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Welding of Uddeholm Tool Steels

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Welding of Uddeholm Tool Steels WELDING OF UDDEHOLM TOOL STEELS TREATMENT WELDING OF TOOL STEEL 1 © UDDEHOLMS AB No part of this publication may be reproduced or transmitted for commercial purposes without permission of the copyright holder. This information is based on our present state of knowledge and is intended to provide general notes on our products and their uses. It should not therefore be construed as a warranty of specific properties of the products described or a warranty for fitness for a particular purpose. Classified according to EU Directive 1999/45/EC For further information see our “Material Safety Data Sheets”. Edition 7, 10.2017 2 TREATMENT WELDING OF TOOL STEEL CONTENTS General information on welding of tool steel ..................... 4 Welding methods for tool steel .......................................... 4 The welding bay ................................................................ 6 Filler material ..................................................................... 7 Hydrogen in tool steel ....................................................... 8 Elevated working temperature .......................................... 9 Welding procedure ............................................................ 10 Heat treatment after welding ............................................. 11 Guidelines for welding in – hot work tool steel ........................................................ 13 – cold work tool steel ..................................................... 14 – plastic mould steel ........................................................ 17 TREATMENT WELDING OF TOOL STEEL 3 GENERAL WELDING deposit is inhibited partly by slag formed from constituents in the elec- INFORMATION METHODS FOR trode coating and partly by gases ON WELDING OF TOOL STEEL created during melting of the elec- trode. TOOL STEEL SHIELDED METAL-ARC The composition of the deposited Tool steel contain up to 2.5% carbon WELDING (SMAW OR MMA) weld metal is controlled via the constitu- as well as alloying elements such as tion of the electrode coating. manganese, chromium, molybdenum, PRINCIPLE tungsten, vanadium and nickel. The An electric arc generated by a DC or POWER SOURCE AC power source is struck between main problem in welding tool steel For MMA welding, it is possible to a coated, rod-like electrode and the stems from its high hardenability. use either an AC or DC power source. work-piece (Fig. 1). Welds cool quickly once the heat However, whichever is used, the The electrodes consist of a central source is removed and the weld metal source must provide a voltage and wire core, which is usually low-carbon and part of the heat-affected zone will current which is compatible with the steel, covered with a coating of harden. This transformation generates electrode. Normal arc voltages are: pressed powder (flux). The constitu- stresses because the weld is normally • normal recovery electrodes: tion of this coating is complex and highly constrained, with a concomi- 20–30 V consists of iron powder, powdered tant risk for cracking unless great • high recovery electrodes: ferro-alloys, slag formers and a care is exercised. 30–50 V In what follows, a description is giv- suitable binder. The electrode is en of the welding equipment, welding consumed under the action of the arc Uddeholm welding consumables are technique and weld consumables during welding and drops of molten of normal recovery type. A suitable that are required in order to weld tool metal are transferred to the work- power source for these is a DC unit with steel successfully. Of course, the skill piece. Contamination by air during an open voltage of 70 V and which is and experience of the welder is also the transfer of molten drops from capable of delivering 250A/30V at 35% a vital ingredient in obtaining satis- electrode to workpiece and during intermittence. factory results. With sufficient care, it solidification and cooling of the weld is possible to achieve weld repairs or adjustments which, in terms of tooling performance, are hardly inferior to that of the base steel. Welding of tooling may be required for anyone of the following reasons: • refurbishment and repair of cracked or worn tooling • renovation of chipped or worn cutting edges, e.g. on blanking tools • adjustment of machining errors in tool making • design changes 4 TREATMENT WELDING OF TOOL STEEL GAS TUNGSTEN-ARC Current is conducted to the electrode LASER WELDING WELDING (GTAW OR TIG) via a contact inside the TIG-gun. Any consumables which are required PRINCIPLE PRINCIPLE during TIG-welding are fed obliquely High power laser light is generated In MMA welding, the electrode from into the arc in the form of rod or wire. and focused through a lens to the which the arc is struck is consumed Oxidation of the weld pool is pre- welding spot. As filler material a thin during welding. vented by an inert-gas shroud which wire with a diameter between 0.1– The electrode in TIG welding is streams from the TIG gun over the 0.6 mm is primarily used. The welder made of tungsten or tungsten alloy electrode and weld. guides