel.	More easily machineable. High strength.
Build-up, Fill Holes, Repair cracks	In all types of cast iron	Gray or alloyed cast irons
Out-of-Position Characteristics	very good	good
Parts Dismantling	often not required	often required
Color Match	Close color match to cast irons	Close color match to cast irons
Tensile Strength	up to 50,000 psi	up to 70,000 psi
AWS A5.15	ENiCl	ENiFeCl
Pre-Heating	Not necessary, although for large parts, suggest pre-heating to 350°F min.	Min. pre-heat of 350°F required
Weld Fusion Zone	Broader. Larger HAZ.	More narrow. Reduces hard areas of HAZ to a minimum.
Cost	Higher, due to high nickel content	More economical, due to lower nickel content

SUGGESTED PROCEDURES

• Use AC or DC reverse polarity.
• Vee out cracks with Aufhauser Groovees cutting/gouging electrode or by grinding.
• Pre-heat heavy castings to 350°F min. for best results with NickelRod 55. (Only necessary for large parts with NickelRod 99.)
• Direct the arc on deposited metal with the electrode at a slight angle in the direction of travel.
• With NickelRod 99, use a short arc; use stringer beads; skip or back-step weld and peen to relieve stresses; cool casting slowly.
• With NickelRod 55, peen lightly between passes and use a skip or back-step welding technique.
• Cool casting slowly with either rod.