ANSI/AWS D11.2-89 (R2006)
An American National Standard
Guide for Welding
Iron Castings
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ANSI/AWS D11.2-89 (R2006)
An American National Standard
Guide for
Welding Iron Castings
Prepared by the
American Welding Society (AWS) D11 Committee on Welding Iron Castings
Under the Direction of the
AWS Technical Activities Committee
Approved by the
AWS Board of Directors, March 3, 1988
Abstract
This standard presents briefly the history and metallurgy of cast iron and the welding processes applicable to it.
A newly developed weldability test is described in detail and instructions given for its application in specific cases.
Provision is made for qualification of welding procedures and welders when necessary; quality control practice is also
included.
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Approved by the
American National Standards Institute
July 14, 1988
ANSI/AWS D11.2-89 (R2006)
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International Standard Book Number: 0-87171-295-4
American Welding Society
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© 1989 by American Welding Society
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Printed in the United States of America
Reaffirmed: April 27, 2006
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ANSI/AWS D11.2-89 (R2006)
Statement on the Use of American Welding Society Standards
All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American
Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the
American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or
made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS
standards must be approved by the governmental body having statutory jurisdiction before they can become a part of
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that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements
of an AWS standard must be by agreement between the contracting parties.
AWS American National Standards are developed through a consensus standards development process that brings
together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process
and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or
verify the accuracy of any information or the soundness of any judgments contained in its standards.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether
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In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on
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else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the
advice of a competent professional in determining the exercise of reasonable care in any given circumstances.
This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.
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any patent or product trade name resulting from the use of this standard.
Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.
On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are posted
on the AWS web page (www.aws.org).
Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,
in writing, to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road,
Miami, FL 33126. With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards
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These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or
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interpretation.
This standard is subject to revision at any time by the AWS D11 Committee on Welding Iron Castings. It must be
reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations,
additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be
addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D11 Committee on
Welding Iron Castings and the author of the comments will be informed of the Committee’s response to the comments.
Guests are invited to attend all meetings of the AWS D11 Committee on Welding Iron Castings to express their
comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the
Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American
Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.
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ANSI/AWS D11.2-89 (R2006)
Personnel (Reaffirmation)
AWS Committee on Welding Iron Castings
E. G. Yevick, Chair
S. Charlip, Vice Chair
J. L. Gayler, Secretary
*J. G. Bielenberg
*R. A. Bishel
R. A. Bushey
J. L. Cooley
D. W. Davis
*R. O. Drossman
R. H. Frost
S. D. Kiser
E. R. Kuch
*R. L. Montana
*L. W. Myers
N. Prager
M. D. Rosensteel
J. D. Simko
J. Turriff
Weld-Met International Group
Nassau Research Corporation
American Welding Society
Retired
Consultant
ESAB Welding & Cutting Products
J C & Associates, Incorporated
Beaver Valley Alloy Foundry
Wear Management Services, Incorporated
Colorado School of Mines
Special Metals
Consultant
Mid-Florida Technical Institute
Consultant
Anchor Research Corporation
Beyond the Bend
Hodge Foundry, Incorporated
Wisconsin Wire Works
*Advisor
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ANSI/AWS D11.2-89 (R2006)
Personnel (Original)
AWS Committee on Welding Iron Castings
L. W. Myers, Chair
R. J. Dybas, 1st Vice Chair
J. E. Jones, 2nd Vice Chair
E. J. Seel, Secretary
K. E. Banks
R. G. Bartifay
*J. G. Bielenberg
R. A. Bishel
R. A. Bushey
R. O. Drossman
E. R. Kuch
*J. C. Margerie
*J. V. Matush
*A. H. Miller
W. F. Ridgway
*L. E. Shoemaker
*R. A. Strahl
*C. F. Walton
E. G. Yevick
W. M. Zimmer
Dresser-Rand
General Electric Company
American Welding Institute
American Welding Society
Teledyne McKay
Aluminum Company of America
Consultant
Inco Alloys International
Alloy Rods
Wear Management Services
Cooper Industries
Centre Technique
Combustion Engineering
DISC
Eutectic Corporation
Inco Alloys International
California Polytechnic State University
Consultant
Weld-Met International
AMPCO Metal
*Advisor
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ANSI/AWS D11.2-89 (R2006)
Foreword
This foreword is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings,
but is included for informational purposes only.
This publication is a reaffirmation of the first edition published in 1989. The content of the standard is identical to the
1989 publication except that the safety and health facts sheets in Appendix F have been updated. Reaffirmation of this
standard by the Committee on the Welding of Iron Castings indicates that this standard’s content is still current with
today’s technology and practices.
This guide was prepared by the American Welding Society Committee on the Welding of Iron Castings as a service
to the industry. Sufficient data have been gathered and organized to yield an authoritative source of sound technical
practices for joining iron castings. The description of iron castings, together with factors to be considered in joining
them, is presented here as clearly and concisely as possible. It is the Committee’s hope that this guide will lead to better
quality and performance.
These recommendations represent the best of current practice in the opinion of the Committee. At the present state of the
art, all recommendations may not be applicable to all products and situations. Selection of pertinent requirements should
be the result of rational decisions and not lack of knowledge on the part of those who are welding iron castings.
