Repair welding - · PDF fileadditional laser welding necessary. ... Repair welding System...

Repair weldingSystem brochure

joke Technology GmbHAsselborner Weg 14 -16

D-51429 Bergisch Gladbach (Germany)Tel. +49 (0) 22 04 / 8 39-0

Fax +49 (0) 22 04 / 8 [email protected]

Brilliant solutions for perfect surfaces

5

Durable repair welding and shortest repair times on moulds and tools are a must in today’s modern production environments. The lack of replacement tools and increas-ingly shorter production times demand the fastest, yet nevertheless impeccable re-pairs – under the same roof!

Conventional TIG welding has too many di-sadvantages here, such as fusion penetration, distortion and structural transformati-on and therefore usually does not allow a final repair job on-site and usually render additional laser welding necessary. This costs time and above all money.

The joke multiSpot technology provides you with the chance to repair your tools safely and cost-efficiently on-site. You therefore not only gain an important piece of free-dom from external service providers, but also achieve results with this system, which are largely consistent with laser welding quality. The cross table and hand weld-ing torch allow you to tackle smallest appli-cations as well as large shapes without a problem. Thanks to the joke multiSpot tech-nology external labour, waiting and down-time is reduced to a minimum. We invite you to discover the versatile features of this system on the following pages.

Welcome to the multiSpot 2 system -exclusively by joke

3

5

Tel. +49 (0) 22 04 / 8 39-0 • Fax +49 (0) 22 04 / 8 39-61 • [email protected]

5. Welding and coating systems // 5.1. Welding units and accessories

Repair welding System brochure

Welding station

joke multiSpot 2 page 4 Aluminium welding system

joke Alu-MASTER page 14Accessories multiSpot 2

page 11Welding unit

joke easyWIG page 16

Laser welding fillers

joke Fill page 33

Flexible arm system

page 20Compact stereomicroscopes

page 17

Laser welding fillers

joke Fill page 22

NEW!

NEW!

We offer you the complete spectrum of device and tool systems for fine surface finishing over

600 pages in our complete catalogue.

Order now!

Tel. +49 (0) 22 04 / 8 39-0 • www.joke.de

4

5



Automatic welding helmetwith extended field of view(Order No. 0 008 375)

Pocket magnifier 2.5 dioptres(Order No. 0 008 315)

Pocket magnifier 3.0 dioptres(Order No. 0 008 314)

Glare protection shield(Order No. 0 008 328)

Compact stereomicroscopesStandard working distance (Order No. 0 008 329)XXL working distance (Order No. 0 008 332)

Flexible bolt(Order No. 0 008 329-3)

Repair weldingSystem overview

Welding unit joke multiSpot 2(Order No. 0 084 500)

Welding unit joke easyWIG (Order No. 0 084 650)

Gas pressure regulator(Order No. 0 008 319)

Spare parts set(Order No. 0 008 323)

Foot pulse switch(Order No. 0 008 325)

Foot pedal controller (Order No. 0 008 324)

Earthing cable(Order No. 0 008 352)

Cross table(Order No. 0 084 510)

Magnet holder with flexible arm(Order No. 0 084 511)

Welding torch holder(Order No. 0 008 313)

Transport trolley(Order No. 0 008 330)

Accessories Workplace Glare protection / optics

Welding units

joke multiSpot 2The reference for pulsed welding for the safe repair of moulds and tools.

joke easyWIGHigh-performance TIG welding unit for complex component geometries.

NEW!

NEW!

Welding unit joke Alu-MASTER(Order No. 0 084 660)

joke Alu-MASTERSpecially optimised

for processing aluminium materials.

Double extraction valve (Order No. 0 008 319-1)

NEW!

5

5

i



Hand welding torch, small, with tipper, flex. welding torch head and 4 m tubing pack (Order No. 0 008 364)

Accessories: Collet housing for tungsten electrodes Ø 1.6 mmCollet Ø 1.6 mm small ceramic nozzle type “D” long welding torch cover

optional:Gas lens Ø 1.6 mmGas lens Ø 1.0 mmCollet housing Ø 1.0 mm

Ceramic nozzle type “A” for gas lensCermic nozzle type “B” for collet housing

Cermic nozzle type “D” for collet housing

Cermic nozzle type “E” for collet housing

Cermic nozzle type “F” for collet housing

Repair weldingSystem overview

joke Fill LASER for laser welding

Spools 50, 100 150, 500 g Rods (300 mm) 75 and 100 g

available in 0.2 – 0.6 mm diameters

Hand welding torch, small, without tipper, flex. welding torch head and 4 m tubing pack(Order No. 0 008 360)

Accessories:Collet housing for tungsten electrodes Ø 1.6 mmCollet Ø 1.6 mm small ceramic nozzle type “D” long welding torch cover

optional:Gas lens Ø 1.6 mmGas lens Ø 1.0 mmCollet housing Ø 1.0 mm

Ceramic nozzle type “A” for gas lensCermic nozzle type “B” for collet housing




Machine welding torches includes 3 m tubing pack (Order No. 0 008 361)

Accessories:Gas lens Ø 1.6 mmCollet with extension Ø 1.6 mm

Ceramic nozzle type “A”

optional:Gas lens Ø 1.0 mm collet with extension Ø 1.0 mmCollet housing Ø 1.0 + 1.6 mm

Cermic nozzle type “B” for collet housing




Hand welding torch, large, with tipper, flex. welding torch head and 4 m tubing pack (Order No. 0 008 363)

Accessories:Gas lens for tungsten electrodes Ø 2.4 mmshort ceramic nozzle type “G”

optional:long ceramic nozzle type “H”

Welding fillers

joke Fill TIG for TIG welding

Rods 500 mm available

in 0.8 – 1.6 mm diameters

Welding torches

More welding fillers on request!We´ll deliver further qualities and/or dimensions of our joke fill welding fillers on request.

6

5

Best-seller!



Steel 1.2367, pore-free surfaces and edge welding

Steel 1.2367, build-up welding

Steel 1.2764, fine edge, wide surface

Steel 1.2343, surfacing + fillet weld

Steel 1.2767, spot welding

Capability of the multiSpot technology Easy, quick and safe. Filler wires from 0.2 mm diameter can be processed. The multiSpot impulse technology is revolutionary and ensures the best possible results are achieved by even, smooth junctures. The single current pulses for smallest and finest welding jobs are triggered with control. Single impulse control for the smallest and finest welding. Controlled triggering of individual impulse. Interval switching with adjustable pauses and welding times ensures precise application and joints.

Steel 1.2767, edge welding

Steel 1.2764, surface application

Steel

Steel 1.2343, build-up welding

Aluminium-bronze

Steel 1.4021, pipe + flange gastight welding

Copper

Titanium

Welding system joke multiSpot 2Applications

7

5

Best-seller!



i

Method Width of the heat affected zone (mm) Hardness in the heat affected zone (HV2)

TIG 1 378

TIG pulsed 0,75 411

TIG-Cro 1,25 545

TIG-Joke 0,50 296

Laser 0,50 293

Comparison of the width and hardness of the heat affected zone (material 1.2343)

Source: „Laser-Präzisionsauftragsschweißen mit zentrischer Werkstoffzufuhr, Fraunhofer Verlag (2009)

Welding system joke multiSpot 2Convincing references

Welding fillers from 0.2 to 2.4 mm pulsed

“With regard to the precision of build-up welding, the multiSpot method (…) offers almost just as good alternatives in comparison to the laser”

Source: „Laser-Präzisionsauftragsschweißen mit zentrischer Werkstoffzufuhr“, Fraunhofer Verlag (2009)

“… results comparable to laser…”Source: „Laser-Präzisionsauftragsschweißen mit zentrischer Werkstoffzufuhr“, Fraunhofer Verlag (2009)

“multiSpot scores pointes particularly with small excarvations”Source: Journal „werkzeug & formenbau“ (Nov 2005), Verlag moderne Industrie

“Result cannot be achieved by conventional TIG units”Source: Journal „werkzeug & formenbau“ (Nov 2005), Verlag moderne Industrie

“With reference to the workpiece size, the multiSpot system is more flexible in direct comparison with the laser”

Source: Journal„Form + Werkzeug“ (2/2007), Carl Hanser Verlag

“The achievable results are similar to laser in wide sections”Source: Journal „Form + Werkzeug“ (2/2007), Carl Hanser Verlag

Finest weld points and junctures

Cost-effective on-site repairs

Accessories for flexible application

Easy, quick and safe

Special pulsed high-energy electric arc

8

5

i

Best-seller!



The system is completeA machine welding torch and different hand welding torches give you the choice: Freehand welding or the exact positioning and point-precise welding of a component with the aid of a cross table. The foot pulse switch generates the welding impulses, whilst the foot pedal controller for the weld-ing torch allows the delicate control of the necessary welding energy for TIG, TIG pulse and AC welding. The transport trolley makes your welding station mobile and flexible. Apart from the welding unit the trolley also offers space for the gas bottle, the cross table and other accessories. The automatic welding helmet with optional pocket magni-fier ensures best visibility at work. The spare part and accessory set delivers everything it promises.

The joke multiSpot 2 technologyThe joke multiSpot technology has revolution-ised repair and modification welding for tool and mould making. Easy, quick and safe – the ideal system for efficient on-site tool repair. Specially developed for pulsed welding ap-plications. Such fine and precise welding has so far only been possible with a laser.

