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Old 01-04-2014, 12:21 PM   #21
hacadacalopolis
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Location: gulf breeze, fl
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2003 L-Series 2.2L Sedan
1996 SC1
Default Re: Broken exhaust manifold! not cracked, completely sheared off!

For common gray

You have to overcome the problem that there is a 50/50 chance of it holding under heat/pressure load.
The grain structure of the casting (microscoply) can have voids and pockets of porosity- so what does that do when your welding... Same exact thing porosity.
Even with your proper preheat and post heat instructions

Most of you probably already know this but if not. Many cast irons can be welded with success, but as in this case with an exhaust manifold in almost every situation as the exhaust mani(with welded repair) will cool after use and eventually crack. Not all cases but it is most likely to happen. This is true

That is why a welder may refuse to qualify welding cast iron subject to such amounts of heat.

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