Tool Service. Welding consumables for toolmaking

Transcription

1 Tool Service for toolmaking

2 Since its foundation in 1966, the Welding Alloys Group has become the global specialist in the development of low and high alloyed cored wires. Individual developments and new innovative products are created by our highly experienced welding engineers and metallurgists in cooperation with customers. Tool Service Base materials and their typical mechanical properties in action Material Short designation number Strength (MPa) Hardness (HRC) X38CrMoV X40CrMoV CrMoV X38CrMoV Selection of welding consumables Field of application Die-casting moulds, plastic moulds, punches, mandrels, dies, die-holders Die-casting moulds, die inserts, extrusion tools Deburring tools / guides / handling, ejecting, grasping devices Wear pattern Thermal fatigue, cracks, grooves, friction, erosion Grooves, edge wear Extensive cracked wear, friction, expansion, edge wear, partial breakouts Chemistry similar to base material ROBOTOOL 46 ROBOTOOL 49W ROBOTOOL KLMONI M ROBODUR KWM 56 ROBOTOOL 40 ROBOTOOL 47 ROBOTOOL 49W Welding Alloys Consumable Based on functionality, dissimilar STELLOC C M Buffer layers/repair of base material TETRA/TRI S 309 LMo NiCrMoV Parting knives, shear blades, gravure edges, mandrels, cold forging punches, hole punches Grooves, cracks, chipping, transverse cracks, erosions, (partial) breakouts, edge wear, general wear ROBOTOOL 34W ROBOTOOL 46 STELLOY 25 HARDFACE NICOMO HARDFACE NICOMO STELLOY 25 GAMMA 182 Table of contents 2 3 Selection of welding consumables...2 for hot working tools for cold working tools...6 for buffering...7 Special tool steels X45NiCrMo Plastic moulds, shear blades ROBOTOOL 49W CrMo Various applications ROBOTOOL X6NiCrTi Bushes, pressure pads Friction HARDFACE NICOMO GSF Kind&Co,Edelstahl KG HB Die plates Erosion GSF Kind&Co,Edelstahl KG HB Hot calibration twister General wear Cold working tools Cr X210 Cr X21Cr MnCr CrMnMo X100 CrMoV X155 CrVMo X210 CrW WCrV X165 CrMoV Parting knives, shear blades, Edge wear, grooves, cracks, rounded NiCrMoV gravure edges, mandrels, cold forging cutting edges NiCr punches, hole punches X19CrNiMo X45NiCrMo G45CrNiMo MnCrV G47CrMn G25CrMo G25CrMo G42CrMo G42CrMo Maraging steel X3NiCoMoTi Die-casting moulds, plastic moulds, cold forging tools Abrasive wear X2NiCoMoTi Tool holder Abrasion, edge wear High-speed steel S S S Cutting edges Edge wear, rounded cutting edges HARDFACE AR S Cast steel GJL HB alloyed SGG HB Gearbox housings, turbine housings, guide GJL HB rails alloyed VSGG HB EN-GJS HB Breakouts, cracks, abrasive wear, rework in the production EN-GJS HB ROBODUR K EN-GJS HB parts in the vehicle construction Crankshafts, rollers, gears, impact stressed EN-GJS HB EN-GJS HB div. Ingot moulds Ingot moulds Erosion, cracks ROBODUR K 250 ROBODUR K 350 ROBODUR K 450 ROBODUR K 500 ROBODUR K 600 ROBODUR K 650 LC HARDFACE L HARDFACE AR CAST NIFE CAST NICI

