Bohler - Manual de Reparatii Prin Sudura

WELDING IN THE TOOL SHOP WITH UTP WELDING CONSUMABLES

High speed steels

Cold working steels

Hot working steels

Injection mould steels

Cast iron

G e n e r a l I n d e x

1. General introduction 3

2. Welding methods 4 - 7

2.1 Welding with coated electrodes

2.2 TIG welding

2.3 MIG/MAG welding

3. General guide lines for welding of tool steels 8 - 9

4. Reasons for failure of build up welding 10

5.1 Summary of high speed steels

5.2 Data of high speed steel 1.3343

6. Welding of cold working tool steels 18 - 24

6.1 Ledeburitic Cr-cutting steel with 5 - 12 % Cr

6.2 Summary of cold working steels

6.3 Data for cold working tool steels 1.2379

6.4 Appropriate UTP welding consumables for cold working tools

7. Welding for hot working tool steels 25 - 36

7.1 Summary of hot working tool steels

7.2 Data for hot working tool steel 1.2714

7.2.1 Data for hot working tool steel 1.2344

7.3 Appropriate UTP welding consumables for hot working tools

8. Welding for steels for plastic injectionmoulds 37 - 42

8.1 Summary of steels for plastic moulds

8.2 Data for plastic mould steel 1.2312

8.3 Appropriate UTP welding consumables for steels for injection moulds

9. Welding of cast iron 43 - 50

9.1 Summary of cast iron materials

9.3 Appropriate UTP TIG rods or MIG wiresfor cast iron welding

9.2 Appropriate UTP products for cast iron welding

10. Availability of the UTP productsfor tool welding 51 - 52

Page Page

5. Welding high speed steels 11 - 17

5.3 Appropriate UTP welding consumables for high speed steels

by E. Villinger SFI/EWE

1. General introduction

Tool steels are split up into 2 groups, cold working tools and hot working tools.

Cutting tools such as blanking punches, cutting blades, trimming tools, shear blades etc. predominately belong to the group of

cold working tools. Cold working tools are designed to work (cut, punch, form etc.) on cold materials such as sheet metal, bars,

profiles, tubes etc. where heat is generated as a result of the actual working process of cutting, forming, punching and from the

friction of the tool on the metal. The temperature of the tool rarely reaches 250° C, eliminating the need of heat resistance in

the base metal.

In the case of hot working tools such as forging dies, injection moulds, hot shear blades, ingots, press rolls and similar, the

metal is worked on in hot condition. Here the properties required are high temperature resistance, good tempering properties

and good hot wear resistance against shock, pressure and friction.

For many years, repair of worn and damaged tools has been standard procedure in many workshops, bringing enormous

financial and technical advantages, since reconditioning by machining or grinding is reduced or even unnecessary.

New production of cutting tools in series by build up welding is only economic, if the savings on base metal cost are higher

than the welding cost. Therefore, in general, only large tools are produced by build up welding. However, the costs are not

always the deciding factor. By using a softer base material the crack resistance is higher and the possibility of dressing the

tool is better and , last but not least, delivery problems of special tool base materials may be solved.

INDEX

2. Welding methods

2.1. Welding with coated electrodes

In the tool steel welding, coated welding electrodes account for approximately 50 of consumables used. For maintenance

welding on tools, the guidelines of the steel manufacturers concerning preparation, pre- heating and interpass temperature

should be followed carefully. High chrome- and tungsten containing alloys should be preheated slowly and thoroughly to

avoid heat stress and cracks due to the low heat conductibility. Depending on the requirement electrodes with rutile or

basic coatings are available.

Rutile coated electrodes have a stable, soft spray arc, which allows welding with low amperage. The weld bead is finely

rippled with a smooth appearance, which is ideal for welding cutting edges. The slag is self detaching.

Basic coated electrodes have a more intense arc with a deeper penetration and a higher bead build up. The bead appearance

is not as fine as that of a rutile coated electrode. The weld deposit has a high toughness. The slag does not have to be

removed on multi pass welding which is an advantage on large welding jobs.

Whenever possible use the stringer bead welding technique. Weaving should be avoided.

lf several layers are needed it is advisable to apply 3 layers with an electrode of 2,5 mm diameter instead of 2 layers with

an electrode of 3,2 mm diameter. Deposit short stringer beades, remove the slag and lightly peen the bead immediately.

Use this procedure until sufficient build up is achieved. Slow cooling in air, under a heat insulating cover or in an oven is

advisable. A post heat treatment may be needed.

INDEX

Manual metal arc welding with coated electrodes

1 Mains connection2 Power source3 Welding cable4 Electrode holder5 Earth cable6 Work piece

A Core wireB CoatingC Protective gasD Solidfied slagE Welding beadF Melt bathG Metal drop in molten slagH Base metalI Drop transfer

78 - 80°

INDEX

Tool repair with coated electrode

INDEX

2.2 TIG weldingThe TIG welding process is particularly suitable for smaller tools and small repair jobs. The advantage is that complicated

cutting edges and particularly detailed shapes can be repaired. A small diameter tungsten electrode allows the welder to

concentrate high temperature on a small spot and deposit the welding consumable accordingly, without damaging the base

material and without any deformation. To control the amperage to the lowest possible setting, the machine should be equipped

with a foot switch. TIG rods are available in a wide range of alloys. The shielding gas should be Argon with a purity of 99,996 vol%.