The special electrical arc formation allows point-exact welding. No other system puts finer points and seams on surfaces, edges, grooves, engravings etc. And this with filler wires from 0.2 mm. Weld penetration and shrinking or distortion of the base material are minimised to a point where they become technically meaningless. joke multispot technology ensures best pos-sible junctures and high-strength diffusion welds are guaranteed.

The two welding modi “TIG DC Puls” and “TIG AC” round off the diverse range of applica-tions for this system.

Welding system joke multiSpot 2

One system – six welding processes

1. multiSpot single pulse for the finest and point-precise welding results

2. multiSpot continuous pulse for finest weld seams

3. TIG DC for smaller and medium repair or build-up jobs

4. TIG DC pulse with continuous electric arc. Lower heat generation than TIG DC

5. TIG AC for welding on aluminium

6. Electrode for rough welding jobs (i.e. in construction)

9

5

1 2 3 4

5 6 7 8 9

10 11 12 13 15

16 17

18

19 20

14

Best-seller!



Technical datajoke multiSpot 2 in accordance with IEC 974.1/EN 60974.1/CE declaration of conformityDimensions (L x W x H) 480 x 260 x 380 mmWeight 26.2 kgInsulation class HType of protection IP 23Cooling type Forced-air cooled Input data Mains voltage U1 230 Volt (single phase), 50/60 HzMains fuse I1 16 A, slow-blowEfficiency factor cos o 0.9 at 150 A extractionPrimary constant power S1 max. 5.0 kVA

Output data No-load voltage U0 85 Volt TIG/TIG/electrodeOperating voltage U2 19.1 – 16.5 V / TIG max. 18 V / Electrode max. 26 VWelding current ignition I2 from 3 AWelding current range I2 3 – 210 APower-on time at 200 A 50 % at +40° CPower-on time at 130 A 100% at +40° CPulse time 20 – 300 msBreak time 20 – 1000 ms

Welding system joke multiSpot 2

Overview of the control elements

1. Ammeter

2. Control lights

3. Overheat indicator

4. Pulse length / t = I1

5. Target value I1

6. Target value I2

7. Down slope time

8. Postsurge gas-flow time

9. Pulse-pause time / t = I2

10. Selector switch TIG 2/4 pulse,

electrode

11. Frequency selector AC welding

current

12. Balance AC welding current

13. Selector switch DC/AC or S-Test

14. LED status indicator for safety control

15. Programme selector

• TIG

• TIG with pulsed arc

• multiSpot single pulse

• multiSpot continuous pulse

16. Foot pulse switch/ pedal controller

connector

17. Foot pulse switch connector

18. Gas connector

19. Welding torch/ tubing pack connector

20. Earthing cable connector

10

5 1

3

4

5

5a

6 7

8

Best-seller!



Complete set joke multiSpot 2 Order No. Price

The set contains:• Cross table• Hand welding torch, large, with 4 m tubing pack• Machine welding torch with 3 m tubing pack• Earthing cable, 3 m with crocodile clip• Argon pressure relief valve with flow meter• Foot pulse switch• Foot pedal controller • Accessory and spare parts set

0 084 500

Welding system joke multiSpot 2Complete set

Foot pedal controller(Order No. 0 008 324)

multiSpot accessory/spare part set(Order No. 0 008 323)

Pressure relief valve (200 bar) with flowmeter(Order No. 0 008 319)

Foot pulse switch(Order No. 0 008 325)

3 m earthing cable with crocodile clip(Order No. 0 008 352)

Hand welding torch, large, with 4 m tubing pack (Order No. 0 008 363)

Machine welding torch with 3 m tubing pack(Order No. 0 008 361)

Cross table(Order No. 0 084 510)

The complete set for a perfect start:

11

5

1

2

3

4

5

6

7

8

9

9

10

10

11

11a

11b11b

11c

11c

11c

11

12

12

13

13

1414

2

5a

11a

Best-seller!



Accessories joke multiSpot 2 Order No. Price

Hand welding torch, large, with 4 m tubing pack and tipper 0 008 363

with flexible burner head, collet Ø 2.4 mm, capacity: DC 240 A / AC 200 A

Hand welding torch, small, with 4 m tubing pack, without tipper 0 008 360

with flexible burner head, collet Ø 1.6 mmcapacity: DC 110 A / AC 95 A

Machine welding torch with 3 m tubing pack 0 008 361

Collet Ø 1.6 mm, capacity: DC 110 A / AC 95 A

Earthing cable with crocodile clip 0 008 352

Pressure relief valve (200 bar) with flowmeter 0 008 319

Double extraction valve for gas pressure reducer 0 008 319-1

Foot pulse switch 0 008 325

for generating welding impulses

Foot pedal controller 0 008 324

for the exact control of the required output for TIG-DC and AC welding

Cross table 0 084 510

Its x-y-z axis and freely movable torch holder ensures the exact positioning of the machine welding torch over the component

Leather gloves, size 9 0 008 350

Leather gloves, size 10 0 008 351

Transport trolley 0 008 330

offers space for the unit, gas bottle, cross table and accessories

Welding torch holder, magnetic 0 008 313

for the secure storage of your welding torch

Automatic welding helmet (with extra large field of view) 0 008 375

with variable protection level (5-9 / 9-13) and adjustable sensitivity

Front pane for automatic welding helmet 0 008 312-3

Replacement-headband for welding helmet 0 008 310-1

Pocket magnifier 2.5 dioptres 0 008 315

Pocket magnifier 3.0 dioptres 0 008 314

Fibreglass pen, including lead 0 008 317

Replacement lead for fibreglass pen 0 008 318

Welding filler holder for Ø 0.2 – 1.0 mm 0 008 316

Welding rod feeding pen Ø 0.2 - 0.6 mm 0 008 316-1

Welding system joke multiSpot 2Accessories

Hand welding torch, small, with 4 m tubing pack, without tipper(Order No. 0 008 360)

Tran

spor

t tro

lley

(Ord

er N

o. 0

008

330

)

12

5

BA D E F G H

i



Spares and consumables / special accessories Order No. Price

Tungsten electrode Ø 1.0 mm, blue 0 008 322



Ceramic nozzle type “H” for hand welding torches, large Ø 10 x 76 mm 0 008 365-5

Ceramic nozzle type “G” for hand welding torches, large Ø 11 x 42 mm 0 008 365-4

Ceramic nozzle type “D” for machine and hand welding torches, small Ø 7 x 30 mm 0 008 360-1

Ceramic nozzle type “E” for machine and hand welding torches, small Ø 6.5 x 48 mm 0 008 365-2

Ceramic nozzle type “F” for collet housing Ø 5 x 48 mm 0 008 365-3

Ceramic nozzle type “A” for Gas lens Ø 8 x 35 mm 0 008 360-8

Ceramic nozzle type “B” for collet housing Ø 8 x 30 mm 0 008 365-1

Insulator for hand welding torch, large 0 008 363-1

Insulator for machine welding torch 0 008 361-9

Insulator for hand welding torch, small 0 008 361-D

Collet Ø 1.6 mm for hand welding torches, large 0 008 363-6

Collet Ø 2.4 mm for hand welding torches, large 0 008 361-8

Gas lens Ø 1.6 mm for hand welding torches, large 0 008 363-5

Gas lens Ø 2.4 mm for hand welding torches, large 0 008 363-2

Collet Ø 1.0 mm with extension hose for machine welding torches 0 008 360-6

Collet Ø 1.6 mm with extension hose for machine welding torches 0 008 361-4

Collet Ø 2.4 mm with extension hose for machine welding torches 0 008 357

Collet Ø 1.0 mm for hand welding torches, light and machine welding torches 0 008 361-5



Collet housing Ø 1.0 mm for machine and hand welding torches, light 0 008 360-7

Collet housing Ø 1.6 mm for machine and hand welding torches, light 0 008 361-7

Collet housing Ø 2.4 mm for machine and hand welding torches, light 0 008 358

Gas lens Ø 1.0 mm for machine and hand welding torches, light 0 008 359

Gas lens Ø 1.6 mm for machine and hand welding torches, light 0 008 360-3

Welding torch cover, long, for machine welding torch 0 008 360-B

Welding torch cover, long, for light hand welding torch 0 008 360-9

Welding torch cover, short, for light hand welding torch 0 008 360-5

Welding torch cover, micro, for light hand welding torch 0 008 360-D

Welding torch cover, long, for hand welding torch, large 0 008 363-3

Welding torch cover, medium, for hand welding torch, large 0 008 363-4

Welding system joke multiSpot 2Spares and consumables

Ceramic nozzles

Gas lens with collet

Gas lenses, collets with exten-sion and electrodes (combi-nation for use with machine welding torches)

Collet housing

Welding torch cover long, short and micro

Insulator

The flexible arm for welding unitsOn page 20, you will discover the new, individually adjustable flexarm system, which has been especially designed for welding workplaces. Talk to Bernd Dörnen about the possibilities this flexible accessory system offers and learn more about repair welding with the joke multiSpot:

Tel. +49 (0) 22 04 / 8 [email protected]

13

5



Spares and consumables set for multiSpot2 Order No. Price

This set contains the following spares and consumables:2 x Tungsten electrode Ø 2.4 mm (Order No. 0 008 321)3 x Tungsten electrode Ø 1.6 mm (Order No. 0 008 320)1 x Ceramic nozzle type “H” for hand welding torches, large (Order No. 0 008 365-5)1 x Ceramic nozzle type “G” for hand welding torches, large (Order No. 0 008 365-4)1 x Ceramic nozzle type “D” for machine and hand welding torches (Order No. 0 008 360-1)1 x Ceramic nozzle type “E” for machine and hand welding torches (Order No. 0 008 365-2)1 x Insulator for hand welding torches, large (Order No. 0 008 363-1)1 x Collet Ø 2.4 mm for hand welding torches, large (Order No. 0 008 361-8)1 x Collet Ø 1.6 mm for hand welding torches, large (Order No. 0 008 361-4)1 x Collet housing Ø 1.6 mm (Order No. 0 008 361-7)1 x Gas lens Ø 2.4 mm (Order No. 0 008 363-2)1 x Gas lens Ø 1.6 mm (Order No. 0 008 360-3)

0 008 323

Welding system joke multiSpot 2Set of spares and consumables

Welding training joke multiSpot 2Basic principles of repair welding

Number of participants: up to max. 4 persons

Duration: 1 day

Course fee per participant: on request!

