i have a 8" by about 6 in wide flat belt pulley on my tractor that has a small chunk broken out of the outside diameter thats shaped like a quarter moon, about 3" by about 2". it is also cracked in both directions for about 4 inches around the diameter. without a picture to explain it, i need to repair the dang thing so i can use it with a buzz saw. its cast iron.
there are a few options available, after i drill a hole at the end of each crack should i :
braze the crack with oxy/act, pre-heat and slow cool
weld the crack with nickel rod, pre-heating, peening, post heating and slow cool
weld the crack with mang. bronze and the tig, again heat and cool
and then form a small chunk of mild steel to replace the missing part.
im not a "welder" but can do any of the above with confidence.
it is abouit 1/4" thick around the diameter and the speed will be maxed out at 550 rpm when in use.