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6. Welding of cold working tool steels 18 - 24 9.1 Summary of cast iron materials
9.2 Appropriate UTP products for
6.1 Ledeburitic Cr-cutting steel with 5 - 12 % Cr cast iron welding
6.2 Summary of cold working steels 9.3 Appropriate UTP TIG rods or MIG wires
for cast iron welding
6.3 Data for cold working tool steels 1.2379
6.4 Appropriate UTP welding consumables 10. Availability of the UTP products
for cold working tools for tool welding 51 - 52
INDEX
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
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
1 Mains connection
2 Power source
3 Welding cable
4 Electrode holder
5 Earth cable
6 Work piece
A Core wire
B Coating
C Protective gas
D Solidfied slag 78 - 80
E Welding bead
F Melt bath
G Metal drop in molten slag
H Base metal
I Drop transfer
INDEX
Clean welding area, removing all contaminants, i.e. paint, oil, grease. Chamfer sharp edges. Prepare broken out parts
and 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 suppliers
recommendations.
Tool steels are usually not welded at room temperature. Pre-heating- and interpass temperature is determined by the type of base
metal, 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. Clean
welding 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 cracks
caused 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 preheating
temperature.
The welding deposit has to be peened IMMEDIATELY after a weld has been deposited and before the temperature falls below
350 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 after
a large welding deposit has been made, such as a filling for pattern change or similar.
INDEX
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.
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.
Application: Cutting tools for rough work and planing with spiral
drill, milling cutter, broaching tools, thread drill,
reamers, wood working tools. Also for cold working
tools for punching, deep drawing, pressing and
cutting.
* The welding deposit can be heat treated in accordance with the base material.
INDEX
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.
Quick repairs can be carried out with little or no pre- heat 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 - - -
6.2 Summary of
1.2067 100 Cr 6 1,0 0,3 0,3 1,5 - - -
cold working
1.2080 X 210 Cr 12 2,0 0,3 0,3 12,0 - - -
steels
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 -
INDEX
BHLER K110
INDEX
b) High cutting pressure (saddle preparation with rounded edges and corners)
INDEX
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
Chemical composition: C Cr Mn Mo V
0,55 1,1 1,7 0,5 0,1
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 heat
conductibility and hot crack resistance.
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/mm 1850 1790 1790 1910 2050 2050 1910 1670 1330 1020
INDEX
Filled up engraving of
a forging die (UTP A 73 G 3)
Steels are selected for plastic moulds according to the operating conditions and for economical purposes. Depending
on the working process we can differentiate between
and
Injections tools
for 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
Nitriding steel
1.2895 34 CrAINi 7 0,35 0,5 1,7 0,2 1,0 Al 1,0
Block steel
1.1730 C45W 0, 45 0, 3 0, 7 - -
INDEX
Chemical composition: C Si Mn Cr Mo S
0,4 0,4 1,5 1,9 0,2 0,07
Die cast form for plastic made from material No. 1.2312
INDEX
8.3 Appropriate UTP welding consumables for steels for injection moulds
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
UTP 86 FN
UTP 8 C
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
Very large and substantial building up repairs can be done by using our Ferro- Nickel MIG wire UTP A 8051 Ti.
INDEX
Tensile strength values are minimum values in accordance with DIN 1691 and DIN 1693
INDEX
807 Nickel free special electrode for colour approx. 230 HB -+/
matching and wear resistant build ups
on GG and GGG cast iron. A buffer
layer with Nickel or Ferro-Nickel is
recommended.
9.3 Appropriate UTP TIG rods and MIG wires for cast iron welding
A 387 Cu-Ni type TIG rod with approx. 70 % Cu and approx. 120 HB
30 % Ni for build up on cast iron. High ductility,
low tensile strength.
A 8051 Ti Ferro-Nickel type MIG wire for high strength approx. 220 HB
joints and build up on all types of cast iron.
INDEX UTP type Electrodes TIG rods MIG/MAG-wires
mm mm mm
63 2,5 / 3,2 / 4,0
630* 2,5 / 3,2 / 4,0
6302* 2,5 / 3,2 / 4,0
A 63 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6
65 D 1,5 / 2,0 / 2,5 / 3,2 / 4,0
A 651 * 1,2 / 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6
67 S 2,5 / 3,2 / 4,0
10. Availability of the A DUR 600 1,2 / 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6
UTP Products for 67 SST* 2,5 / 3,2 / 4,0
73 G 2 2,5 / 3,2 / 4,0
tool welding
A 73 G 2 1,6 / 2,0 / 2,4 1,0 / 1,2 / 1,6
73 G 3 2,5 / 3,2 / 4,0
A 73 G 3 1,6 / 2,0 / 2,4 1,0 / 1,2 / 1,6
73 G 4 2,5 / 3,2 / 4,0
A 73 G 4 1,6 / 2,0 / 2,4 1,0 / 1,2 / 1,6
82 AS 2,5 / 3,2 / 4,0
641 Kb* 2,5 / 3,2 / 4,0
A 641 * 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6
653* 2,0 / 2,5 / 3,2 / 4,0
665* 2,5 / 3,2 / 4,0
A 66* 1,2 / 1,6
673 2,0 / 2,5 / 3,2 / 4,0
A 673 1,6 / 2,0 / 2,4 1,2 / 1,6
690 2,0 / 2,5 / 3,2 / 4,0
A 696* 1,6 / 2,4 1,2
702 2,5 / 3,2 / 4,0
A 702 1,6 / 2,0 / 2,4 1,2
807* 2,5 / 3,2 / 4,0 *) available on demand
A 80 M 1,6 1,0/1,2/1,6
*) available on demand