Included in course fee: practice material, joke book, participation certificate

Programme: 1. Basic principles of welding technology• basic principles of the multiSpot welding method• significance, action and interaction of the control elements• influence of TIG welding on the multiSpot method• applications

2. Practical exercises• welding of surfaces, edges and grooves• minimising fusion penetration and heating of the workpiece• application possibilities for the cross table• freehand welding

Dates on request!

5

14

NEW!


Aluminium welding systemjoke Alu-MASTER

Aluminium welding system joke Alu-MASTERExperience new dimensions in aluminium welding. The ultrahigh-energy arc allows maximum, high-efficiency energy yield. Owing to the optimised energy balance of up to 90% minus percen-tage, the electrode remains sharp even at maximum load. The optimum prerequisite for perfect welding results on aluminium.

The introductory set provides you everything that you need to get started straight away. If you already use a welding system from our company incl. accessories, you can also order the Alu-MASTER “solo” and continue to use your existing accessories since these are 100% compatible.

Using the joke Alu-MASTER,

you can weld on extremely fine

seams and points for microrepair

on aluminium tools and moulds.


The tungsten electrode remains

sharp even at maximum load!

15

5



NEW!Aluminium welding system

joke Alu-MASTER

Aluminium welding systemjoke Alu-MASTEROwing to the special frequency range with optimised balance setting of up to 90% minus percentage, the tungsten electrode remains sharp even at maximum load while simulta-neously achieving a good cleaning effect. Excellent welding properties are obtained as a result.

Technical datajoke Alu-MASTER

Mains voltage 230 V, 50/60 Hz

Phases 1

Fuse 16 A slow-blow

Protection class IP 23

Insulation class H

Dimensions (H x L x W) 430 x 500 x 260 mm

Weight 26 kg

Standards EN 6097.4, IEC 974.1,

S / CE certification

No-load voltage 85 V

Max. output current 210 A

Primary constant power (TIG/Electrode)

c.d.f. 50/35 % 5,0 kvA

c.d.f. 100 % 3,7 kvA

Applicable in the temperature range 0 - 40 °C

Downslope 0 - 10 Sek.

(on final value)

Postsurge gas-flow time 2 - 16 sec.

Electrode welding

Welding current range 10 - 160 A

Welding current c.d.f 35 % 160 A (26 V)


TIG DC welding

HF ignition yes



Welding current c.d.f 100 % 130 A (15,2 V)

TIG AC welding

HF ignition yes

AC frequency range 30 - 200 Hz

Balance setting 10 - 90 %



Welding current c.d.f 100 % 130 A (15,2 V)

Aluminium welding system joke Alu-MASTER Order No. Price

Introductory set joke Alu-MASTER 0 084 661

The introductory set contains:1 x welding unit joke Alu-MASTER1 x earthing cable with crocodile clip1 x hand welding torch, large1 x foot controller

Welding unit joke Alu-MASTER 0 084 660

Basic unit without accessories

All accessory components of the multiSpot 2 system are compatible with the new joke Alu-MASTER (see page 10/11!)

16

5



Welding unit joke easyWIG

Welding unit joke easyWIGHigh-performance TIG unit with finest spark behaviour. The extremely stable electric arc facilitates welding even on complex compo-nent geographies.

The compact measurements and the ex-tremely low weight make this unit very handy and suitable for mobile applications. The optional foot controller further enhances its functionality.

Technical Datajoke easyWIG

Mains voltage 230 V, 50/60 Hz

Phases 1

Mains fuse 16 A slow-blow

Type of protection IP 23

Insulation class H

Dimensions (H x L x W) 340 x 365 x 165 mm

Weight 12.7 kg

Mark of conformity EN 6097.4, IEC 974.1, S /

CE identification

No-load voltage 85 V

Max. output current 165 A

Power consumption

Primary constant power (ED 60/40 % TIG/electrode) 4.4 kvA / 6 kvA

Temperature range 0 – 40 °C

Upslope/Downslope 0 - 20 sec.

(on final value)

Postsurge gas-flow time 0 - 25 sec.

Presurge gas-flow time 0.5 sec.

Electrode welding


for 10min/40 °C 40 % c.d.f. 140 A (25 V)

TIG DC welding

HF ignition yes


for 10min/40 °C 60 % c.d.f. 165 A (16.4 V)

for 10min/40 °C 10 % c.d.f. 120 A (14.0 V)

Welding unit joke easyWIG Order No. Price

Complete set joke easyWIG 0 084 650

The set contains:• joke easyWIG welding unit• Earthing cable with crocodile clip• Hand welding torch, small, with tipper

Welding unit joke easyWIG 0 084 651

Basic unit without accessories

Optionale accessories joke easyWIG Order No. Price

Hand welding torch, small, without tipper 0 008 360

with flexible burner head, capacity: DC 110 A / AC 95 A

Hand welding torch, small, with tipper 0 008 364

with flexible burner head, capacity: DC 110 A / AC 95 A

Foot volume controller for joke easyWIG 0 084 611

17

5



Compact stereomicroscopesfor welding workplaces

Settings for filter level and dimming(sensitivity and delay)

The eyepieces can be adapted to the observer’s eyes

Compact stereomicroscopes Order No. Price

Compact stereomicroscope with XXL working distance 0 008 332

This welding microscope leaves nothing to be desired. The extended working distance of approx. 225 mm allows trouble-free use even on workpiece geometries that are not readily accessible. Owing to the 10 x magnification, precise positioning and welding is possible. The first-rate glare protection cassette appeals by the following advantages: power supply by solar cell and button cell, variable degree of protec-tion 4/5-9 and 9-13 (DIN), variable sensitivity adjustment, dual-setting adjustment of opening delay, sensor slide for regulation of incidence of light from ambient light.

Technical data:Working distance approx. 225 mmMagnification 10 xFilter cassette degree of protection 4/5-9 and 9-13 (DIN)Scope of delivery stereomicroscope with filter cassette,

magnetic foot and flexible arm

Compact stereomicroscope with standard working distance 0 008 329

Brings the optics close to the welding point. Including automatic glare protection cassette and variable blackness value 4/9-13 (DIN). Sen-sitivity and delay can be regulated in two settings respectively. The 10 x magnification allows even more precise positioning and welding. The working distance between the glare protection cassette and the workpiece is approx. 57 mm. Energy supply by solar cells.

Technical data:Working distance approx. 57 mmMagnification 10 xFilter cassette degree of protection 4/9-13 (DIN)Scope of delivery stereomicroscope with filter cassette,

magnetic foot and flexible arm

Flexible bolt for compact stereomicroscope 0 008 329-3

For even greater flexibility in positioning the compact stereomicro-scope (order no. 0 008 329)

NEW!

18

5

Inno-Check



Universal workplace lightingwith magnetic foot and XXL swan neck

Magnetic foot with switch for

positioning on the workpiece

can be flexibly used in large moulds

XXL swan necks (each 800 mm) compatible with all joke cold light sources magnetic foot for rapid fixing

Universal workplace lighting Order No. Price

for direct connection to our cold light sources. Delivery incl. magnetic foot for positioning on the workpiece in addition to two XXL swan necks (each 800 mm) and a flexible fibre optic supply lead (2000 mm)

0 200 778

XXL swan neckssmallest bending radius 55 mm!

NEW!

Universal workplace lightingSpecially designed for lighting tasks in tool buil-ding as well as cutting and moulding. The magne-tic foot with a switch enables quick positioning of the swan neck fibre optics directly on the work piece. Thanks to the long, flexible feed line (2,000mm), the swan necks can be placed on large work pieces almost independently of the cold light source.

19

5

Best-seller!



Cold light sources P 100 W • P 150 W

Cold light sources P 100 W • P 150 WPowerful cold light source 100 or 150 watts of luminous power. For both models longlife illuminants as accessories are optionally available.

For both models brightness can be contin-uously adjusted by a rotary switch.The cold light sources are available without, with single swan-necked or double swan-necked light guide.

