Method for repairing a casting

A method of repairing defects on a fireside surface of a metal cylinder head of an internal combustion engine comprising:

• identifying an area on the fireside face of the cylinder head that contains a defect;
• machining a cavity in the metal to remove the defect from the cylinder head;
• preheating the cylinder head to a first temperature;
• preheating the cavity to a second temperature greater than the first temperature and less than the melting temperature of the metal;
• melting a filler material in a container;
• pouring the molten filler material into the cavity, the molten filler material further heating the cavity so that the filler material and cavity are chemically bonded after solidification.

A method of repairing defects on a metal part comprising:

• identifying an area on the part that contains a defect;
• machining a cavity in the metal to remove the defect from the part;
• preheating the part to a first temperature;
• preheating the cavity to a second temperature greater than the first temperature and less than the melting temperature of the metal;
• melting a filler material in a container;
• pouring the molten filler material into the cavity, the molten filler material further heating the cavity so that the filler material and cavity are chemically bonded after solidification.

A method of repairing defects on a metal part comprising:

• identifying an area on the part that contains a defect;
• machining a cavity in the part to remove the defect from the part;
• filling a hole in the cavity with a plug;
• melting a filler material in a container;
• preheat the cavity to a temperature of at least 950 degrees F.;
• and
• pouring the molten filler material into the cavity preheated to at least 950 degrees F., the plug preventing the molten filler material from flowing through the hole, and the molten filler material further heating the cavity so that the filler material and cavity are chemically bonded after solidification.