WELDING IN THE TOOL SHOP WITH UTP WELDING CONSUMABLES

High speed steels

Cold working steels
Hot working steels
Injection mould steels
Cast iron
 General Index

Page Page

1. General introduction 3 7. Welding for hot working tool steels 25 - 36

2. Welding methods 4-7 7.1 Summary of hot working tool steels

7.2 Data for hot working tool steel 1.2714
2.1 Welding with coated electrodes
7.2.1 Data for hot working tool steel 1.2344
2.2 TIG welding
7.3 Appropriate UTP welding consumables
2.3 MIG/MAG welding
for hot working tools
3. General guide lines for welding
of tool steels 8-9 8. Welding for steels for plastic injection
moulds 37 - 42
4. Reasons for failure of build up welding 10
8.1 Summary of steels for plastic moulds
5. Welding high speed steels 11 - 17
8.2 Data for plastic mould steel 1.2312
5.1 Summary of high speed steels 8.3 Appropriate UTP welding consumables
5.2 Data of high speed steel 1.3343 for steels for injection moulds

5.3 Appropriate UTP welding consumables

for high speed steels 9. Welding of cast iron 43 - 50

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

2.1. Welding with coated electrodes

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

Manual metal arc welding with coated electrodes

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

Tool repair with coated electrode

INDEX

2.2 TIG welding

The TIG welding process is particularly suitable for smaller tools and small repair jobs. The advantage is that complicated
cutting edges and particularly detailed shapes can be repaired. A small diameter tungsten electrode allows the welder to
concentrate high temperature on a small spot and deposit the welding consumable accordingly, without damaging the base
material and without any deformation. To control the amperage to the lowest possible setting, the machine should be equipped
with a foot switch. TIG rods are available in a wide range of alloys. The shielding gas should be Argon with a purity of 99,996 vol%.

The principle of TIG welding

1 Mains connection A Gas nozzle

2 Power source B Electrode clamp
3 Welding cable C Non consuming tungsten electrode
4 Earth cable D Shielding gas cover
5 Shielding gas bottle E Welding bead
6 Shielding gas hose F Melt bath
7 Welding torch G Arc
8 Welding rod H Welding rod
9 Base material I Base material
INDEX

2.3 MIG/MAG welding

The MIG/MAG welding process is suitable for depositing large quantities of welding consumable economically. Typical applications
are the production of large shear blades out of low alloy base metal or the filling of forging dies to change the pattern or building
up on rolls and cones etc.
With synergic pulsed arc welding sets, a spatter free deposit can be achieved which, in turn, prevents welding inclusions due to
welding over spatter. Generally welding is done with solid wires of 1,2 mm or 1,6 mm diameter. As shielding gas for high alloy tool
steel wires Argon or a multi component gas should be used.
Flux cored wires are used when no solid wire in the required alloy is available, such as a cobalt alloy. These wires are also welded
with shielding gas.

The principle of MIG/MAG welding

1 Mains connection 7 Wire electrode

2 Power source 8 Shielding gas hose
3 Spool of electrode wire 9 Earth cable
A Gas nozzle F Melt bath
4 Wire feeder unit 10 Welding torch
B Wire nozzle G Drop transfer
5 Shielding gas bottle 11 Base material
C Wire electrode H Base material
6 Welding cable
D Shielding gas cover I Arc
E Welding bead
INDEX

3. General guide lines for welding of tool steels

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

Welding boot equipped for tool welding

Pre-heat and heat maintaining table

INDEX 4. Reasons for failure of build-up welding
1. Pre-heating to low
To hard
2. No slow cooling
Mistake in the heat
application 3. Pre-heating to fast
Thermal shock
4. Cooling to fast

Mixing to big 5. To big electrode or to high amps

Structure problems To much stress Prep. incorrect 6. Bevelling to big

7. No peening or cold peening

Welding mistakes 8. To long welding beads

9. Welding cond. not considered

pre-heating or cold welding

H2 embrittlement 10. No re-drying of electrodes

Porosity 11. No thorough cleaning of weld area

Reduc. of hardness 12. To little hardsurfacing on top of

buffer layer
13. Less than 3 layers of hard surfacing
Mixing to big
14. To big electrode or to high amps
Hardness to low or not
constant 15. Wrong selection of electrode
Not enough hardness
16. Heat treatment not corresponding
to the weld deposit
To high hardness 17. Pre-heating to low

18. No measuring of depos. Before

Bead appearance, result Not enough deposit stopping the building up
after machining after machining 19. Qualification of welder not sufficient
INDEX

5. Welding high speed steels

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.