Cold light source P 100 W Order No. Price

without swan-necked light guide 0 200 710

with single swan-necked light guide, 53 cm 0 200 740

with double swan-necked light guide, 53 cm 0 200 700

Lamp Halogen 100 W, 12 VColour temperature 3200 KLamp service life approx. 50 hLight brightness by rotary switchCooling by fanDimensions (W x H x D) approx. 110 x 155 x 240 mmConnection voltage 230 V, 50/60 HzFuse 1 A, slow blowProtection class IP 20Weight without light guide approx. 4.0 kgWeight with light guide approx. 4.4 kg

Spare parts/accessories P 100 Order No. Price

Illuminant, halogen 100 W 0 200 721

Illuminant, halogen 100 W, Longlife 0 200 725

Lamp service life approx. 1500 h, colour temperature 3050K

Single swan-necked light guide, 53 cm 0 200 730

Double swan-necked light guide, 53 cm 0 200 720

Cold light source P 150 W Order No. Price

without swan-necked light guide 0 200 765

with single swan-necked light guide, 53 cm 0 200 766

with double swan-necked light guide, 53 cm 0 200 767

Lamp Halogen 150 W, 15 VColour temperature 3250 KLamp service life ca. 50 hLight brightness by rotary switchLength of light guide approx. 53 cmGlass fibre Ø 4 mmCooling by fanDimensions (W x H x D) approx. 230 x 200 x 120 mmConnection voltage 230 V, 50/60 HzFuse 1 A, slow blowProtection class IP 20Weight without light guide approx. 4.0 kgWeight with light guide approx. 4.4 kg

Spare parts/accessories P 150 W Order No. Price

Illuminant, halogen 150 W 0 200 768

Illuminant, halogen 150 W, Longlife 0 200 769

Lamp service life approx. 500 h, colour temperature 3050K

Single swan-necked light guide, 53 cm 0 200 730

Double swan-necked light guide, 53 cm 0 200 720

Illustr. shows model P 150 W

20

5


Flexible arm systemFor welding stations

Flexible arm systemThis Flexible arm system is the ideal supple-ment in order to make your work even easier when welding and optimise the results obtainable. You have a choice between a flexible arm for the machine torch recepta-cle on the cross table and two flexible arms with a magnetic foot as further accessories: work for example with the glare protection shield even without a welding helmet with the proper protection for your eyes at all times. With the stereomicroscopes likewise available with a flexible arm, you can place even finer welding seams on the workpiece.

Flexible arm system Order No. Price

Magnetic foot with flexible arm for welding torch 0 084 511

For flexible use of the cross table upper section in larger moulds. The upper section is push-fitted into the magnetic foot and can therefore be positioned almost everywhere. The flexible arm, by means of which the torch can be variably set in almost any desired working position, is installed on the cross table upper section using a locating bolt.

Glare protection shield with magnetic foot 0 008 328

This protection shield allows you to work safely even without a welding helmet! The glare protection cassette works with variable blackness values (DIN). Sensitivity and delay can be adjusted in two settings respectively. The power supply is provided by solar cells. Since work is performed without magnification in this case, the working distance can be variably configured.

21

5

i


5. Welding and coating systems // 5.2. Welding fillers

Welding fillers joke FillBasic principles / Overview

Welding filler Suitable for material no.

joke Fill 100 1.2343 • 1.2344 • 1.2082 • 1.2083 • 1.2367 • 1.2606 and similar

joke Fill 105 1.2713 • 1.2714 • 1.2740 • 1.2743 • 1.2744 • 1.2747 • 1.2764 • 1.2766 • 1.2767 and similar

joke Fill 110 1.2311 • 1.2312 • 1.2162 • 1.2738 and similar

joke Fill 115 connections and intermediate layers for almost all tool steels

joke Fill 120 crack-proof, elastic, high-strength bases and intermediate layers in addition to connections, including different steels


joke Fill 140 case hardening, quenched and tempered and hot-work steels

joke Fill 145 1.2343 • 1.2344 • 1.2362 • 1.2363 • 1.2367 and similar

joke Fill 150 STAVAX • 1.2083 • 1.2316 • 1.4115 • 1.4120 and similar

joke Fill 151 1.2072 • 1.2316 • 1.4015 and similar

joke Fill 155 1.2842 • 1.2762 • 1.2743 • 1.2721 • 1.2710 and similar

joke Fill 160 1.2358 • 1.2363 • CARMO • CALMAX and similar



joke Fill 185 1.2343 • 1.2344 and similar

joke Fill 190 1.2343 • 1.2344 • 1.2362 • 1.2367 • 1.2606

joke Fill 195 1.4301 • 1.4541 • 1.4571 and similar

joke Fill 200 1.2343 • 1.2344 • 1.2311 • 1.2312 • 1.2738 • 1.2767 and similar

joke Fill 230 eroding electrodes • point electrodes and most copper materials

joke Fill 240 Ampco 8 - 12 - 15 - 16 - 18 - 20 - 21 - M4 and similar bronzes

joke Fill 242 Ampcoloy • Moldmax and other copper materials

joke Fill 250 aluminium materials up to F30

joke Fill 255 aluminium materials up to F28

joke Fill 260 titanium and titanium alloys

joke Fill 350 1.3243 • 1.3245 • 1.3246 • 1.3249 • 1.3333 • 1.3340 • 1.3344 • 1.3346 • 1.3348 and similar

Welding fillers joke FillThe welding fillers from the joke Fill series are available for prac-tically all applications and in all diameters and grades. They are optimally chosen and are specifically tailored to the requirements of repair and modification welding in tool and mould building.

The fillers are optionally supplied on reels (50, 100, 150 and 500 g) or as straightened rods (300 or 500 mm length) respectively.

In addition to the already large selection of standard products, we also offer you many special solutions. Please consult Bernd Dörnern about this matter: Tel. +49 (0) 22 04 / 8 39-0

Guide analysis on request!Corresponding guide analyses for all welding fillers from our range are available on request.

22

5



Product information:Martensitic Cr-Mn filler with corrosion-resistant characteristics. Polishable, erodible, nitrable, etchible and hardenable. Temperable up to 2 layers. Ideal for structurally synchro-nous build-up layers on plastics, blow and injection moulds and compression moulds.

Achievable severities:First layer: approx. 48-56 HRC, de-pending on composition

Suitable for material Nos.:1.2343 • 1.2344 • 1.2082 • 1.2083 • 1.2367 • 1.2606 and similar

Product information:Cr-Ni-Mo-Mn filler with reduced carbon content. Additional stabilising elements to reduce hard carbide rims. Polishable, erod-ible, nitrable, etchible and heat treatable. Temperable up to 2 layers. For plastic and injection moulds, colour synchronous on 2-5 % nickelous tool steels. The weld metal can withstand temperature changes.

Achievable severities:First layer: approx. 360-420 HB

Suitable for material Nos.:1.2713 • 1.2714 • 1.2740 • 1.2743 • 1.2744 • 1.2747 • 1.2764 • 1.2766 • 1.2767

Laser welding fillers joke Fillspools and rods (300 mm)

joke Fill 100 Laser

joke Fill 105 Laser

Design Spools 50 g Spools 100 g Spools 150 g Spools 500 g Rods 75 g Rods 150 g

Dimensions Order No. Price Order No. Price Order No. Price Order No. Price Order No. Price Order No. Price

Ø 0.1 mm 0 084 011 0 084 011-M 0 084 011-2 0 084 011-4 - -

Ø 0.2 mm 0 084 012 0 084 012-M 0 084 012-2 0 084 012-4 - -

Ø 0.3 mm 0 084 013 0 084 013-M 0 084 013-2 0 084 013-4 0 084 013-8 0 084 013-7

Ø 0.4 mm 0 084 014 0 084 014-M 0 084 014-2 0 084 014-4 0 084 014-8 0 084 014-7

Ø 0.5 mm 0 084 015 0 084 015-M 0 084 015-2 0 084 015-4 0 084 015-8 0 084 015-7

Ø 0.6 mm 0 084 016 0 084 016-M 0 084 016-2 0 084 016-4 0 084 016-8 0 084 016-7



Ø 0.1 mm 0 084 031 0 084 031-M 0 084 031-2 0 084 031-4 - -

Ø 0.2 mm 0 084 032 0 084 032-M 0 084 032-2 0 084 032-4 - -

Ø 0.3 mm 0 084 033 0 084 033-M 0 084 033-2 0 084 033-4 0 084 033-8 0 084 033-7

Ø 0.4 mm 0 084 034 0 084 034-M 0 084 034-2 0 084 034-4 0 084 034-8 0 084 034-7

Ø 0.5 mm 0 084 035 0 084 035-M 0 084 035-2 0 084 035-4 0 084 035-8 0 084 035-7

Ø 0.6 mm 0 084 036 0 084 036-M 0 084 036-2 0 084 036-4 0 084 036-8 0 084 036-7

23

5


Product information:Cr-Mo-Mn filler with reduced carbon and silicon content. Additional stabilising elements to reduce hard carbide rims. Polishable, erod-ible, nitrable, etchible and heat treatable. The weld metal is synchronous to structure and treatment of parent material.

Achievable severities:First layer approx. 360-400 HB

Suitable for material Nos.:1.2311 • 1.2312 • 1.2162 • 1.2738 and similar

Product information:Cr-Ni-Mo-Mn filler, heat and corrosion-proof. The weld metal is temperable, but cold hard-ening through pressure/impact. Polishable and erodible, but not nitrable and chrome-platable. Suitable for base and intermediate layers as well as compounds on most tool steels.

