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TOTAL WELDING SOLUTIONS PROVIDER
FORGING INDUSTRY
FORGING INDUSTRY APPLICATIONS
Welding is divided into the three basic phases
1. Repair Repair of Column , Tup , Sow Block and die etc.
2. RebuildRebuild of Tup , Anvil and die etc.
3. Flood WeldingFlood welding of Tup , sow block and die etc.
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Mechanically Induced State of Tension
Relative movementDie / Forging
Thermally induced State of Tension Loss of Cohesion
Mec
han
ical
stre
ssT
her
mal
stre
ssMechanically Die Load
Thermal Die Load
Deformation – Cracking - Fracture
Wear – Deformation – Temperature fatigue CrackingForging Die
General Information for Repair and Flood Welding of Forging Die
Before Starting of welding we have to ensure the Die Preparation for the welding. It is necessary activities to get the proper and good result of Die Welding. Procedure for the Die Welding is as follows.
1. Die PreparationA. Scarfing :- It is a process to remove the wear and crack surface of the Die cavity which helps to make the proper welding surface. Minimum surface removal is approx about 5-6 mm per side. For Scarfing process we can use the CARVER product as follows.
Carver 9102 :- available is size of 9.0 mm and 12.0 mmIt is a fast process compared to gouging and machining & very economical.
After Scarfing die should be visually inspected and should be free of crack or any other defect in the die. If any crack or sharp corner observed than remove the same by means of scarfing and grinding. Cracks should be scarfed out and the area checked for defects using a surface crack Test procedure if required. (e.g. dye penetration of magnetic particle inspection)
Dies After forging
Dies afterScarfing
Forging Die and Scarfing Process
General Information for Repair and Flood Welding of Forging Die
2. Preheating
Uniform Pre-Heating is an essential preliminary step for welding to avoid Stress cracking and substantial differences in brightness. In order to reduce stress and Colour differences between the welding zones, this should be followed, At least in the case of alloyed tool steel , Minimum Temperature for Preheating is about 300 to 350 degree Centrigrade. Before starting welding , the die must be covered with insulation mats ( e.g glass wool lined ) to extend the possible welding time. It is also advisable to apply bonding thermometer.
1.Information on preparing and carrying our contract welding.2.Recommendations on temperature control.3.Suggestions for material – specific selection of welding filler.
During WeldingIntermediate Temperature :- It is essential to ensure the workpiece
temperature does not fall below Ms( in the case of the above materials , 300 degree ) . before the welding repair is completed . Otherwise significant transformation stresses occurs that can lead to crack formation. Therefore homogeneous reheating is necessary. In order to avoid frequent delays because of reheating , work times can be extended by continuous heating. E.g using a circular gas burner under the mould during welding.
Welding will be carried out with the help of CARVER products. During Welding Each and every layer should be hammered to ensure the proper joint of welding. Scales should be removed with the help of needle scaler and wire brush to make the surface clean for second layer. This process must be followed to avoid the welding defects like blow holes , scales , lack of fusion , crack and improper joint of welding. In order to avoid coarse structures and unnecessarily high susceptibility to hardening in the welding zone, the lowest possible current should be used and electrodes that are as thin and homogeneous as possible.
Welded DieCARVER make welding Consumables for forging Dies are :-CARVER 9535 :- For Hammer Forging DiesCARVER 9580 :- For Press Forging DiesCARVER 9880 :- For Crack Repair and Joining layers.
4. Post HeatingTemperature Reduction :- When welding has been completed , the die
should be covered and slowly cooled to around 150 degrees. Enabling the austenitic welding material to be converted into martensite. When 150 degree temperature reached , the die must be heated up directly to stress relieving temperature. A stress relieving temperature is 50 degree less than previous tempering temperature is to be performed , with soak time 1 hr/25mm wall thickness.
5. Forging LubricantImportance of Forging Lubricants on DieLubricate :Lubricate :-- Reduce the friction metal to metal thus allowing metal flow to Reduce the friction metal to metal thus allowing metal flow to occur occur in a smooth and controlled way.in a smooth and controlled way.Reduce :Reduce :-- make possible the removal of the forged part from the die.make possible the removal of the forged part from the die.Cooling :Cooling :-- remove undesirable heat from dies.remove undesirable heat from dies.Protect :Protect :-- protect and as a consequence extend the die life.protect and as a consequence extend the die life.
Lubricants used in Forging Lubricants used in Forging Graphite in water dispersions.Graphite in water dispersions.Graphite in oil dispersions.Graphite in oil dispersions.Synthetic compounds based on organic salts.Synthetic compounds based on organic salts.Solid lubricants dispersions based on MoS2, Boron Nitride, GlassSolid lubricants dispersions based on MoS2, Boron Nitride, Glass..
Trimming Tool
Hard Facing electrode usedfor Trimming tool
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Other Spares like Shearing Machine Blade
Welding
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Repair of Column 10 ton Pneumatic hammer
Damaged Part of Column
Scarfing of Damaged Part
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Repair of Column 10 ton Pneumatic hammer
Scarfed Part of ColumnAnd kept for Preheatingprocess
Welding of Damaged Part
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Repair of Column 10 ton Pneumatic hammer
Welded Part of Column And kept for Stress Relievingprocess
After Stress RelieveMachining will be done
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WELDED AND MACHINED TUP OF MPM 6300B HAMMER
Welding and Machining
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RAM OF AERY HAMMER
Welding in shank Area
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WELDED AND GRINDED CYLINDER HEAD OF MPM 16000B HAMMER
Welded Area
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WELDED AND GRINDED COLUMN OF MPM 16000B ( 5 TON ) HAMMER
Welded Area
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Joining of Anvil by Welding
Joining of Anvil ( base ) of 25000 lbs Pneumatic Forging hammer which is broken in two halves
Electrode consumption :- 3500 Kg Time Elapsed :- 32 Days
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MANDREL FOR RING ROLLING FORGING
Welding
Machining
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BOLSTER FOR PRESS
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FABRICATED COLUMN
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