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Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary,
AWS D11 Committee on Welding of Iron Castings, American Welding Society, 550 N.W. LeJeune Road, Miami, FL
33126.
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ANSI/AWS D11.2-89 (R2006)
Table of Contents
Page No.
Personnel (Reaffirmation)........................................................................................................................................... v
Personnel (Original) ................................................................................................................................................. vii
Foreword ................................................................................................................................................................... ix
List of Tables ............................................................................................................................................................ xiii
List of Figures .......................................................................................................................................................... xiv
1. Scope and History .............................................................................................................................................. 1
1.1 Scope. ......................................................................................................................................................... 1
1.2 History ........................................................................................................................................................ 1
2. Cast Iron — Its Metallurgy and Weldability .................................................................................................. 1
2.1 Metallurgy. ................................................................................................................................................. 1
2.2 Difficulties in Welding Iron Castings ......................................................................................................... 4
2.3 AWS Weldability Test Program ................................................................................................................. 6
2.4 Preweld Testing for Weldability .............................................................................................................. 11
3. General Considerations When Welding Iron Castings................................................................................. 14
3.1 Base Metal Preparation ............................................................................................................................ 14
3.2 Joint Design .............................................................................................................................................. 15
3.3 Heat Input ................................................................................................................................................. 17
3.4 Preheat ...................................................................................................................................................... 17
3.5 Electrode Manipulation ............................................................................................................................ 20
3.6 Peening ..................................................................................................................................................... 21
3.7 Cooling ..................................................................................................................................................... 21
3.8 Postweld Heat Treatment ......................................................................................................................... 21
4. Gas Processes.................................................................................................................................................... 23
4.1 Oxyfuel Welding (OFW).......................................................................................................................... 23
4.2 Flame Spraying of Gray Iron (FLSP) ....................................................................................................... 27
4.3 Braze Welding .......................................................................................................................................... 27
5. Arc Welding Processes .................................................................................................................................... 30
5.1 General ..................................................................................................................................................... 30
5.2 Shielded Metal Arc Welding (SMAW) .................................................................................................... 30
5.3 Gas Metal Arc Welding (GMAW) ........................................................................................................... 35
5.4 Flux Cored Arc Welding (FCAW) ........................................................................................................... 37
5.5 Gas Tungsten Arc Welding (GTAW)....................................................................................................... 41
5.6 Submerged Arc Welding (SAW).............................................................................................................. 44
6. Surfacing and Overlaying ............................................................................................................................... 45
6.1 Processes .................................................................................................................................................. 45
6.2 Thermal Spraying ..................................................................................................................................... 45
6.3 Other Processes ........................................................................................................................................ 47
6.4 Surfacing Materials .................................................................................................................................. 48
6.5 Technique ................................................................................................................................................. 50
7. Applications ...................................................................................................................................................... 50
7.1 Casting Defect Repair .............................................................................................................................. 50
7.2 Repair of Machining Defects.................................................................................................................... 51
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Page No.
7.3
7.4
Repair of Castings After Service .............................................................................................................. 51
Fabrication................................................................................................................................................ 51