Achievable severities:Hardness first layer: approx. 320-370 HB, expansion up to 33 % max. - tensile strength ca. 820-880 N/mm²

Suitable for material Nos.:various

joke Fill 110 Laser

joke Fill 115 Laser




Ø 0.1 mm 0 084 051 0 084 051-M 0 084 051-2 0 084 051-4 - -

Ø 0.2 mm 0 084 052-1 0 084 052-M 0 084 052-2 0 084 052-4 - -

Ø 0.3 mm 0 084 053 0 084 053-M 0 084 053-2 0 084 053-4 0 084 053-8 0 084 053-7

Ø 0.4 mm 0 084 054 0 084 054-M 0 084 054-2 0 084 054-4 0 084 054-8 0 084 054-7

Ø 0.5 mm 0 084 055 0 084 055-M 0 084 055-2 0 084 055-4 0 084 055-8 0 084 055-7

Ø 0.6 mm 0 084 056 0 084 056-M 0 084 056-2 0 084 056-4 0 084 056-8 0 084 056-7



Ø 0.3 mm 0 084 073 0 084 073-M 0 084 073-2 0 084 073-4 0 084 073-8 0 084 073-7

Ø 0.4 mm 0 084 074 0 084 074-M 0 084 074-2 0 084 074-4 0 084 074-8 0 084 074-7

Ø 0.6 mm 0 084 076 0 084 076-M 0 084 076-2 0 084 076-4 0 084 076-8 0 084 076-7

24

5




Product information:Nickel-based filler with Cr-Mo-Mn-Fe-Nb and elements to avoid hard carbide transitions. Corrosion, acid, heat-proof and extremely cold-resistant. Erodible and polishable. Not nitrable, temperable or chrome platable. For crack-proof, elastic, tough hardened bases and intermediate layers as well as almost all possible compounds of various steels such as GS, GG – GGG 70.

Achievable severities:First layer: approx. 220-250 HB, expansion up to 46 % max. - tensile strength approx. 700-760 N/mm²


Product information:Cr-Mo-Mn-Vanadine filler for hot-work steels. Polishable, erodible, nitritable, etchible and heat treatable. Can be hardened to approx. 58 HRC. For plastic, blowing and injection moulds. Readily machinable. Shock-tempera-ture resistant.

Achievable severities:First layer: approx. 46-52 HRC.


joke Fill 120 Laser

joke Fill 125 Laser



Ø 0.1 mm 0 084 091 0 084 091-M 0 084 091-2 0 084 091-4 - -

Ø 0.2 mm 0 084 092 0 084 092-M 0 084 092-2 0 084 092-4 - -

Ø 0.3 mm 0 084 093 0 084 093-M 0 084 093-2 0 084 093-4 0 084 093-8 0 084 093-7

Ø 0.4 mm 0 084 094 0 084 094-M 0 084 094-2 0 084 094-4 0 084 094-8 0 084 094-7

Ø 0.5 mm 0 084 095 0 084 095-M 0 084 095-2 0 084 095-4 0 084 095-8 0 084 095-7

Ø 0.6 mm 0 084 096 0 084 096-M 0 084 096-2 0 084 096-4 0 084 096-8 0 084 096-7



Ø 0.25 mm 0 084 112 0 084 112-M 0 084 112-2 0 084 112-4 - -

Ø 0.3 mm 0 084 113 0 084 113-M 0 084 113-2 0 084 113-4 0 084 113-8 0 084 113-7

Ø 0.4 mm 0 084 114 0 084 114-M 0 084 114-2 0 084 114-4 0 084 114-8 0 084 114-7

Ø 0.5 mm 0 084 115 0 084 115-M 0 084 115-2 0 084 115-4 0 084 115-8 0 084 115-7

Ø 0.6 mm 0 084 116 0 084 116-M 0 084 116-2 0 084 116-4 0 084 116-8 0 084 116-7

25

5




Product information:High-alloy Co-Cr-Mo-Mn-W-Fe filler for many heat-treated, case-hardened and heat-resistant steels with universal charac-teristics. Suitable for nitrided steels, edge and acid-proof. Not chrome-platable. Polishable, but only delayed erodible. Structure thermally very resistant.

Achievable severities:First layer: aprox. 24-36 HRC. Through artificial ageing and pressure/impact, the hardness can be enhanced by up to 35 %! Expansion approx. 18-25 %.


Product information:Cr-Mo-V-W filler with stabilising elements. Dense structure. Air-hardening and shock-temperable. Edge and highly heat-proof. Conditionally chrome-platable; polishable, erodible, nitritable, etchible and heat treatable. Good heat conduction properties. For aluminium and zinc die cast moulds, structures and slide tolls.

Achievable severities:First layer: approx. 56-59 HRC. Through multi-layer welding hardenable to approx. 58 HRC.

Suitable for material Nos.:1.2343 • 1.2344 • 1.2362 • 1.2363 • 1.2367and similar

joke Fill 140 Laser

joke Fill 145 Laser



Ø 0.1 mm 0 084 131 0 084 131-M 0 084 131-2 0 084 131-4 - -

Ø 0.2 mm 0 084 132 0 084 132-M 0 084 132-2 0 084 132-4 - -

Ø 0.3 mm 0 084 133 0 084 133-M 0 084 133-2 0 084 133-4 0 084 133-8 0 084 133-7

Ø 0.4 mm 0 084 134 0 084 134-M 0 084 134-2 0 084 134-4 0 084 134-8 0 084 134-7

Ø 0.5 mm 0 084 135 0 084 135-M 0 084 135-2 0 084 135-4 0 084 135-8 0 084 135-7

Ø 0.6 mm 0 084 136 0 084 136-M 0 084 136-2 0 084 136-4 0 084 136-8 0 084 136-7



Ø 0.25 mm 0 084 152 0 084 152-M 0 084 152-2 0 084 152-4 - -

Ø 0.3 mm 0 084 153 0 084 153-M 0 084 153-2 0 084 153-4 0 084 153-8 0 084 153-7

Ø 0.4 mm 0 084 154 0 084 154-M 0 084 154-2 0 084 154-4 0 084 154-88 0 084 154-7

Ø 0.5 mm 0 084 155 0 084 155-M 0 084 155-2 0 084 155-4 0 084 155-8 0 084 155-7

Ø 0.6 mm 0 084 156 0 084 156-M 0 084 156-2 0 084 156-4 0 084 156-8 0 084 156-7

26

5




Product information:Martensitic Cr filler with stabilising ele-ments. Polishable, erodible, nitrable, etchible and temperable. Not chrome-palatable! Corrosion- and wear-proof. For GRP plastic and blow moulds.

Achievable severities:First layer: approx. 48-54 HRC, depending on composition Can be hardened to approx. 60 HRC.

Suitable for material Nos.:STAVAX • 1.2083 • 1.2316 • 1.4115 • 1.4120 and similar

Product information:Cr filler with stabilising elements, polisha-ble, erodible, nitratable and heat-treatable. Non-chrome-platable! Rust-proof and corrosion-proof. For build-up layers and connections on steels of identical and similar

type, such as 1.2074, 1.2316, 1.4015 etc. The welded material is resistant to seawater, dilute and anorganic acids, heat-proof to air and oxidising incinerating plants up to 950ºC, in addition to combustion gases containing sulphur at high temperatures.

Achievable severities:approx. HB 240-310. HRC approx. 24-31.

joke Fill 150 Laser

joke Fill 151 Laser



Ø 0.1 mm 0 084 171 0 084 171-M 0 084 171-2 0 084 171-4 - -

Ø 0.2 mm 0 084 172 0 084 172-M 0 084 172-2 0 084 172-4 - -

Ø 0.3 mm 0 084 173 0 084 173-M 0 084 173-2 0 084 173-4 0 084 173-8 0 084 173-7

Ø 0.4 mm 0 084 174 0 084 174-M 0 084 174-2 0 084 174-4 0 084 174-8 0 084 174-7

Ø 0.5 mm 0 084 175 0 084 175-M 0 084 175-2 0 084 175-4 0 084 175-8 0 084 175-7

Ø 0.6 mm 0 084 176 0 084 176-M 0 084 176-2 0 084 176-4 0 084 176-8 0 084 176-7



Ø 0.4 mm 0 084 194-1 0 084 194-7M 0 084 194-7 0 084 194-4 0 084 189-1A 0 084 189-1

Ø 0.5 mm 0 084 194-2 0 084 194-8M 0 084 194-8 0 084 194-5 0 084 189-2A 0 084 189-2

Ø 0.6 mm 0 084 194-3 0 084 194-9M 0 084 194-9 0 084 194-6 0 084 189-3A 0 084 189-3

27

5




Product information:Universal Cr-Mn-Al-Ti filler for cold-cutting applications and heat-treated steels. Nitritable, crack- and abrasion-proof. Inductive- and flame-hardenable. Good suitability also for sealing and clo-sing edges of plastic blow moulds.

Achievable severities:First layer: approx. 56-60 HRC, depending on composition. Can be hardened to approx. 62 HRC

Suitable for material Nos.:1.2842 • 1.2762 • 1.2743 • 1.2721 • 1.2710and similar

Product information:Cr-Mo-Mn-W-V filler with extremely wear-proof and tough hardened characteristics. Suitable for hard build-up layers on cold-work steels with more than 5 % chrome content. Crack-proof and fast hardening, good edge stability. Thermally treatable like parent material. The weld metal is nitritable, erodible, chrome platable and heat treatable.

Achievable severities:First layer: approx. 58-60 HRC, depending on composition. Can be hardened to approx. 62 HRC.

