Many of the plane threads run into the same issue - pitting in cast iron. I've no requirement, but have been scratching my head and doing a bit of digging out of interest. Even the machine tool refurb guys don't seem to have anything short of the cast iron equivalent of a Dutchman. There doesn't really seem to be a decent solution out there. People like Belzona and Devcon do a range of metal power filled repair compounds (including some quite fancy high abrasion resistance versions), but it's just not going to be the same thing. It'd be interesting to know if they have the adhesion, strength and toughness to function in the repair of e.g. a chip missing in an edge as at a plane mouth.
There's various options for welding and/or brazing. Trouble is most entail heating to red heat (around 1,500 deg F ) and slow cooling in sand or lime, they won't match the colour and will likely require milling, grinding and other machining processes to restore surfaces. (which may not be feasible anyway as a result of localised hardening if it's let cool a bit too fast) Then there's the possibility of distortion and other effects as a result of the heating. There's high nickel welding rods that don't need so much pre-heating, but which won't be a good colour match - and may cause localised hardening/brittleness beside the weld.
There's potentially multiple requirements in a single job. Widespread pitting requires only cosmetic repairs, but would require an enormous amount of reworking if any of the welding or brazing techniques were used. Against that there's only marginal benefit in making cosmetic repairs with a filler the colour of which won't match the cast iron.
Has anybody come across anything that actually works? Maybe some sort of oddball low temperature brazing alloy that looks right afterwards? (thinking of something like a cast iron equivalent of the low melting point welding (more correctly soldering/brazing) rods now available for aluminium...
PS Found two documents just now which may be of interest, especially the second. The first is a discussion of the issues in welding cast iron, the second links a 'low temperature cast iron solder' which if the properties are suitable could be very interesting (but its probably a soft solder):
http://fulltorque.com/pdf/GMRC%20white%20paper.pdf
http://www.esabna.com/euweb/as_handbook/596as2_12.htm