8. Welding Procedure and Performance Qualification ..................................................................................... 51
8.1 General ..................................................................................................................................................... 51
8.2 Welding Procedure Qualification ............................................................................................................. 52
8.3 Welding and Welding Operator Performance Qualification ..................................................................... 52
9. Quality Control ................................................................................................................................................ 52
9.1 General ..................................................................................................................................................... 52
9.2 Quality Control Practices and Procedures ................................................................................................ 52
9.3 Acceptance Criteria .................................................................................................................................. 54
10. Safety and Health ............................................................................................................................................. 54
10.1 Fumes and Gases ...................................................................................................................................... 54
10.2 Radiation .................................................................................................................................................. 55
10.3 Electric Shock .......................................................................................................................................... 55
10.4 Fire Prevention. ........................................................................................................................................ 55
10.5 Explosion.................................................................................................................................................. 55
10.6 Burns ........................................................................................................................................................ 55
10.7 Further Information .................................................................................................................................. 55
Appendix A — Weldability Test ............................................................................................................................ 51
A1. Introduction. ............................................................................................................................................. 57
A2. Equipment Required ................................................................................................................................. 57
A3. Welding Conditions .................................................................................................................................. 58
A4. Test Procedure .......................................................................................................................................... 59
Appendix B — Applications ................................................................................................................................... 63
Appendix C — Welding Procedure and Performance Qualification.................................................................. 83
C1. General ..................................................................................................................................................... 83
C2. Welding Procedure Qualification ............................................................................................................. 83
C3. Inspection Results Required ..................................................................................................................... 95
C4. Welding and Welding Operator Performance Qualification ..................................................................... 97
Appendix D — Recommended System for Classification of Welds in Iron Castings,
and Associated Quality Levels ................................................................................................... 105
D1. Classification of Welds in Iron Castings ................................................................................................ 105
D2. Test Requirements .................................................................................................................................. 105
Appendix F — Safety and Health ........................................................................................................................ 111
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Appendix E — ASME Code Cases ...................................................................................................................... 109
E1. Case 1867. .............................................................................................................................................. 109
E2. Case 1939. .............................................................................................................................................. 109
ANSI/AWS D11.2-89 (R2006)
List of Tables
Table
Page No.
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List of Figures
Figure
Page No.
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Page No.
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Figure
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ANSI/AWS D11.2-89 (R2006)
Guide for
Welding Iron Castings
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Copyright American Welding Society
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22
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
ANSI/AWS D11.2-89 (R2006)
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ANSI/AWS D11.2-89 (R2006)
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Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
ANSI/AWS D11.2-89 (R2006)
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ANSI/AWS D11.2-89 (R2006)
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
Copyright American Welding Society
Provided by IHS under license with AWS
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26
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ANSI/AWS D11.2-89 (R2006)
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Provided by IHS under license with AWS
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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32
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34
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ANSI/AWS D11.2-89 (R2006)
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
Copyright American Welding Society
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36
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ANSI/AWS D11.2-89 (R2006)
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38
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ANSI/AWS D11.2-89 (R2006)
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ANSI/AWS D11.2-89 (R2006)