1 Mains connection2 Power source3 Welding cable4 Earth cable5 Shielding gas bottle6 Shielding gas hose7 Welding torch8 Welding rod9 Base material

A Gas nozzleB Electrode clampC Non consuming tungsten electrodeD Shielding gas coverE Welding beadF Melt bathG ArcH Welding rodI Base material

The principle of TIG welding

INDEX

2.3 MIG/MAG weldingThe MIG/MAG welding process is suitable for depositing large quantities of welding consumable economically. Typical applications

are the production of large shear blades out of low alloy base metal or the filling of forging dies to change the pattern or building

up on rolls and cones etc.

With synergic pulsed arc welding sets, a spatter free deposit can be achieved which, in turn, prevents welding inclusions due to

welding over spatter. Generally welding is done with solid wires of 1,2 mm or 1,6 mm diameter. As shielding gas for high alloy tool

steel wires Argon or a multi component gas should be used.

Flux cored wires are used when no solid wire in the required alloy is available, such as a cobalt alloy. These wires are also welded

with shielding gas.

1 Mains connection2 Power source3 Spool of electrode wire4 Wire feeder unit5 Shielding gas bottle6 Welding cable

A Gas nozzleB Wire nozzleC Wire electrodeD Shielding gas coverE Welding bead

The principle of MIG/MAG welding

F Melt bathG Drop transferH Base materialI Arc

7 Wire electrode8 Shielding gas hose9 Earth cable10 Welding torch11 Base material

INDEX

♦ Clean welding area, removing all contaminants, i.e. paint, oil, grease. Chamfer sharp edges. Prepare broken out partsand cracks in U-form. Check surface with dye penetrant to ensure that there are no further defects or cracks.

♦ Select the appropriate filler material and welding electrode or wire diameter for the job in hand.

♦ Wires must be perfectly clean (to avoid porosity); electrodes must be dry. Re-dry if necessary in accordance with the suppliersrecommendations.

♦ Tool steels are usually not welded at room temperature. Pre-heating- and interpass temperature is determined by the type of basemetal, the size and shape of the tool. (Danger of hardness peaks and cracks)

♦ Welding has to be done with lowest possible heat input, which means using the lowest possible amperage and voltage. Cleanwelding bead often, removing slag and residues.

♦ On crack susceptible cold working tools apply short stringer beads with small diameter electrodes or wires to avoid risk of crackscaused by shrinkage stress. To obtain heavier deposits angle the tool and weld slightly upwards.

♦ Changing of pattern or other substantial welding work should be done in a soft annealed condition and with a high preheatingtemperature.

♦ The welding deposit has to be peened IMMEDIATELY after a weld has been deposited and before the temperature falls below350° C, which is the lowest interpass temperature for high alloyed tool steel. Never peen cold material !

♦ Deposit enough material, in general to a depth of about 1,5 - 2 mm, to allow correct machining/grinding.

♦ After welding slow cooling is necessary and eventually an annealing to reduce welding stress. A post heat treatment is a must aftera large welding deposit has been made, such as a filling for pattern change or similar.

3. General guide lines for welding of tool steels

INDEX

Welding boot equipped for tool welding

Pre-heat and heat maintaining table

INDEX

Mistake in the heat application

To much stress

Welding mistakes

Prep. incorrect

Mixing to big

Thermal shock

To hard1. Pre-heating to low

2. No slow cooling

3. Pre-heating to fast

4. Cooling to fast

5. To big electrode or to high amps

6. Bevelling to big

7. No peening or cold peening

8. To long welding beads

9. Welding cond. not consideredpre-heating or cold welding

10. No re-drying of electrodes

11. No thorough cleaning of weld area

12.To little hardsurfacing on top ofbuffer layer

13.Less than 3 layers of hard surfacing

14.To big electrode or to high amps

15. Wrong selection of electrode

16.Heat treatment not correspondingto the weld deposit

17.Pre-heating to low

18.No measuring of depos. Beforestopping the building up

19. Qualification of welder not sufficient

Porosity

H2 embrittlement

Reduc. of hardness

Mixing to big

Not enough hardness

Not enough depositafter machining

To high hardness

Bead appearance, resultafter machining

Hardness to low or notconstant

Structure problems

4. Reasons for failure of build-up weldingINDEX

5. Welding high speed steels

High speed steels have, depending on the chemical composition and the heat treatment, a high retention of hardness and high heat resistance up to 600° C. Cutting tools made of high speed steel have good edge retention properties at high temperature giving a high cutting performance.

High speed steels are also used for cold cutting tools combining abrasion resistance with toughness. These properties are obtained through a high percentage of special carbides.

For repair of high speed steels tools, UTP 690 is used. This easy to use rutile coated electrode is distinguished by its spray arc, smooth bead surface and self detaching slag.

Complimentary products: TIG wire UTP A 696 is available.

These welding consumables have been developed predominantly for the production of new cutting tools using non- or low alloy base materials. They are also used for repairs on large cutting and forming tools. The hardness of the untreated welding deposit is approx. 60 HRC. A second or third tempering at 550° C is needed to eliminate the remaining austenite (during cooling the remaining austenite is changed to martensite), producing a final hardness of 64 - 65 HRC (secondary hardening).

When repairing cutting edges, the damaged area has to be cleaned first and pre- heated to appr. 150° C. This pre-heating is

sufficient if the damage is small and/or the crack does not go into the base metal. If large parts are broken out or if large surfaces

need to be built up, the tool has to be pre- heated thoroughly to 450 - 600° C.

