Washington Alloy Nickel 55

Washington Alloy
Nickel 55 NI-55 SMAW

Washington Alloy Nickel 55 is formulated for versatile joining and surfacing applications involving cast iron, malleable iron, and ductile iron, as well as for dissimilar metals like mild steel, stainless steel, wrought alloys, or high nickel alloys. With a core wire composition of around 55% nickel and 45% iron, it produces weld deposits that exhibit significantly lower weld shrinkage stress, minimizing the risk of cracking in the weld or heat-affected zones. This product generates strong, ductile weld deposits, even when working with low-grade cast iron that contains high levels of phosphorus or other impurities. Washington Alloy Nickel 55 is particularly effective for welding thicker sections, including motor blocks, housings, machine parts, frames, defective castings, and for rebuilding worn areas. The resulting weld deposits can be machined, and their color closely resembles that of cast iron.

TYPICAL CHEMISTRY:
Carbon 0.058 Manganese 1.27
Nickel 55.03 Phosphorus 0.024
Silicon 0.66 Iron Balance
Copper 2.45
Sulfur 0.024

Power: AC/DCEP(DC+)
SPECIFICATIONS: AWS A5.15 ENiFe-CI ASME SFA 5.15 ENiFe-CI

Rod Size	Amps	Amazon	Shopify
3/32"	50-80	[see price on Amazon]	[see price on Shopify]
1/8"	80-120	[see price on Amazon]	[see price on Shopify]
5/32"	110-140	[see price on Amazon]	[see price on Shopify]
3/16"	130-170	[see price on Amazon]	[see price on Shopify]

Nickel 55 Procedure

To weld cast iron to mild steel, begin by thoroughly cleaning both surfaces to remove any oil, rust, or paint. Preheat the cast iron to approximately 400–600°F to minimize the risk of cracking caused by thermal shock. Use a nickel-based electrode, preferably an ENiFe-CI (Nickel 55) rod, which offers good ductility and compatibility with both metals. If only minor machining is needed, this is the most balanced option. Perform short, controlled welds to limit heat input, and after each weld pass, lightly peen the weld bead with a hammer to relieve internal stresses. Once welding is complete, allow the piece to cool slowly by wrapping it in an insulating blanket or burying it in dry sand to prevent rapid cooling, which can lead to cracks. This procedure helps ensure a stronger, more stable joint between cast iron and mild steel.