Suitable for material Nos.:1.2358 • 1.2363 • CARMO • CALMAX and similar

joke Fill 155 Laser

joke Fill 160 Laser



Ø 0.25 mm 0 084 1925 0 084 1925-M 0 084 1925-2 0 084 1925-4 - -

Ø 0.3 mm 0 084 1933 0 084 1933-M 0 084 1933-2 0 084 1933-4 0 084 1933-8 0 084 1933-7

Ø 0.4 mm 0 084 1944 0 084 1944-M 0 084 1944-2 0 084 1944-4 0 084 1944-8 0 084 1944-7

Ø 0.5 mm 0 084 195 0 084 195-M 0 084 195-2 0 084 195-4 0 084 195-8 0 084 195-7

Ø 0.6 mm 0 084 196 0 084 196-M 0 084 196-2 0 084 196-4 0 084 196-8 0 084 196-7



Ø 0.3 mm 0 084 213 0 084 213-M 0 084 213-2 0 084 213-4 0 084 213-8 0 084 213-7

Ø 0.4 mm 0 084 214 0 084 214-M 0 084 214-2 0 084 214-4 0 084 214-8 0 084 214-7

Ø 0.5 mm 0 084 215 0 084 215-M 0 084 215-2 0 084 215-4 0 084 215-8 0 084 215-7

Ø 0.6 mm 0 084 216 0 084 216-M 0 084 216-2 0 084 216-4 0 084 216-8 0 084 216-7

28

5



Product information:Cr-Mn-Si-V welding filler with structure-stabilising elements. Not chrome-platable, but nitritable and erodible. The weld metal is very similar to 12 % Cr steels.

Achievable severities:First layer: approx. 58-60 HRC, depending on composition. Can be hardened to approx. 62 HRC.


joke Fill 165 Laser

Product information:Cr-Mo-Mn-V filler with hardenable cha-racteristics. Very tough with good edge retention. Particularly suitable for quick repairs. Nitrable, erodible and chrome platable. Air- and flame-hardenable.

Achievable severities:First layer: approx. 56-59 HRC, depending on composition. Hardenable to approx. 60 HRC.


joke Fill 180 Laser



Ø 0.1 mm 0 084 231 0 084 231-M 0 084 231-2 0 084 231-4 - -

Ø 0.2 mm 0 084 232 0 084 232-M 0 084 232-2 0 084 232-4 - -

Ø 0.3 mm 0 084 233 0 084 233-M 0 084 233-2 0 084 233-4 0 084 233-8 0 084 233-7

Ø 0.4 mm 0 084 234 0 084 234-M 0 084 234-2 0 084 234-4 0 084 234-8 0 084 234-7

Ø 0.5 mm 0 084 235 0 084 235-M 0 084 235-2 0 084 235-4 0 084 235-8 0 084 235-7

Ø 0.6 mm 0 084 236 0 084 236-M 0 084 236-2 0 084 236-4 0 084 236-8 0 084 236-7



Ø 0.25 mm 0 084 252 0 084 252-M 0 084 252-2 0 084 252-4 - -

Ø 0.3 mm 0 084 253 0 084 253-M 0 084 253-2 0 084 253-4 0 084 253-8 0 084 253-7

Ø 0.4 mm 0 084 254 0 084 254-M 0 084 254-2 0 084 254-4 0 084 254-8 0 084 254-7

Ø 0.5 mm 0 084 255 0 084 255-M 0 084 255-2 0 084 255-4 0 084 255-8 0 084 255-7

Ø 0.6 mm 0 084 256 0 084 256-M 0 084 256-2 0 084 256-4 0 084 256-8 0 084 256-7

29

5




Product information:Cr-Ni-Mo filler for connection weldings of many chrome-nickel steels, including welding to one another. Rustproof and acid-proof. Polishable and erodible, but not hardenable, nitratable and chrome-platable. Also suitable for buffer layers with hard build-up layers.

Achievable severities:First layer: approx. 300-350 HB. Expansion max. approx. 35%, tensile strength approx. 720-760 N/mm2.

Suitable for material Nos.:1.4301 • 1.4541 • 1.4571 and similar

joke Fill 195 Laser

Product information:Ni-Co-Mo filler especially for aluminium and zinc die casting. This martensitic weld metal is crack-proof and tough. Through artificial ageing, hardness of ca. 50-54 HRC can be achieved. Not chrome-platable.

Achievable severities:First layer: approx. 40-46 HRC, depending on composition.

Suitable for material Nos.:1.2343 • 1.2344 and similar

joke Fill 185 Laser

Product information:Suitable for repairs on hot-work steel. Good heat conducting properties. Nitrable.

Achievable severities:First layer: 42-48 HRC.

Suitable for material Nos.:1.2343 • 1.2344 • 1.2362 • 1.2367 • 1.2606

joke Fill 190 Laser



Ø 0.2 mm 0 084 312 0 084 312-M 0 084 312-2 0 084 312-4 - -

Ø 0.3 mm 0 084 313 0 084 313-M 0 084 313-2 0 084 313-4 0 084 313-8 0 084 313-7

Ø 0.4 mm 0 084 314 0 084 314-M 0 084 314-2 0 084 314-4 0 084 314-8 0 084 314-7

Ø 0.5 mm 0 084 315 0 084 315-M 0 084 315-2 0 084 315-4 0 084 315-8 0 084 315-7

Ø 0.6 mm 0 084 316 0 084 316-M 0 084 316-2 0 084 316-4 0 084 316-8 0 084 316-7



Ø 0.3 mm 0 084 273 0 084 273-M 0 084 273-2 0 084 273-4 0 084 273-8 0 084 273-7

Ø 0.4 mm 0 084 274 0 084 274-M 0 084 274-2 0 084 274-4 0 084 274-8 0 084 274-7

Ø 0.6 mm 0 084 276 0 084 276-M 0 084 276-2 0 084 276-4 0 084 276-8 0 084 276-7



Ø 0.3 mm 0 084 293 0 084 293-M 0 084 293-2 0 084 293-4 0 084 293-8 0 084 293-7

Ø 0.4 mm 0 084 294 0 084 294-M 0 084 294-2 0 084 294-4 0 084 294-8 0 084 294-7

Ø 0.5 mm 0 084 295 0 084 295-M 0 084 295-2 0 084 295-4 0 084 295-8 0 084 295-7

Ø 0.6 mm 0 084 296 0 084 296-M 0 084 296-2 0 084 296-4 0 084 296-8 0 084 296-7

30

5




Product information:Cr-Mo-W-Si filler for aluminium and zinc die cast moulds made predominantly from 5% chrome steel. Also for plastic moulds with edge wear, when hardness and toughness is required. Polishable, not etchible, condition-ally chrome platable, resistant to temperature change.

Achievable severities:First layer: approx. 52-58 HRC, depending on composition. Can be hardened to approx. 60 HRC. Annealed approx. 230 HB at 770 °C.

Suitable for material Nos.:1.2343 • 1.2344 • 1.2311 • 1.2312 • 1.2738 • 1.2767and similar

joke Fill 200 Laser

Product information:Cu-Ag-Cr-Fe filler with very good electric and heat conducting characteristics. Intensive cooling from -20 °C results in up to 30% im-proved hardness! Suitable for compounds of copper/bronze with steel.

Achievable severities:First layer: approx. 70-90 HB. Expansion approx. 25-35 %. Tensile strength approx. 290-340 N/mm2.

Suitable for material Nos.:Eroding electrodes • Point electrodesand most copper materials

joke Fill 230 Laser



Ø 0.1 mm 0 084 331 0 084 331-M 0 084 331-2 0 084 331-4 - -

Ø 0.2 mm 0 084 332 0 084 332-M 0 084 332-2 0 084 332-4 - -

Ø 0.3 mm 0 084 333 0 084 333-M 0 084 333-2 0 084 333-4 0 084 333-8 0 084 333-7

Ø 0.4 mm 0 084 334 0 084 334-M 0 084 334-2 0 084 334-4 0 084 334-8 0 084 334-7

Ø 0.5 mm 0 084 335 0 084 335-M 0 084 335-2 0 084 335-4 0 084 335-8 0 084 335-7

Ø 0.6 mm 0 084 336 0 084 336-M 0 084 336-2 0 084 336-4 0 084 336-8 0 084 336-7



Ø 0.2 mm 0 084 412 0 084 412-M 0 084 412-2 0 084 412-4 - -

Ø 0.3 mm 0 084 413 0 084 413-M 0 084 413-2 0 084 413-4 0 084 413-8 0 084 413-7

Ø 0.4 mm 0 084 414 0 084 414-M 0 084 414-2 0 084 414-4 0 084 414-8 0 084 414-7

Ø 0.5 mm 0 084 415 0 084 415-M 0 084 415-2 0 084 415-4 0 084 415-8 0 084 415-7

31

5




Product information:Al-Mn-Cu-Fe filler. Multi-alloy bronze with very good dry running characteristics on steels with good heat conductivity. Crack-free and non-porous. No hardened joints when applied to steel. Very low shrinkage rate.

Also suitable for crack welding on cool chan-nels and plastic moulds.

Achievable severities:First layer on steel: approx. 220-280 HB.First layer on bronze: approx. 200-240 HB.Improved hardness by approx. 30% through intensive cooling!

joke Fill 240 Laser

Product information:Cu-Ni-Si filler with good conductive char-acteristics. Loy-specific colour characteris-tics. Intensive cooling from -20° C results in improved hardness by up to 30%. Suitable for joining copper/bronze with steel.

Achievable severities:First layer: approx. 60 - 84 HB. Expansion approx. 23 - 32 %,Tensile strength approx. 200 - 280 N/mm2.