INDEX

For small repairs use a TIG torch with a small diameter tungsten electrode.

Use lowest possible amperage, fuse the surface carefully and deposit the TIG wire in stringer beads.

Cutting tool with edge built up with UTP 690

INDEX

Typical tools made out of high speed steel

INDEX

Material No. DIN-Design. Chemical composition in %

C Cr Mo V W Co

1.3202 S 12-1-4-5 1,35 4,0 0,8 3,8 12,0 4,8

1.3207 S 10-4-3-10 1,23 4,0 3,8 3,3 10,0 10,5

1.3243 S 6-5-2-5 0,92 4,0 5,0 1,9 6,4 4,8

1.3245 S 6-5-2-5 S 0,92 4,0 5,0 1,9 6,4 4,8

1.3247 S 2-10-1-8 1,0 4,0 9,5 1,2 1,5 8,0

1.3255 S 18-1-2-5 0,8 4,0 0,7 1,6 18,0 4,8

1.3316 S 9-1-2 0,8 4,0 0,8 1,6 8,5 -

1.3333 S 3-3-2 1,0 4,0 2,6 2,3 2,8 -

1.3340 SC 6-5-2-S 0,97 4,0 5,0 1,9 6,4 -

1.3341 S 6-5-2S 0,9 4,0 5,0 1,9 6,4 -

1.3342 SC 6-5-2 0,97 4,0 5,0 1,9 6,4 -

1.3343 S 6-5-2 0,9 4,0 5,0 1,9 6,4 -

1.3344 S 6-5-3 1,2 4,0 5,0 2,9 6,4 -

1.3346 S 2-9-1 0,8 4,0 8,5 1,2 1,8 -

1.3348 S 2-9-2 1,0 3,8 8,6 2,0 1,7 -

5.1 Summary of high speed steelsINDEX

BÖHLER S600INDEX

5.2 Data for high speed steel 1.3343

DIN Designation: S 6-5-2

Chemical composition: C Si Mn Cr Mo W V

0,9 0,3 0,3 4,0 5,0 6,4 1,9

Properties: Standard alloy for high speed steels, hightoughness and good cutting properties, heatresistant up to 600° C, universally applicable

Application: Cutting tools for rough work and planing with spiraldrill, milling cutter, broaching tools, thread drill,reamers, wood working tools. Also for cold workingtools for punching, deep drawing, pressing andcutting.

Hot forming: 1100 - 900° C slow cooling invermiculite or in the oven

Soft annealing: 770 - 840° C / 4 h oven cooling annealinghardness 240 - 300 HB

Stress relief annealing: 600 - 650° C / 1 - 2 h oven cooling

Heating: 450 - 600° C (0,5 min/mm)= 50 mm thick = 25 min

Pre-heating: a) 850° C air circulation ovenb) 850 and 1050° C in a salt bath

Hardening: a) 1190 - 1230° C / warm bath 550° C/air orb) 1190 - 1230° C / oil orc) 1190 –1230° C / air

Tempering: 540 - 560° C min. 2 x

Hardness after tempering: 64 - 66 HRC

INDEX

Coatedelectrode

TIG rodMIG / MAG wire

Application Hardnessweld deposit

UTP 690* UTP A 696* Build up welding on worntools and of broken outparts on cutting tools.New production of toolsin combination with lowclass base metals.

60 – 65 HRC

UTP 65 DUTP 653

UTP A 651 High strength and toughjoints on cracked andbroken tools. Cover with3 layers UTP 690 /UTP A 696

approx. 220 HB

* The welding deposit can be heat treated in accordance with the base material.

5.3 Appropriate UTP welding consumables for high speed steels

INDEX

6. Welding of cold working tool steels

6.1 Ledeburitic Cr- cutting steel with 5 - 12 % Cr

These cold working steels are mainly used for press tools for car body parts due to their high resistance against sliding and

frictional wear.

For large repairs on these air hardened tool steels, the correct preheat is critical. The tools are prepared for welding by grinding.

The pre- heating has to be done slowly but thoroughly to 450 - 480° C. Allow one hour for every 25 mm of thickness of material

to be welded.

The build up welding should be applied as follows:

Quick repair small repairs on the hard tool, 1 - 2 layers

Large repair multi layer build up on the hard tool

Repair with identical material changing of shape or pattern on a soft annealed tool

Quick repairs can be carried out with little or no preheat of approx. 150° C using Chromium steel electrode UTP 665 or

TIG rod UTP A 66. With the pick up of C from the base material, the welding deposit will reach a hardness of approx. 55 HRC.

For large repairs (more than 2 layers), the tool has to be pre- heated completely to 450 - 480° C. The consumables to be

used for welding are the electrode UTP 67 S (basic coated), or the UTP 673 (rutile coated), or the TIG wire UTP A DUR 600.

The hardness of the weld deposit is 56 - 60 HRC.