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41
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42
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
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Not for Resale, 08/27/2013 04:05:15 MDT
ANSI/AWS D11.2-89 (R2006)
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
Copyright American Welding Society
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44
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45
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ANSI/AWS D11.2-89 (R2006)
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
46
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Provided by IHS under license with AWS
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ANSI/AWS D11.2-89 (R2006)
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47
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48
Copyright American Welding Society
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No reproduction or networking permitted without license from IHS
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Not for Resale, 08/27/2013 04:05:15 MDT
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
51
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ANSI/AWS D11.2-89 (R2006)
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
Copyright American Welding Society
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ANSI/AWS D11.2-89 (R2006)
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53
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Not for Resale, 08/27/2013 04:05:15 MDT
ANSI/AWS D11.2-89 (R2006)
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54
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
ANSI/AWS D11.2-89 (R2006)
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Copyright American Welding Society
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No reproduction or networking permitted without license from IHS
Licensee=ISATIS Group in iran Revised Sub Account/5620002316
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ANSI/AWS D11.2-89 (R2006)
This page is intentionally blank.
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ANSI/AWS D11.2-89 (R2006)
Appendix A
Weldability Test
This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings,
but is included for informational purposes only.
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
Licensee=ISATIS Group in iran Revised Sub Account/5620002316
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Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
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Not for Resale, 08/27/2013 04:05:15 MDT
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
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Not for Resale, 08/27/2013 04:05:15 MDT
ANSI/AWS D11.2-89 (R2006)
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
61
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ANSI/AWS D11.2-89 (R2006)
This page is intentionally blank.
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Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
62
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ANSI/AWS D11.2-89 (R2006)
Appendix B
Examples of Applications
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings,
but is included for informational purposes only.
63
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ANSI/AWS D11.2-89 (R2006)
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Provided by IHS under license with AWS
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Not for Resale, 08/27/2013 04:05:15 MDT
ANSI/AWS D11.2-89 (R2006)
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
Copyright American Welding Society
Provided by IHS under license with AWS
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65
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Provided by IHS under license with AWS
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ANSI/AWS D11.2-89 (R2006)
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Provided by IHS under license with AWS
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Not for Resale, 08/27/2013 04:05:15 MDT
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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ANSI/AWS D11.2-89 (R2006)
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Copyright American Welding Society
Provided by IHS under license with AWS
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ANSI/AWS D11.2-89 (R2006)
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ANSI/AWS D11.2-89 (R2006)
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ANSI/AWS D11.2-89 (R2006)
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ANSI/AWS D11.2-89 (R2006)
7̀4
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Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
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Copyright American Welding Society
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Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS
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No reproduction or networking permitted without license from IHS
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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ANSI/AWS D11.2-89 (R2006)
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No reproduction or networking permitted without license from IHS
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--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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Copyright American Welding Society
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No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
Appendix C
Welding Procedure and Performance Qualification
This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings,
but is included for informational purposes only.
--`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
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Copyright American Welding Society
Provided by IHS under license with AWS
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ANSI/AWS D11.2-89 (R2006)
Appendix D
Recommended System for Classification of Welds in
Iron Castings, and Associated Quality Levels
This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings,
but is included for informational purposes only.
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ANSI/AWS D11.2-89 (R2006)
Appendix E
ASME Code Cases*
This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings,
but is included for informational purposes only.
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ANSI/AWS D11.2-89 (R2006)
Appendix F
Safety and Health Fact Sheets
This appendix is not a part of AWS D11.2-89(R2006), Guide for Welding Iron Castings,
but is included for informational purposes only.
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The following pages present copies of short articles (Fact Sheets) on Safety and Health topics published by the
American Welding Society. Each article is available free of charge from the American Welding Society website,
www.aws.org.
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ANSI/AWS D11.2-89 (R2006)
Safety and Health
Fact Sheet No. 1
October 2003
© 2003 American Welding Society
Fumes and Gases