Suitable for material Nos.:Ampcoloy • Moldmax and other copper materials

Product information:Al filler with very high suitability for quick repairs on aluminium section steels. Fine-flowing. Perfect, non-porous surface fusing even for difficult applications.

Suitable for material Nos.:Aluminium materials up to F30

joke Fill 242 Laser

joke Fill 250 Laser



Ø 0.2 mm 0 084 432 0 084 432-M 0 084 432-2 0 084 432-4 - -

Ø 0.3 mm 0 084 433 0 084 433-M 0 084 433-2 0 084 433-4 0 084 433-8 0 084 433-7

Ø 0.4 mm 0 084 434 0 084 434-M 0 084 434-2 0 084 434-4 0 084 434-8 0 084 434-7

Ø 0.5 mm 0 084 435 0 084 435-M 0 084 435-2 0 084 435-4 0 084 435-8 0 084 435-7

Ø 0.6 mm 0 084 436 0 084 436-M 0 084 436-2 0 084 436-4 0 084 436-8 0 084 436-7



Ø 0.3 mm 0 085 013 0 085 013-M 0 085 013-2 0 085 013-4 0 085 013-8 0 085 013-7

Ø 0.4 mm 0 085 014 0 085 014-M 0 085 014-2 0 085 014-4 0 085 014-8 0 085 014-7

Ø 0.5 mm 0 085 015 0 085 015-M 0 085 015-2 0 085 015-4 0 085 015-8 0 085 015-7



Ø 0.3 mm 0 084 453 0 084 453-M 0 084 453-2 0 084 453-4 0 084 453-8 0 084 453-7

Ø 0.4 mm 0 084 454 0 084 454-M 0 084 454-2 0 084 454-4 0 084 454-8 0 084 454-7

Ø 0.5 mm 0 084 455 0 084 455-M 0 084 455-2 0 084 455-4 0 084 455-8 0 084 455-7

Ø 0.6 mm 0 084 456 0 084 456-M 0 084 456-2 0 084 456-4 0 084 456-8 0 084 456-7

32

5

i




How many metres are on a spool (50 g) ?The different specific weights of the materials result in the listed lengths with the same spool weight:

Diameter Steel Copper Aluminium Aluminium bronze

0.1 mm 806 m - - -

0.2 mm 200 m - - -

0.25 mm 128 m - - -

0.3 mm 89 m 81 m 278 m 89 m

0.4 mm 50 m 45 m 151 m 51 m

0.5 mm 36 m 29 m - -

0.6 mm 22 m - 69 m 33 m

Product information:Al filler for use with the most important wrought aluminium alloys in mould making. Anodisable and polishable. Low heating and cooling aging. Zinc-Alu alloys must be fumigated through multiple overmelting.

Suitable for material Nos.:Aluminium materials F28 and above

Product information:Titanium welding filler for joint and build-up welding on titanium and titanium alloys. Most frequently used filler for components in general medicine and dentistry, aero-nautical and space technology. Largely corresponds to material No. 3.7025.

Suitable for material Nos.:Titanium and titanium alloys

joke Fill 255 Laser

joke Fill 260 Laser



Ø 0.3 mm 0 084 473 0 084 473-M 0 084 473-2 0 084 473-4 0 084 473-8 0 084 473-7

Ø 0.4 mm 0 084 474 0 084 474-M 0 084 474-2 0 084 474-4 0 084 474-8 0 084 474-7

Ø 0.6 mm 0 084 476 0 084 476-M 0 084 476-2 0 084 476-4 0 084 476-8 0 084 476-7

Design Spools rolled (1 m)

Dimensions Order No. Price

Ø 0.3 mm 0 085 485

Ø 0.5 mm 0 085 486

33

5



Welding filler joke Fill 115 - TIG Design Dimensions Weight Order No. Price *

Rods 500 mm Ø 0.8 mm 500 g 0 084 061

Ø 1.0 mm 1.000 g 0 084 062

Ø 1.2 mm 1.000 g 0 084 063

Ø 1.6 mm 1.000 g 0 084 064

For compounds and intermediate layers on hard cold-work stainless steels. Structure: tough, elastic, rust-free, crack-proof, erodible. Not heat-treatable or chrome-platable.

Suitable for material Nos.: various

TIG welding fillers joke FillRods 500 mm


Rods 500 mm Ø 0.8 mm 500 g 0 084 001

Ø 1.0 mm 1.000 g 0 084 002

Ø 1.2 mm 1.000 g 0 084 003

Ø 1.6 mm 1.000 g 0 084 004


Rods 500 mm Ø 0.8 mm 500 g 0 084 021

Ø 1.0 mm 1.000 g 0 084 022

Ø 1.2 mm 1.000 g 0 084 023

Ø 1.6 mm 1.000 g 0 084 024


Rods 500 mm Ø 0.8 mm 500 g 0 084 041

Ø 1.0 mm 1.000 g 0 084 042

Ø 1.2 mm 1.000 g 0 084 043

Ø 1.6 mm 1.000 g 0 084 044

For heat-treated and stainless steels. Etchible, erodible and polishable. Nitrable, chrome-platable. Note thermic pre- and post-treatment


For structurally synchronous build-up layers on steel. Etchible, erodible, structurable and polish-able. Chrome-platable, coatable and heat-treatable. Note thermic normalisation.

Suitable for material Nos.: 1.2713 • 1.2714 • 1.2740 1.2743 • 1.2744 • 1.2747 1.2764 • 1.2766 • 1.2767 and similar

For structurally synchronous build-up layers on acidic and wear-proof injection moulding steels. Chrome-platable and coatable. Etchible, erodible, polishable and heat-treatable.

Suitable for material Nos.: 1.2343 • 1.2344 • 1.2082 • 1.2083 • 1.2367 • 1.2606and similar

* plus alloy surcharge




34

5




Rods 500 mm Ø 0.8 mm 500 g 0 084 081

Ø 1.0 mm 1.000 g 0 084 082

Ø 1.2 mm 1.000 g 0 084 083

Ø 1.6 mm 1.000 g 0 084 084

For compounds and intermediate layers on hot-work and stainless steels. Structure: tough, elastic, corrosion, acid and crack-proof, erodible. Not heat-treatable, nitrable or chrome-platable.

Suitable for material Nos.: various


Rods 500 mm Ø 0.8 mm 500 g 0084101

Ø 1.0 mm 1.000 g 0084102

Ø 1.2 mm 1.000 g 0084103

Ø 1.6 mm 1.000 g 0084104

Filler for hot-work steels. Heat-treatable and an-nealable similar to parent material. Structurally synchronous or similar to many hot-work steels. Tension-regulating in the Martensite area. Chrome-platable. Hardness of weld metal 34 to 42 HRC, depending on composition of parent materials.Hardenable to approx. 58 HRC.

Suitable for material No. 1.2343 • 1.2344 • 1.2360 • 1.2362 and similar


Rods 500 mm Ø 0.8 mm 500 g 0 084 121

Ø 1.0 mm 1.000 g 0 084 122

Ø 1.2 mm 1.000 g 0 084 123

Ø 1.6 mm 1.000 g 0 084 124

High-alloy Cr-Co-Mn-Mo-W-Fe welding filler with universal characteristics for use on case-hardened, heat-treated and hot-work steels. Corrosion, acid and scale-proof. Good surface fusing with nitrated steels. Not chrome-platable and nitrable.

Suitable for material Nos. 1.2713 • 1.2343 • 1.2767 and similar



Rods 500 mm Ø 0.8 mm 500 g 0 084 141

Ø 1.0 mm 1.000 g 0 084 142

Ø 1.2 mm 1.000 g 0 084 143

Ø 1.6 mm 1.000 g 0 084 144

Air-hardening characteristics of 48 - 56 HRC. Etchible, erodible and polishable. Chrome-platable and coatable. Note thermic normalisation.

Suitable for material Nos. 1.2343 • 1.2344 • 1.2362 • 1.2363 • 1.2367 and similar





35

5




Rods 500 mm Ø 1.0 mm 1.000 g 0 084 182

Ø 1.2 mm 1.000 g 0 084 183

Ø 1.6 mm 1.000 g 0 084 184


Rods 500 mm Ø 1.0 mm 1.000 g 0 084 202

Ø 1.2 mm 1.000 g 0 084 203

Ø 1.6 mm 1.000 g 0 084 204

Suitable for hard build-up layers on cold-work steels and forming dies with more than 5% chrome content. Air-hardening character-istics to approx. 61 HRC. Thermally treatable like parent material. In the case of more than 3 layers: 1 x base layer with joke Fill 115. Nitrable, erodible, polishable and etchible. Chrome-platable and coatable.

Suitable for material Nos. 1.2379 • 1.2601 • 1.2436 • 1.2080 • 1.2363 and similar

Medium-alloy Cr-Mn-Al-Ti filler for nitrided and case-hardened steels as well as low and medium-alloyed heat-treated steels. The weld metal is highly hardenable and very nitrable. Crack-proof even with multi-layer welding. Highly abrasion-proof. Chrome-platable, but not very etchible. Best gliding properties against high-alloy materials. Hardness of weld metal: 50-54 HRC. Through flame hardening up to 64 HRC. Nitrided up to approx. 69 HRC (500 degrees).