INDEX

Material No. DIN-Design. Chemical composition in %

C Si Mn Cr Mo V W

1.1730 C 45 W 0,45 0,3 0,6 - - - -

1.1740 C 60 W 0,6 0,3 0,6 - - - -

1.2003 75 Cr 1 0,75 0,4 0,7 0,4 - - -

1.2063 1 45 Cr 6 1,45 0,3 0,6 1,5 - - -

1.2067 100 Cr 6 1,0 0,3 0,3 1,5 - - -

1.2080 X 210 Cr 12 2,0 0,3 0,3 12,0 - - -

1.2162 21 MnCr 5 0,2 0,3 1,3 1,2 - - -

1.2201 X165CrV1 2 1,6 0,3 0,3 12,0 - 0,1 -

1.2210 115 CrV 3 1,2 0,2 0,2 0,7 - 0,1 -

1.2362 X63CrMoV5-1 0,6 1,0 0,4 5,3 1,3 0,3 -

1.2363 X100CrMoV5-1 1,0 0,3 0,3 5,3 1,1 0,2 -

1.2378 X220CrVMo12-1 2,2 0,2 0,3 12,0 - 2,0 -

1.2379 X155CrVMo12-1 1,55 0,3 0,3 12,0 0,7 1,0 -

1.2436 X210CrW12 2,1 0,3 0,3 12,0 - - 0,7

1.2541 35WCrV7 0,35 0,9 0,9 1,0 - 0,2 2,0

1.2542 45WCrV 7 0,5 0,9 0,9 1,0 - 0,2 2,0

1.2547 45WCrV7 7 0,5 0,9 0,9 1,6 - 0,2 2,0

1.2550 60WCrV 7 0,6 0,6 0,6 1,1 - 0,2 2,0

1.2601 X 1 6 5CrMoV12 1,6 0,3 0,3 12,0 0,6 0,5 0,5

1.2718 55NiCr 10 0,55 0,2 0,2 0,6 - Ni 2,8 -

1.2767 X45NiCrMo 4 0,45 0,3 0,3 1,4 0,3 Ni 4,0 -

1.2842 90MnCrV 8 0,9 0,3 0,3 0,4 - 0,1 -

6.2 Summary of

cold working

steels

INDEX

BÖHLER K110INDEX

6.3 Data for cold working tool steel 1.2379

DIN Designation: X 155 CrVMo 12 1

Chemical composition: C Cr Mo V

1,55 12,0 0,7 1,0

Properties: Ledeburitic 12 % Cr steel. Highest wear resistance,good toughness. Good cutting edge- and hardnessretention. Nitridable after special heat treatment.

Application: Thread rollers and -dies, cold extrusion-, cutting-and punching tools for sheet metal up to 6 mm.Cold pilger tools, circular shear knives and deepdrawing tools.


Soft annealing: 830 - 860° C / 4 h oven cooling annealinghardness max. 250 HB

Hardening: 1000 -1050° C/warm bath 550° C/air

Hardness after quenching: 63 HRC

Tempering °C: 100 200 300 400 500 525 550 600

Hardness after tempering HRC: 63 61 58 58 58 60 56 50

INDEX

Punching die with build up cutting edge

Cutting jaw with partial edge repair

INDEX

6.4 Appropriate UTP welding consumables for cold working tools

Coatedelectrode

TIG rodM I G /MAG wire


UTP 665 UTP A 66 Cutting edge build up onannealed Cr-cutting tools.Crack resistant tough, forone or max. two layers(quick repair)

approx. 55 HRC

UTP 67 SST Multi layer build up on softannealed Cr steel, colour andstructure match.

40 HRCuntreated

UTP 67 S UTP A DUR 600 Universal build up alloy fortempered cold steel andunalloyed base steel. Naturalhardness for multi layer buildup

56 - 58 HRCuntreated

UTP 673 UTP A 673 Multi layer build up onannealed cold working toolsand unalloyed base material,natural hardness

58 - 60 HRCuntreated

UTP 65 D UTP A 651 High tensile and tough jointson cracked and broken cuttingtools. On cutting edgesoverlay with hard deposit.

approx. 220 HB

INDEX

Welding preparation and seam build up on cutting edges

a) Low cutting pressure (bevelled edge preparation)

b) High cutting pressure (saddle preparation with rounded edges and corners)

INDEX

7. Welding of hot working tool steel

Hot working steels have, due to their chemical composition, high heat resistance, reteniton of hardness and good hot wear

resistance against impact, pressure and friction up to 550° C.

The Mo- Cr steels are, due to their good heat conductibility, very resistant against hot cracks under thermal shock, making

them ideal for press dies, injection moulds and hot rolling rolls etc. (1.2343, 1.2344, 1.2606).

The Ni- Cr- Mo steels are, due to their toughness, particularly suitable against impact load (1.2713, 1.2714).

Welding on hot working tool steels can be done with precipitaion hardening, martensitic or workhardening welding

consumables. lt is also important that cracks are gouged out completely. The Cr- Mo steels must be pre-heated

to approx. 400° C, the Ni- Cr- Mo steels to min. 300° C.

The welding can be done with consumables with characteristics similar to the base metal, which give the required hardness.

These tool steels should after substantial quantities of welding material have been deposited, be stress relieved at approx. 550° C.

INDEX

Partial repair of an Al-injection mould

Filling of a defect with UTP 73 G 3

INDEX

For build up welding on injection tools the use of age

hardenable martensitic material (Maraging Steel) is

recommended, due to its high wear resistance. For

this repair the tool is pre-heated to approx. 150° C

and welded by maintaining this temperature. The

deposited material has a hardness of approx. 37 HRC.

Age hardening at 480° C / 3 - 4 h will bring

the tool to a hardness of 53 HRC.