3 ROBOTOOL Cored wires for toolmaking Advantages of WELDING ALLOYS cored wires and stick electrodes for the toolmaking industry: > ROBOTOOL is the only range of seamless, laser-welded cored wires in the world. > Cost savings by avoiding the need to buy new construction tools. > Repairability of worn tools. > Improvement of wear resistance and lifetime of the tools. > Optimisation of tools through a specific selection of the base material and welding consumables. > Correction of manufacturing defects during the toolmaking. Welding-guidlines for the toolmaking industry 1. Selection of the correct welding consumable regarding the base material and stress of the tool. 2. Before welding, the work piece should be thoroughly cleaned to avoid pore formation and smoke emitting. 3. Complete preheating to avoid crack formation. 4. Hammering during the cooling phase to improve the stress condition. 5. Postheating and a slow cool-down to reduce stresses. Iron-based C Mn Si P S Cr Ni Mo V Ti W Fe Co Hardness (HRC) Tensile strength (MPa) ROBOTOOL 46-G Bal ROBOTOOL 47-G Bal G Bal ROBOTOOL (S) 34W Bal ROBOTOOL (S) 45 W Bal ROBOTOOL (S) 49W Bal ROBOTOOL (S) 54W Bal HARDFACE (S) 37-G Bal HARDFACE (S) 41-G Bal HARDFACE (S) 43-G Bal HARDFACE (S) 46-G Bal HARDFACE VMOLC-G Bal M-G Bal MOLC-G Bal G Bal Nickel-based C Mn Si Cr Mo Ni W Fe Co Hardness (HB) Tensile strength (MPa) STELLOY C-G Bal HB WH STELLOY C-O Bal HB WH STELLOY Ni 520-G Bal STELLOY Ni 520Co-G Bal > Cobalt-based C Mn Si Cr Mo Ni W Fe Co Hardness (HRC) Tensile strength (MPa) STELLOY 1-G Bal G* Bal STELLOY 12-G* Bal G* Bal STELLOY 25-G Bal. 210 HB 705 Microstructure Close-contoured welding of a forging die ROBOTOOL 45W-G in welded condition, ROBOTOOL 46-G in welded condition, = 202 C ROBOTOOL 47-G after heat treatment, = 231 C ROBOTOOL 34W-G in welded condition, magnification: x200, etched with Nital ROBOTOOL 34W-G after heat treatment, magnification: x200, etched with Nital 4 5 * TIG cold wire version also available.

4 ROBOTOOL welding consumables for toolmaking C Mn Si Cr Mo W Fe V Hardness (HRC) Tensile strength (MPa) HARDFACE AR-G Bal > 2200 HARDFACE 250-E Bal HB 835 HARDFACE 400-E Bal. - ~400 HB 1350 HARDFACE L-E Bal. - ~ HARDFACE AR-E Bal ~ Aluminium cover to reduce the heat emissions C Mn Si Cr Mo Ni W Fe Co Hardness (HRC) Tensile strength (MPa) HARDFACE 40-E Bal. - ~ HARDFACE 48-E Bal. - ~ HARDFACE 58-E Bal. - ~ E Bal E Bal E Bal. 33 HRC WH STELLOY 25-E Bal. 220 HB 740 Cold working tools C Mn Si Partial repair of a aluminium-injection-mold Build-up welding of an engraving (1.2713) with -G Solid wires and TIG rods C Mn Si Cr Mo Ti V Hardness (HRC) Tensile strength (MPa) AX-WZ AX-WZ AX-WA 3-SG AX-WA 4-SG Cr Mo Cored wires Ni W V Al Ti Co Hardness (HRC) Tensile strength (MPa) ROBODUR K 250-G HB ~770 ROBODUR K 350-G HB ~1095 ROBODUR K 450-G ~1290 ROBODUR K 600-G ~2145 ROBODUR K 650-G ~1955 ROBODUR K LMONI-G ~1955 HARDFACE L-O/G HB > 2200 HARDFACE T-O/G HB 1190 HARDFACE P-O/G HB 1350 HARDFACE AR-G > 2200 HARDFACE NICOMO-G >52 after PWHT Solid wires and TIG rods C Mn Si Cr Mo V W Al Ti Hardness (HRC) Tensile strength (MPa) AX HB 770 AX HB 1095 AX 450 W AX AX AX 600 Mo AX Repair and Buffering Cored wires C Mn Si Cr Mo Ni S P Nb Fe Tensile strength (MPa) TRI S 307-O Bal. 630 TRI S 312-O Bal. 860 TRI S 309LMo-O Bal G Bal GAMMA 182-G Bal TETRA S 307-G Bal. 610 TETRA S 312-G Bal. 860 TETRA S 309LMo-G Bal. 760 C Mn Si Cr Mo Ni Nb Fe Tensile strength (MPa) TETRA 312-E Bal. 800 TETRA 307-E Bal. 620 TETRA 309LMo-E < Bal. 700 TETRA SUPRA S-E > > Bal E < Bal GAMMA 182-E < Bal ISO 9001 Certified Forging die, hardfaced with STELLOY Ni 520-G Hardfacing of a forging die with HARDFACE 48-E Die-cast tool for aluminium, hardfaced with ROBOTOOL 46-G 6 7

5 Our Technical Spark Solves Your Industrial Challenges WA Consumables of advanced welding consumables WA Machines of automated equipment for wear protection WA IntegraTM of engineered wear protection solutions A worldwide presence Local presence Welding Alloys Subsidiaries WA distributors or sales representatives Strategic Trading Partners Welding Alloys Group WA Cored Wire, WA Integra, WA MultiSurfacer, Hardplate, Hardlite, Tuffplate, DRILL-GUARD and 3-DCarb trade and registered marks and logos are the property of the Welding Alloys Group. v1.0