Repair BROKEN Cast Iron Transmission Housing | Flame Spray Welding
Cutting Edge Engineering AUstralia
I would be curious to see how well the finished repair holds up. It looks like it ought to be strong enough, but I wonder if all that heat might have distorted the case, leading to the misalignment of the internal parts, leading to reduced life span. On the other hand, the machine this came out of likely cost $500,000. A machine like that would need to be generating around $15K a month just to pay for itself, never mind the operating expense, so a couple of months work might pay for a new transmission.
That weld is pretty ugly, but then you need practice to get good, and I expect there won't be that many occasions when you need to weld plate steel to cast iron.
It's kind of amazing how thin they can make cast iron parts. When you look at cast iron parts, the flanges around the edges are pretty thick, but you can't really see how thick the iron is in between those flanges.
The area repaired is not a load bearing/stressed part, so the weld is pretty much there just to keep the oil inside.
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You could use epoxy just as well, if you could get it to stick and stay stuck
Even heating and cooling during the repair is the issue, most of the time.
Generally, flame spray is used to build up parts like shafts so they can be re-machined to repair them for wear damage.