Depending on material involved ranges
from irritation of eyes, skin, and
respiratory system to more severe
complications.

Effects may occur immediately or at
some later time.

Fumes can cause symptoms such as
nausea, headaches, dizziness, and
metal fume fever.

The possibility of more serious health
effects exists when
highly
toxic
materials are involved. For example,
manganese overexposure can affect
the central nervous system resulting in
impaired speech and movement.

In confined spaces the gases might
displace breathing air and cause
asphyxiation.
INTRODUCTION
Many welding,
cutting,
and
allied
processes produce fumes and gases,
which may be harmful to your health.
DEFINITION
Fumes are solid particles
which
originate from welding consumables,
the base metal, and any coatings
present on the base metal.

In addition to shielding gases that may
be used, gases are produced during the
welding process or may be produced by
the effects of process radiation on the
surrounding environment.

Acquaint yourself with the effects of
these fumes and gases by reading the
Material Safety Data Sheets (MSDSs)
for all materials used (consumables,
base metals, coatings, and cleaners).


HOW TO AVOID OVEREXPOSURE
For help, consult
a
recognized
specialist in Industrial Hygiene or
Environmental Services.
The amount and composition of these
fumes and gases depend upon the
composition of the filler metal and base
material, welding process, current level,
arc length, and other factors.
POSSIBLE
EXPOSURE
EFFECTS
OF
OVER-

Keep your head out of the fumes.

Do not breathe the fumes.

Use enough ventilation or exhaust at
the arc, or both, to keep fumes and
gases from your breathing zone and
general area.

In some cases, natural air movement
provides enough ventilation and fresh
air.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect,
consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet.
AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.
Fact Sheet No. 1 — 10/03
Page 1
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
ANSI/AWS D11.2-89 (R2006)

Where ventilation is questionable, use
air sampling to determine the need for
corrective measures.

Use mechanical ventilation to improve
air quality.

If engineering controls are not feasible,
use an approved respirator.

Work in a confined space only if it is
well ventilated, or while wearing an airsupplied respirator.
Fumes
from
welding or cutting and oxygen depletion
can alter air quality causing injury or
death. Be sure the breathing air is
safe.

Follow OSHA guidelines for permissible
exposure limits (PELs) for various
fumes.

Follow the American Conference of
Governmental
Industrial
Hygienists
recommendations for threshold limit
values (TLVs) for fumes and gases.

Have a recognized specialist
in
Industrial Hygiene or Environmental
Services check the operation and air
quality and make recommendations for
the specific welding or cutting situation.
American Conference of Governmental
Industrial Hygienists (ACGIH). Threshold
Limit Values for Chemical Substances and
Physical Agents and Biological Exposure
Indices, available from ACGIH, 1330
Kemper Meadow Drive, Cincinnati, OH
45240-1634 (telephone: 513-742-2020;
web site: www.acgih.org).
American Welding Society (AWS). Fumes
and Gases in the Welding Environment
and other welding related safety and health
publications,
available
from
Global
Engineering Documents, 15 Inverness
Way East, Englewood, CO 80112-5776
(telephone: 800-854-7179; web site:
www.global.ihs.com).
Mine Safety and Health Administration
(MSHA). Code of Federal Regulations,
Title 30 Mineral Resources, Parts 1 to 199,
available from the U.S. Government
Printing
Office,
Superintendent
of
Documents, P.O. Box 371954, Pittsburgh,
PA 15250-7954 (telephone: 202-693-9400;
web site: www.msha.gov).
For specific information, refer to the
applicable Material Safety Data Sheet
(MSDS) available from the manufacturer,
distributor, or supplier.
TLV is a registered trademark of the ACGIH.
INFORMATION SOURCES
Occupational
Safety
and
Health
Administration (OSHA). Code of Federal
Regulations, Title 29 Labor, Parts 1910.1
to 1910.1450, available from the U.S.
Government
Printing
Office,
Superintendent of Documents, P.O. Box
371954,
Pittsburgh,
PA
15250-7954
(telephone: 800-321-6742; web site:
www.osha.gov).
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect,
consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet.
AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.
Fact Sheet No. 1 — 10/03
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