On forging tools, very good results are obtained

by using work hardening high Ni- and Co-base

alloys. These alloys have an initial hardness after

deposition of approx. 240 and 320 HB respectively.

In operation, due to impact and pressure the hardness

will increase to approx. 45 HRC. The available welding

consumables can be used for partial repairs, for

complete reconditioning, or for filling whole defects.

For their particulars see table 7.3.

Build up of the whole die pattern with Ni-alloy

INDEX

Build up welding on a mandril with UTP A 73 G 3

Build up welding on an axial roller with UTP AF CELSIT 721

INDEX

Material No DIN-Design. Chemical composition in %

C Si Mn Cr Mo Ni V W

1.2311 40 CrMnMo 7 0,4 0,3 1,5 1,9 0,2 - - -

1.2312 40 CrMnMoS 8-6 0,4 0,4 1,5 1,9 0,2 - - S 0,7

1.2323 48 CrMoV 6-7 0,45 0,3 0,8 1,5 0,8 - - -

1.2343 X 38 CrMoV 5-1 0,38 1,0 0,4 5,3 1,3 - 0,4 -

1.2344 X 40 CrMoV 5-1 0,4 1,0 0,4 5,3 1,4 - 1,0 -

1.2362 X 63 CrMoV 5-1 0,6 1,0 0,4 5,3 1,2 - 0,3 -

1.2365 X 32 CrMoV 3-3 0,32 0,3 0,3 3,0 2,8 - 0,5 -

1.2367 X 40 CrMoV 5-3 0,4 0,4 0,5 5,0 3,0 - 0,9 -

1.2564 X 30 WCrV 4-1 0,3 0,9 0,4 1,0 - - 0,2 3,8

1.2567 X 30 WCrV 5-3 0,3 0,2 0,3 2,4 - - 0,6 4,3

1.2581 X 30 WCrV 9-3 0,3 0,2 0,3 2,6 - - 0,4 8,5

1.2606 X 37 CrMoW 5-1 0,37 1,0 0,5 5,3 1,5 - 0,3 1,3

1.2678 X 45 CoCrWV 5-5-5 0,45 0,4 0,4 4,5 0,5 2,0 Co 4,5 4,5

1.2710 45 NiCr 6 0,45 0,3 0,8 1,4 - 1,7 - -

1.2713 55 NiCrMoV 6 0,55 0,3 0,8 0,7 0,3 1,7 0,1 -

1.2714 55 NiCrMoV 7 0,56 0,3 0,8 1,1 0,5 1,7 0,1 -

1.2744 57 NiCrMoV7-7 0,57 0,3 0,8 1,1 0,8 1,7 0,1 -

1.2764 X 19 NiCrMo 4 0,2 0,3 0,3 1,2 0,2 4,0 - -

1.2767 X 45 NiCrMo 4 0,45 0,3 0,3 1,3 0,3 4,0 - -

1.2082 X 20 Cr 13 0,2 0,5 0,7 13 - - - -

1.2787 X 22 CrNi 17 0,22 0,4 0,5 16,5 - 1,7 - -

1.2792 X 30 CrNiMoV 3-1 0,3 0,3 0,7 2,8 0,6 1,0 0,4 -

1.2731 X 50 NiCrWV 13-13 0,5 1,3 0,8 13 - 13 - 1,3

1.2885 X 32 CrMoCoV 3-3-3 0,32 0,3 0,3 3,0 2,8 Co 2,8 0,5 -

1.2888 X 20 CoCrWMo 10-9 0,2 0,25 0,5 8,5 2,2 Co 9,5 - 6,8

1.2889 X 45 CoCrMoV 5-5-3 0,45 0,4 0,4 4,5 3,0 Co 4,5 2,0 -

1.2898 X 30 CoCrMoV 3-3-3 0,3 - - 3,0 2,8 Co 2,8 0,5 -

1.2709 X 3 NiCoMoTi 18-9-5 0,03 < 0,1 < 0,15 - 5,0 18 Co 10 Ti 1

7.1 Summary of

hot working

tool steels

INDEX

BÖHLER W500INDEX

DIN Designation: 56 NiCrMoV 7

Chemical composition: C Cr Mn Mo V

0,55 1,1 1,7 0,5 0,1

Properties Die steel with high toughness andexcellentthrough hardening

Application Forging dies of all kinds, forming dies shearknives, extruder screws, cutting blades



Hardening: 830 - 870° C / oil860 – 900° C / air

Hardness after quenching: Oil 58 HRCAir 56 HRC

Tempering: 300 350 400 450 500 550 600 650

Hardness after tempering

HRC Oil 52 51 50 48 46 43 40 36

HRC Air 50 49 48 46 43 40 36 33

7.2 Data for hot working tool steel 1.2714

INDEX

BÖHLER W302INDEX

DIN Designation: X 40 CrMoV 5 1

Chemical composition: C Si Cr Mo V

0,40 1,0 5,3 1,4 1,0

Properties: High heat resistance, high hot wear resistance, good heatconductibility and hot crack resistance.

Application: Universally suitable, particularly for injection- and continuouscast moulds for AI-alloys, for forging tools and dies and hotshear knives.

