Ryan Lewis - Metal Working Hub

How to MIG Weld Cast Iron: Wire Selection and Crack Prevention

Most attempts to MIG weld cast iron end with a crack that appears either during cooling or the first time […]

Undersized fillet welds fail under load because the throat—the shortest path from root to face—carries the stress, not the leg

Direct fusion welding of copper pipe to aluminum pipe almost always fails. Aluminum melts near 660 °C while copper requires

A drilled hole in the wrong location, a rust perforation through a panel, or a removed fastener leave metal with

Caulk and sealant joints on galvanized steel gutters fail within a few seasons under thermal expansion, UV exposure, and freeze-thaw

Welding dissimilar material thicknesses is one of the easiest ways to create weak joints if heat input isn’t properly controlled.

Carbide precipitation and loss of corrosion resistance appear quickly when heat input stays too high or shielding gas introduces excess

Solder refuses to wet stainless steel wire and simply balls up or rolls off the surface. That failure occurs because

Inconsistent heat control remains the most common failure when operators attempt gas welding on mild steel. The puddle either freezes

Understanding what is the deposition rate in welding is essential when evaluating welding productivity, filler metal efficiency, and overall project