Cast iron welding expertise with UTP - voestalpine Böhler Welding

24 March 2026 |

At UTP, part of the voestalpine Böhler Welding family, we enable customers worldwide to weld cast iron with confidence. Cast iron components are widely used in automotive, machinery and industrial applications. Their unique material structure makes welding a significant challenge. Read more about the solutions we offer!

To support manufacturers, repair shops and industrial service providers, UTP offers a complete portfolio of welding consumables engineered specifically for grey (GJL), nodular (GJS), vermicular (GJV) and malleable cast irons, as well as cast iron to steel joints.

CAST IRON
WHITE CAST IRON (MALLEABLE CAST IRON)		GREY CAST IRON
"White" mottled cast iron DIN EN 1562 GJMW	Black mottled cast iron DIN EN 1562 GJMB	Nodular cast iron (spheroidal cast iron) DIN EN 1563 GJS	Lamellar graphite cast iron (grey cast iron) DIN EN 1561 GJL	Vermicular graphite cast iron DIN EN 16079 GJV

Our solutions are designed to deliver maximum crack resistance, clean weld appearance and excellent machinability.

The welding challenges we solved

Cast iron’s high carbon content provides excellent castability and vibration damping, but also results in:

Low tensile strength
Limited ductility
High sensitivity to thermal stress

For these reasons, precise heat control and specialized filler metals are essential, especially in repair and production environments.

Our proven approach – Cold Welding Technology

UTP supports cold welding methods to minimize thermal load and prevent cracking. This includes:

Short welding beads
Low interpass temperature
Controlled heat input
Hammering/peening to counteract shrinkage stresses

These practices enable safe and reliable repairs even on aged or brittle components.

UTP consumables for cast iron welding

Nickel-Iron electrodes

UTP 83 FN	High deposition rate, smooth bead formation, excellent machinability
UTP 86 FN	Outstanding wetting, stable arc, exceptional crack resistance
UTP 85 FN	High productivity for construction and production welding

Pure Nickel electrodes

UTP 8

Ideal for brittle or aged cast iron; also recommended as a buttering layer before Ni‑Fe electrodes

Wires & Flux‑Cored Wire Options

UTP A 8051 Ti	Reliable GMAW/GTAW wire for nodular iron and mixed joints
UTP FNM4 G	Fe‑Ni alloy flux‑cored wire for cast iron and cast‑iron–to‑steel joints

Case Study: Repair of a 150 mm thick cast component with a 80 mm crack

Initial situation

A large cast component with a wall thickness of 150 mm showed:

a 80 mm deep fatigue crack
the component was critical to the production process
a replacement part required a 9 months lead time — resulting in severe downtime

The manufacturer initially believed such a repair would be impossible due to cast iron’s reputation for being difficult to weld. The risk of cracking and distortion is especially high in components with large cross‑sections.

On‑Site Repair Welding – the complete repair was successfully carried out on‑site within 5 days, restoring full functionality.

Repair procedure

1. Crack identification and preparation

The crack was fully exposed and removed. A U‑shaped groove was prepared to ensure complete elimination of damaged material.

2. Selection of welding parameters and filler materials

Defined based on wall thickness, material condition and required mechanical properties.

3. Welding & thermal management

Controlled temperature monitoring throughout the process. Sequenced welding to minimize residual stresses.

4. Multi‑layer repair welding

UTP 86 FN used to fill the prepared groove.
Intermediate passes were inspected.
Shrinkage stresses minimized through systematic peening/hammering.

Result

The crack was fully eliminated and the component returned to service within 5 days. The repair prevented 9 months of production downtime and avoided the cost of replacing a large cast component. The repair significantly extended the component’s service life.

Why companies trust UTP?

With decades of metallurgical expertise, in‑house production and global technical support, UTP empowers customers to achieve durable, clean, and structurally sound results. Whether repairing critical components or integrating cast iron into new designs.

We deliver what we promise: Tailor Made Protectivity™ for cast iron welding.

Learn more