the wire to the area to be welded. which has a very high melting point The laser beam melt the wire and the (about 3300°C/6000°F) and is there- POWER SOURCE base material. The molten material fore not consumed during the process TIG welding can be performed with a solidifies leaving behind a small raised (Fig. 2). The arc is initially struck by regular MMA power source provided area. The welder continues spot by spot subjecting the electrode-workpiece this is complemented with a TIG and line by line. An Argon gas at higher gas to a high-frequency voltage. The control unit. A water cooled gun is purity than used at TIG-welding should resulting ionization permits striking normally not necessary as the actual be used to shields the process from without the necessity for contact welding time is very limited. A gas oxidation (Fig. 3). between electrode and workpiece. lens is also a desirable feature in The tungsten electrode is always con- order that the inert gas protection nected to the negative terminal is as efficient as possible. Welding of a DC power source because this is facilitated if the current can be minimizes heat generation and increased steplessly from zero to the thereby any risk of melting the electrode. optimum level. Core wire Electrode holder Electrode holder + Pole Cooling water Power source Coating – Pole Slag Protective gas Tungsten electrode – Pole Weld Filler material Power source Melt pool + Pole Fig. 1 Shielded Metal-Arc Welding SMAW (MMA) Fig. 2 Gas Tungsten Arc Welding GTAW (TIG) Protective gas Protective glass Laser beam Deposited material Filler wire Fusion zone Workpiece Fig. 3 Laser Welding TREATMENT WELDING OF TOOL STEEL 5 POWER SOURCE be equipped with a dry cabinet for be positioned securely and accu- For deposition welding normally a storage of electrodes. This should rately. It is advantageous if the work- pulsed solid state laser of Nd: YAG be thermostatically controlled in the bench is rotatable and adjustable type is used. range 50–150°C (120–300°F). The vertically, since both these features electrodes should be removed from facilitate the welding operation. Typical performance: their containers and lie loose on racks. Nominal output 150–200 W For welding of tooling outside the Max pulse output 10–12 kW PREHEATING EQUIPMENT Pulse time 0.5–20 ms welding bay, it will also be found useful Tool steel cannot be welded at room Frequence 0.5–20 Hz to have a portable heated container in temperature without considerable Spot diameter 0.5–2.0 mm (0.1–0.5 mm) which the electrodes can be carried. risk for cracking and it is generally necessary to pre-heat the mould or WORKBENCH die before any welding can be THE WELDING BAY It is particularly important during attempted (see later). While it is critical welding operations, of the type certainly possible to weld tools In order to be able to effect satis- performed with tool steel, that the successfully by preheating in a factory welding work on tool steel, welder enjoys a comfortable work- furnace, the chances are that the the following items of equipment are ing position. Hence, the workbench temperature will fall excess ively prior to be regarded as minimum require- should be stable, of the correct height to completion of the work. Hence, ments. a sufficiently level that the work can it is recommended that the tool be main-tained at the correct tempera- DRY CABINET ture using an electrical heating box The coated electrodes used for MMA supplied from a current-regulated DC welding are strongly hygroscopic source. This equipment also enables and should not be allowed to come the tool to be heated at a uniform and into contact with anything other than controlled rate. To place the tool on dry air. Otherwise, the weld will be a heated table or plate could some- contaminated with hydrogen (see times be sufficient to maintain the later). Hence, the welding bay should temperature. Electrical elements for an insulated For minor repairs and adjustments, it preheating box. is acceptable that the tool is pre-heated using a propane torch. Hence, liquid propane cylinders should be available in the welding bay. GRINDING MACHINES The following should be available: • disc grinder with a suitable wheel for preparing the joint and grinding out of any defects which may occur during welding. Wheel dimension depends on defect size, which has to be grinded. • flat grinder capable of ≥25 000 rpm for grinding of minor defects and of the finished weld • if a welded mould is subsequently to be polished or photo-etched, it may be necessary to have a grinder capable of giving a sufficiently fine finish Preheating in an insulated box. • small rotating metal files in different shapes and sizes 6 TREATMENT WELDING OF TOOL STEEL FILLER MATERIAL Filler rods are normally produced For the three main application from electroslag remelted stock. The segments for tool steel (cold work, The chemical composition of a weld coated electrodes are of basic type, hot work and plastic moulding), the deposit is determined by the compo- which are far superior to rutile elec- important weld-metal properties are: sition of the consumable (filler metal), trodes as regards weld cleanliness.
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