Suitable for material Nos.: Nitrided steels • case-hardened steels • heat-treated steels (low and medium-alloyed)


Rods 500 mm Ø 1.0 mm 1.000 g 0 084 162

Ø 1.2 mm 1.000 g 0 084 163

Ø 1.6 mm 1.000 g 0 084 164

This martensitic chrome material contains stabilising additives and is also suitable for alloy-like steels. Heat-treatable, rust- and wear-proof. Polishable, erodible and nitrable. Conditionally etchible, not chrome-platable.Hardness of weld metal: 45 - 50 HRC.

Suitable for material Nos. STAVAX • 1.2083 • 1.2316 • 1.4115 and similar







Rods 500 mm Ø 0.8 mm 500 g 0 084 190

Ø 1.0 mm 1.000 g 0 084 191

Ø 1.2 mm 1.000 g 0 084 192

Ø 1.6 mm 1.000 g 0 084 193

Cr-Mn-Mo-Si filler with low carbon content. Heat-resistant up to 600°C, tough at sub-zero temperatures up to approx. -60 °C. Nitrat-able and chrome-platable. The fine-flowing material is particularly suitable for heat-resistant and quenched and tempered steels and case hardening steels from the vessel, pipe and apparatus building field in the oil industry. Expansion approx. 20 - 28%. Hardness approx. 230 - 340 HB, depending on the mixture. Tensile strength approx. 890 N/mm2. Annealed up to approx. 1350 N/mm2.

suitable for material no.:Fk construction steel • low-alloy chrome steels • quenched and tempered steels • heat-resistant steels

36

5




Rods 500 mm Ø 0.8 mm 500 g 0 084 221

Ø 1.0 mm 1.000 g 0 084 222

Ø 1.2 mm 1.000 g 0 084 223

Ø 1.6 mm 1.000 g 0 084 224

Welding filler for modifications in soft condition with subsequent hardening and tempering. Highly chippable and coatable.

Suitable for material No. 1.2379 • 1.2080 • 1.2436 • 1.2601 and similar


Rods 500 mm Ø 0.8 mm 500 g 0 084 241

Ø 1.0 mm 1.000 g 0 084 242

Ø 1.2 mm 1.000 g 0 084 243

Ø 1.6 mm 1.000 g 0 084 244

For quick repair of hard cold-work and forming dies. Hardness after air cooling: 58 – 61 HRC. In the case of multiple layers: 1 x base layer with joke Fill 115.

Suitable for material Nos.: 1.2379 • 1.2080 • 1.2436 • 1.2601 and similar


Rods 500 mm Ø 0.8 mm 500 g 0 084 281

Ø 1.0 mm 1.000 g 0 084 282

Ø 1.2 mm 1.000 g 0 084 283

Ø 1.6 mm 1.000 g 0 084 284

Suitable for repairs on hot-work steel. Good heat conductivity. Nitrable. Hardness 42-48 HRC.

Suitable for material Nos.: 1.2343 • 1.2344 • 1.2362 • 1.2367 • 1.2606


Rods 500 mm Ø 1.0 mm 1.000 g 0 084 262

Ø 1.2 mm 1.000 g 0 084 263

Ø 1.6 mm 1.000 g 0 084 264

Improves durability for build-up layers on hot-work steels. Compression moulding dies, aluminium die cast moulds, closing edges, hot cutting tools.

Suitable for material Nos.: 1.2343 • 1.2344 • 1.2714 and similar






37

5




Rods 500 mm Ø 0.8 mm 500 g 0 084 341

Ø 1.0 mm 1.000 g 0 084 342

Ø 1.2 mm 1.000 g 0 084 343

Ø 1.6 mm 1.000 g 0 084 344

Cr-Mo-Si-W-Mn-V filler for plastic moulds with edge wear, when hardness and toughness are required. Not etchible, only conditionally chrome-platable. The mould metal is temperature change-resistant similar to temperature-conducting hot-work steels, but with better durability. Hardness 52-58 HRC, depending on composition and pre-heating of the parent material.Can be hardened to approx. 62 HRC.

Suitable for material Nos. 1.2311 1.2312 1.2343 1.2344 1.2603 1.2738 1.27441.2767 1.2842 and similar


Rods 500 mm Ø 1.2 mm 1.000 g 0 084 403

Ø 2.0 mm 1.000 g 0 084 405

Welding filler with hardening elements for copper and its alloys. Cu – CuBe – CuNiCr. Tough and crack-proof on steel. High electrical conductivity.HB 90. after intensive cooling up to 130 HB

Suitable for material Nos.: Eroding electrodes • point electrodes and most copper materials


Rods 500 mm Ø 0.8 mm 500 g 0 084 421

Ø 1.0 mm 1.000 g 0 084 422

Ø 1.2 mm 1.000 g 0 084 423

Ø 1.6 mm 1.000 g 0 084 424

Super aluminium-bronze welding filler. Tough, crack and wear-proof. No hardness increase with steel. Suitable for (Ampco) 8 – 12 – 15 – 16 – 18 – 20 ~ 21 ~ M-4 and similar bronzes.Hardness HB 240, through intensive cooling up to 300 HB.


Rods 500 mm Ø 0.8 mm 500 g 0 084 321

Ø 1.0 mm 1.000 g 0 084 322

Ø 1.2 mm 1.000 g 0 084 323

Ø 1.6 mm 1.000 g 0 084 324

Cr-Ni-Mo filler for joint welding of many chrome-nickel steels, even with each other. Corrosion- and acid-proof. Polishable and erodible, but not hardenable, nitritable and chrome-platable. Also suitable for puffer layers with hard build-ups.

Suitable for material Nos.: 1.4301 • 1.4306 • 1.4401 • 1.4404 • 1.4541 • 1.4571 and similar






38

5




Rods 500 mm Ø 1.0 mm 1.000 g 0 084 442

Ø 1.6 mm 1.000 g 0 084 444

Special aluminium alloy, Al-Mg-Si, fine-flowing, e.g. for repair of Al-Zn Pb (Zamag) tools. Note thermic treatment for maximal values

Suitable for material Nos.: Aluminium materials up to F30


Rods 500 mm Ø 1.6 mm 1.000 0 084 464Al-Mg-Mn-Cu filler. For wrought aluminium alloys from F 28 to F 53. Condition-changing through cold and hot aging. Increased hardness achievable through compression hardening. Particularly suit-able for repairs on plastic moulds and tool inserts. The hardness is dependent on the composition to the parent material and can vary between approx. 280 - 420 N/mm2 depending on the condition.

Suitable for material Nos.: Aluminium materials F28 and above


Rods 500 mm Ø 1.6 mm 1.000 g 0 085 004Cu-Ni-Si filler with good conductive characteris-tics. Loy-specific colour characteristics. Intensive cooling from -20 °C results in improved hardness by up to 30%. Suitable for joining copper/bronze with steel.

Hardness first layer: approx. 60 - 84 HB. Expansion approx. 23 - 32 %, tensile strength approx. 200 - 280 N/mm2.

Suitable for material Nos.: Ampcoloy • Moldmax and other copper materials


Rods 500 mm Ø 1,0 mm 1000 g 0 084 489

Ø 1,2 mm 1000 g 0 084 490

Ø 1,6 mm 1000 g 0 084 491

High-alloy Mo-Cr-W-V filler. The thermal hardness corresponds to super-speed steel (HSS). Pressure, abrasion and impact-proof. Also extremely crack-proof, even in case of multilayer build-up layers. Observe preheating: high-speed steels approx. 400 – 500 ºC, Cr tool steels: approx. 300 – 40 ºC.

Hardness approx. 57 – 62 HRC, hardened to 66 HRC. Soft-annealed approx. 230 – 280 HB.






suitable for material nos:1.3243 • 1.3245 • 1.3246 • 1.3249 • 1.3333 • 1.3340 • 1.3344 • 1.3346 • 1.3348and similar

39

5

i



Hardness comparison tableaccording to DIN 50150

Conversion table for hardness values, extract from DIN 50150

Rockwell hardness HRC Brinell hardness HB Vickers hardness HV HV tensile strength N/mm2 or MPa

25 253 266 854

26 254 273 873

27 265 279 897

28 272 286 914

29 274 294 944

30 287 302 970

31 295 310 995

32 302 318 1024

33 311 327 1052

34 320 336 1082

35 329 345 1111

36 337 355 1139

37 346 364 1168

38 354 373 1198

39 363 382 1227

40 373 392 1262

41 382 402 1296

42 392 412 1327

43 402 423 1362

44 413 434 1401

45 424 446 1442

46 436 459 1481

47 448 471 1524

48 460 484 1572

49 474 499 1625

50 488 513 1668

51 502 528 1733

52 518 545 1793

53 532 560 1845

54 548 578 1912

55 566 596 1979

56 585 615 2050

57 603 634 2121

58 - 654 -

59 - 675 -

60 - 698 -

Surface TechnologyOberflächentechnik

joke Technology GmbHAsselborner Weg 14 -16

D-51429 Bergisch Gladbach (Germany)Tel. +49 (0) 22 04 / 8 39-0

Fax +49 (0) 22 04 / 8 [email protected]

© Copyright joke Technology GmbH • 1st December 2010 issue • All rights reserved for technical changes, inaccuracies and printing errors • All prices plus statutory VAT in addition to postage and packaging • Reprinting, even in excerpts, only with prior written agreement.

Brilliant solutions for perfect surfaces

Repair welding - · PDF fileadditional laser welding necessary. ... Repair welding System...

Documents

Transcript of Repair welding - · PDF fileadditional laser welding necessary. ... Repair welding System...