Hot forming: 1100 - 900° C slow cooling in vermiculiteor in the oven


Hardening: 1020 -1050° C oil / air or500 - 550° C hot bath

Hardness after quenching: 54 HRC (1910 N/mm²)

Tempering °C 100 200 300 400 450 500 550 600 650 700

Hardness after

tempering HRC 53 52 52 54 56 56 54 50 42 32

N/mm² 1850 1790 1790 1910 2050 2050 1910 1670 1330 1020

7.2.1 Data for hot working tool steel 1.2344

INDEX

New engraving in forging die

Filled up engraving of a forging die (UTP A 73 G 3)

INDEX

Coatedelectrode

TIG rodMIG /MAG wire


73 G 4

73 G 3

73 G 2

A 73 G 4

A 73 G 3

A 73 G 2

Single- and multi-layer buildup on similar CrMo- andNiCrMo steels for shearblades, moulds, dies,trimming dies, rolls fill welding

38 - 42 HRC

45 - 48 HRC

702 A 702 Build up on CrMo steels inparticular injection moulds(Maraging steel)

37 - 40 HRCuntreated51 - 54 HRCaged 4 h / 480° C

Celsit 706

Celsit 712

Celsit 701

A Celsit 706 VAF Celsit 706

A Celsit 712 SNAF Celsit 712

A Celsit 701 NAF Celsit 701

Heat resistant Co-alloys forapplications involving thermalshock such as hot shearblades, hot punching- andtrimming tools. Partial build upwelding.

40 - 43 HRC

48 - 53 HRC

52 - 57 HRC

700

7000

7008

Celsit 721

A 776

A 776

A 776

A Celsit 721AF Celsit 721

High heat resistant Ni-alloy fortools having to support veryhigh pressure and thermalshock such as forging tools,mandrils, shear blades.Machinable with cutting tools

220 HB (400 K)

240 HB (400 K)

260 HB (450 K)

320 HB (450 K)(Co-alloy)

65 D

653

7015 Mo

6218 Mo

A 651

A 651

A 068 HH

A 6222 Mo

Buffer layers, welding ofcracks, joining, as well aseasy machinable, high heatresistant build up.

220 HB (350 K)

240 HB (350 K)

190 HB (350 K)

230 HB (450 K)

7.3 Appropriate

UTP welding

consumables for

hot working tools

INDEX

Cutting edge build up with Ni-alloy

Hot cutting blade of a billet shear

INDEX

8. Welding of steels for plastic injection moulds

Steels are selected for plastic moulds according to the operating conditions and for economical purposes. Depending on the working process we can differentiate between

Press- and injection toolsfor hardenable plastics (Duroplast)

and

Injections toolsfor non hardenable plastics (Thermoplast)

The welding consumable requirements can differ, however high wear resistance, good heat conductibility, dimensional accuracy at temperatures of 160 - 220° C, and a polishable deposit are required in both cases.

In addition, press tools have to have high pressure resistance and toughness. For certain plastics corrosion resistance is also needed.

The decision to use either low- or high alloy steel as a base material depends on the application of the form of the die. Frequently used are the annealable steels quality 1.2311 and 1.2312. Welding on these materials is done with a pre-heat of 350 - 400° C.

In general the weld filler metal used has a similar alloy to the base metal and is applied either as an electrode or a TIG rod (see table 6.3). In case where a tool has been surface hardened and has to be repair welded, the hard layer must be removed prior to welding. For this kind of repair, the TIG rod UTP A 702 has proved to be very useful.

INDEX

Material-No. DIN-Design. Chemical composition in %

C Si Mn Cr Mo Ni V S

Hardened steel

1.2162 21 Mn Cr 5 0,21 0,3 1,3 1,2 - – – –

1.2341 X 6 CrMo 4 0,04 0,1 0,1 3,8 0,5 – – –

1.2764 X 19 NiCrMo 4 0,19 0,3 0,3 1,3 0,2 4,1 – –

Heat treatable steel

1.2311 40 CrMnMo 7 0,4 0,3 1,5 1,9 0,2 – – –

1.2312 40 CrMnMoS 6-8 0,4 0,4 1,5 1,9 0,2 – – 0,07

1.2347 X 40 CrMoVS 5-1 0,4 1,0 - 5,2 1,3 – 1,0 0,1

1.2378 40 CrMnNiMo 8-6-4 0,4 0,3 1,5 2,0 0,2 1,0 – –

1.2766 35 NiCrMo 16 0,35 0,3 0,5 1,3 0,3 4,0 – –

Corrosion resistant steel

1.2082 X 21 Cr 13 0,2 0,4 0,4 13,0 - – – –

1.2083 X 40 Cr 13 0,42 0,4 0,3 13,0 - – – –

1.2316 X 36 CrMo 17 0,36 0,4 0,4 17,0 1,2 – – –

1.4120 X 20 CrMo 13 0,2 0,4 0,4 13,0 1,2 – – –

Through hardening steel

1.2713 55 NiCrMoV 6 0,55 0,3 0,8 0,7 0,3 1,7 0,1 –

1.2343 X 38 CrMoV 5-1 0,38 1,0 0,4 5,3 1,3 – 0,4 –

1.2767 X 45 NiCrMo 4 0,45 0,3 0,3 1,4 0,3 4,0 – –

1.2842 90 MnCrV 8 0,9 0,3 2,0 0,4 - – 0,1 –

1.2080 X 210 Cr 12 2,0 0,3 0,3 12 - – – –

Nitriding steel

1.2895 34 CrAINi 7 0,35 – 0,5 1,7 0,2 1,0 Al 1,0

Age hardening steel

1.2709 X 3 NiCoMoTi 18-9-5 ≤ 0,03 ≤ 0,1 ≤ 0,15 Ti 1,0 5,0 18,0 Co 10,0

Block steel

1.1730 C45W 0, 45 0, 3 0, 7 - - – – –

8.1 Summary of steels

for plastic moulds

INDEX

DIN Designation: 40 CrMnMoS 8 6

Chemical composition: C Si Mn Cr Mo S0,4 0,4 1,5 1,9 0,2 0,07

Properties: Through heat treatable, good machinability also inheat treated condition, polishable

