unlurk

These guys might have a clue... www.alloybellows.com

I only know of them because they are a local company (to me...) Good luck !

relurk

"Chris Wilson" wrote in message
...
I have put up a photo of a Toyota Supra twin turbo cast iron exhaust
manifold on my web site. It shows how Toyota, or whoever makes the
manifolds for them, have welded in a flexible stainless steel expansion
belows between 2 pairs of 3 cylinders. The manifold casting is
definitely cast iron and magnetic, the bellows are definitely stainless
and none magnetic. The weld fusion looks to have been an automated
process. How is such a fusion done, and more specifically, how, in the
amateur workshop with access to a decent TIG machine, can one offs of a
similar nature be attempted? I would like to directly weld a flexible
stainless steel bellows to a cast iron manifold to mount a waste gate
on, which itself is rigidly supported, the bellows being to allow
thermal expansion and contraction.

Pic is at http://chriswilson.tv/manifold.jpg


Thanks
--
Best regards,
Chris.

"Chris Wilson" wrote: (clip) I would like to directly weld a flexible
stainless steel bellows to a cast iron manifold (clip)
^^^^^^^^^^^^^
There are people better qualified than I am to answer this, but, anyway,
here goes. Cast iron can be welded using nickel rod. Cast iron can be
welded to carbon steel with nickel rod. Stainless rod is sometimes used to
weld cast iron, since it is high in nickel. So, logically, stainless should
be weldable to cast iron using nickel rod.

In article , Chris
Wilson wrote:

I have put up a photo of a Toyota Supra twin turbo cast iron exhaust
manifold on my web site. It shows how Toyota, or whoever makes the
manifolds for them, have welded in a flexible stainless steel expansion
belows between 2 pairs of 3 cylinders. The manifold casting is
definitely cast iron and magnetic, the bellows are definitely stainless
and none magnetic. The weld fusion looks to have been an automated
process. How is such a fusion done, and more specifically, how, in the
amateur workshop with access to a decent TIG machine, can one offs of a
similar nature be attempted? I would like to directly weld a flexible
stainless steel bellows to a cast iron manifold to mount a waste gate
on, which itself is rigidly supported, the bellows being to allow
thermal expansion and contraction.

Pic is at http://chriswilson.tv/manifold.jpg


Thanks

If I was going to do this, and someday I just might have to, I would
lay a pure nickle layer on the cast iron, and then use a 321 stainless
steel filler to weld in a 321 SS bellows.

321 is used a lot for exhaust systems since it handles heat so well.
There are alloys of inconel, hastelloy, and Haynes alloys that can take
much higher heat, but 321 seems to work.

check out these guys for parts.

www.burnsstainless.com/