Application: Plastic forms and - moulds, form holding blocks,receiver coatings

Hot forming: 1050 - 850° C slow cooling in vermiculiteor in the oven

Soft annealing: 710 - 740° C / 4 h oven cooling / 235 HB

Hardening: 840 - 870° C oil / air or180 - 220° C hot bath

Hardness after quenching: 51 HRC (1730 N/mm²)

Tempering °C 100 200 300 400 500 600 700Hardness aftertempering HRC

51 50 48 46 42 36 28

N/mm² 1730 1670 1570 1480 1330 1140 920

8.2 Data for plastic mould steel 1.2312

INDEX

Die cast form for plastic made from material No. 1.2312

INDEX

Coatedelectrode

TIG rodMIG /MAG wire


641 Kb A 641 Build up and joints on casehardening and heat treatablesteel

approx. 200 HB

73 G 473 G 373 G 2

A 73 G 4A 73 G 3A 73 G 2

Build up on similar heat treatableand through hardened steel withcorresponding hardness

38 - 42 HRC45 - 48 HRC55 - 58 HRC

65665

A 651A 66

Build up welding on corrosionresistant steels with highC-content

approx. 220 HBapprox. 350 HB

636306302

A 63 Crack resistant and toughjoints and build up,stainless

approx. 180 HB

6025 A 6025 Build up and joints on Ni-containingcase hardening- and heat treatablesteel

approx. 180 HB

702 A 702 Build up on nitriding and agedsteels

approx. 37 HRC

8.3 Appropriate UTP welding consumables for steels for injection moulds

INDEX

Plastic press die lower and upper partmade from material 1.2162

INDEX

9. Welding of cast iron

Welding of cast iron is needed when cracks or surface wear appear and/or when a change of pattern is required.

Cast iron tools are generally used for forming sheet metal for the car industry and are, as such, large parts.

Due to this, welding can only be carried out using the “cold welding" method.

In addition to the standard forms of cast iron, with lamellar or nodular graphite structure, there are also CrMo-

and CrNi alloyed cast irons in use. Cast iron with lamellar graphite is very brittle, has virtually no yield strength

and no elongation. The pressure resistance is approx. 6 x higher that the tensile strength and is therefore similar

in its behaviour to that of concrete.

It is therefore evident, that the flakes of graphite reduce the resistance of the ferritic of the perlitic structure.

On the other hand, graphite improves the gliding properties of the cast iron material and gives good wear

resistance when forming tools.

The most successful way to carry out cold welding on cast iron is by using either pure Nickel or Ferro- Nickel electrodes

with a graphite coating. Steel electrodes have, due to their very limited elongation, a tendancy to produce cracks or

even to break out.

Prior to welding, the base material surface has to be cleaned thoroughly. A skindrying with an oxyacetylene torch

with a reducing flame may be necessary to clean oil and grease from the welding area.

From experience it has been shown that organic residues on the surface to be welded lead to porosity.

If porosity appears in the first layer, this layer must be removed again by grinding.

INDEX

Substantial change of the form of a cast iron press tool

UTP 86 FN

UTP 8 C

INDEX

As a buffer layer for a build up, and for buttering on a joint the electrode recommended is a pure Nickel type.

These types of electrode have in general a very good alloying characteristic and can be welded with

DC straight polarity or with AC. The crack resistance is improved by depositing short beads followed

immediately by a peening.

The welding deposit of Nickel is highly ductile and workable. Residual stress is relieved during cooling

by peening the weld lightly.

Ferro- Nickel type electrodes are recommended for cover layers on build up and joints.

The welding deposit has a slightly higher tensile strength, corresponding to GGG 50.

To grind Nickel base deposits Fe- and S- free grinding discs are recommended.

The discs are normally marked accordingly.

The highest crack resistance on multi layer welding is obtained by using an electrode with a Bi- metallic

Ferro- Nickel core wire (UTP 86 FN), weldable on DC straight polarity or AC. The current carrying capacity

of this electrode is very high and prevents overheating completely. Also this deposit should be peened to

reduce welding stress.

Very large and substantial building up repairs can be done by using our Ferro- Nickel MIG wire UTP A 8051 Ti.

INDEX

Form change on a cast iron press tool

Micrograph of the transition zone GGG 40 to UTP 86 FN

INDEX

Material

typ

Mat. No. Structure Tensile

strength

N/mm²

Hardness

HB

Yield strength

(min) Rp0,2

N/mm²

Elong.

(min) A5

%

GG 10 0.6010 ferritic 100 100 -150

GG 15 0.6015 150 140 -190

GG 20 0.6020 200 170 - 210

GG 25 0.6025 250 180 - 240

GG 30 0.6030 300 200 - 260

GG 35 0.6035 350 210 - 280

GG 40 0.6045 perlitic 400 230 - 300

GGG 35.3 0.7033 ferritic 350 - 400 110 -150 220 22

GGG 40.3 0.7043 400 - 450 120 -165 250 18

GGG 40 0.7040 400 - 550 135 -185 250 15

GGG 50 0.7050 500 - 650 170 - 220 320 7

GGG 60 0.7060 600 - 750 200 - 250 380 3

GGG 70 0.7070 700 - 850 235 - 285 440 2

GGG 80 0.7080 perlitic 800 -1000 270 - 335 500 2

GG - CrMo alloyed cast iron

GG - CrNi

Tensile strength values are minimum values in accordance with DIN 1691 and DIN 1693

9.1 Summary of cast

iron materials

INDEX

Edge build up on a cast iron press tool with UTP 807

INDEX

UTPElectrodes

Application Hardness Current

8 C Buffer layer on joints and building upon large cast iron parts with lamellargraphite structure.

Joint welds on thin walled cast iron parts

approx. 180 HB = - / -.

85 FN

86 FN

Joining and build up welding on GGand GGG cast iron parts, particularlyfor multi-layer welding and for wearresistant building up on worn out tools.

approx. 190 HB

approx. 220 HB

= + /

807 Nickel free special electrode for colourmatching and wear resistant build upson GG and GGG cast iron. A bufferlayer with Nickel or Ferro-Nickel isrecommended.

approx. 230 HB - + /

82 AS Electrode for gouging and chamfering - - / --

9.2 Appropriate UTP products for cast iron welding

INDEX

9.3 Appropriate UTP TIG rods and MIG wires for cast iron welding

UTP type Application Hardness

A 80 Ni TIG rod with approx. 95 % Ni for build up andjoints

approx. 150 HB

A 387 Cu-Ni type TIG rod with approx. 70 % Cu and30 % Ni for build up on cast iron. High ductility,low tensile strength.

approx. 120 HB

A 80 M Ni-Cu type TIG rod with approx. 70 % Ni and30 % Cu (Monel) for joining and build up on allkinds of cast iron.

approx. 150 HB

A 068 HH Ni-Cr-Fe type rod with approx. 70 % Ni and20 % Cr for joining and build up on all kinds ofcast iron, high tensile strength

approx. 180 HB

A 8051 Ti Ferro-Nickel type MIG wire for high strengthjoints and build up on all types of cast iron.

approx. 220 HB

INDEX

UTP type ElectrodesØ mm

TIG rodsØ mm

MIG/MAG-wiresØ mm

63630*6302*A 63

2,5 / 3,2 / 4,02,5 / 3,2 / 4,02,5 / 3,2 / 4,0

1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

65 DA 651 *

1,5 / 2,0 / 2,5 / 3,2 / 4,01,2 / 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

67 SA DUR 600

2,5 / 3,2 / 4,01,2 / 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

67 SST* 2,5 / 3,2 / 4,0

73 G 2A 73 G 2

2,5 / 3,2 / 4,01,6 / 2,0 / 2,4 1,0 / 1,2 / 1,6

73 G 3A 73 G 3

2,5 / 3,2 / 4,01,6 / 2,0 / 2,4 1,0 / 1,2 / 1,6

73 G 4A 73 G 4

2,5 / 3,2 / 4,01,6 / 2,0 / 2,4 1,0 / 1,2 / 1,6

82 AS 2,5 / 3,2 / 4,0

641 Kb*A 641 *

2,5 / 3,2 / 4,01,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

653* 2,0 / 2,5 / 3,2 / 4,0

665*A 66*

2,5 / 3,2 / 4,01,2 / 1,6

673A 673

2,0 / 2,5 / 3,2 / 4,01,6 / 2,0 / 2,4 1,2 / 1,6

690A 696*

2,0 / 2,5 / 3,2 / 4,01,6 / 2,4 1,2

702A 702

2,5 / 3,2 / 4,01,6 / 2,0 / 2,4 1,2

807* 2,5 / 3,2 / 4,0

6025*A 6025*

2,5 / 3,2 / 4,02,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

10. Availability of the

UTP Products for

tool welding

*) available on demand

INDEX

10. Availability of the

UTP Products for

tool welding

*) available on demand

UTP type ElectrodesØ mm

TIG rodsØ mm

MIG/MAG-wiresØ mm

88 C*A 80 Ni

2,5 / 3,2 / 4,02,5 / 3,2 / 4,0

1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

A 80 M 1,6 1,0/1,2/1,6

85 FN86 FNA 8051 Ti

2,5 / 3,2 / 4,02,5 / 3,2 / 4,0

2,4 0,8 / 1,2

A 387 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

700*70007008*A 776

2,5 / 3,2 / 4,02,5 / 3,2 / 4,02,5 / 3,2 / 4,0

1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

6218 Mo*A 6222 Mo

2,5 / 3,2 / 4,01,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

7015 MoA 068 HH

2,5 / 3,2 / 4,01,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

Celsit 706A Celsit 706 VAF Celsit 706

3,2 / 4,03,2 / 4,0

1,2 / 1,6

Celsit 712A Celsit 712 SNAF Celsit 712

3,2 / 4,03,2 / 4,0

1,2 / 1,6

Celsit 701A Celsit 701 NAF Celsit 701

3,2 / 4,03,2 / 4,0

1,2 / 1,6Celsit 721A Celsit 721AF Celsit 721

3,2 / 4,03,2 / 4,0

1,2 / 1,6

INDEX

Bohler - Manual de Reparatii Prin Sudura

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