Complimentary products: TIG wire UTP A 696 is available.

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.

Cutting tool with edge built up with UTP 690

INDEX

Typical tools made out of high speed steel

INDEX
5.1 Summary of high speed steels

Material No. DIN-Design. Chemical composition in %

C Cr Mo V W Co
1.3202 S 12-1-4-5 1,35 4,0 0,8 3,8 12,0 4,8
1.3207 S 10-4-3-10 1,23 4,0 3,8 3,3 10,0 10,5
1.3243 S 6-5-2-5 0,92 4,0 5,0 1,9 6,4 4,8
1.3245 S 6-5-2-5 S 0,92 4,0 5,0 1,9 6,4 4,8
1.3247 S 2-10-1-8 1,0 4,0 9,5 1,2 1,5 8,0
1.3255 S 18-1-2-5 0,8 4,0 0,7 1,6 18,0 4,8
1.3316 S 9-1-2 0,8 4,0 0,8 1,6 8,5 -
1.3333 S 3-3-2 1,0 4,0 2,6 2,3 2,8 -
1.3340 SC 6-5-2-S 0,97 4,0 5,0 1,9 6,4 -
1.3341 S 6-5-2S 0,9 4,0 5,0 1,9 6,4 -
1.3342 SC 6-5-2 0,97 4,0 5,0 1,9 6,4 -
1.3343 S 6-5-2 0,9 4,0 5,0 1,9 6,4 -
1.3344 S 6-5-3 1,2 4,0 5,0 2,9 6,4 -
1.3346 S 2-9-1 0,8 4,0 8,5 1,2 1,8 -
1.3348 S 2-9-2 1,0 3,8 8,6 2,0 1,7 -
INDEX
BHLER S600
INDEX
5.2 Data for high speed steel 1.3343

DIN Designation: S 6-5-2

Chemical composition: C Si Mn Cr Mo W V
0,9 0,3 0,3 4,0 5,0 6,4 1,9
Properties: Standard alloy for high speed steels, high
toughness and good cutting properties, heat
resistant up to 600 C, universally applicable

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.

Hot forming: 1100 - 900 C slow cooling in

vermiculite or in the oven

Soft annealing: 770 - 840 C / 4 h oven cooling annealing

hardness 240 - 300 HB

Stress relief annealing: 600 - 650 C / 1 - 2 h oven cooling

Heating: 450 - 600 C (0,5 min/mm)
= 50 mm thick = 25 min

Pre-heating: a) 850 C air circulation oven

b) 850 and 1050 C in a salt bath

Hardening: a) 1190 - 1230 C / warm bath 550 C/air or

b) 1190 - 1230 C / oil or
c) 1190 1230 C / air

Tempering: 540 - 560 C min. 2 x

Hardness after tempering: 64 - 66 HRC
INDEX

5.3 Appropriate UTP welding consumables for high speed steels

Coated TIG rod Application Hardness

electrode MIG / MAG wire weld deposit

UTP 690* UTP A 696* Build up welding on worn 60 65 HRC

tools and of broken out
parts on cutting tools.
New production of tools
in combination with low
class base metals.

UTP 65 D UTP A 651 High strength and tough approx. 220 HB

UTP 653 joints on cracked and
broken tools. Cover with
3 layers UTP 690 /
UTP A 696

* The welding deposit can be heat treated in accordance with the base material.
INDEX

6. Welding of cold working tool steels

6.1 Ledeburitic Cr- cutting steel with 5 - 12 % Cr

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.

The build up welding should be applied as follows:

Quick repair small repairs on the hard tool, 1 - 2 layers

Large repair multi layer build up on the hard tool
Repair with identical material changing of shape or pattern on a soft annealed tool

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

6.3 Data for cold working tool steel 1.2379

DIN Designation: X 155 CrVMo 12 1

Chemical composition: C Cr Mo V
1,55 12,0 0,7 1,0
Properties: Ledeburitic 12 % Cr steel. Highest wear resistance,
good toughness. Good cutting edge- and hardness
retention. Nitridable after special heat treatment.
Application: Thread rollers and -dies, cold extrusion-, cutting-
and punching tools for sheet metal up to 6 mm.
Cold pilger tools, circular shear knives and deep
drawing tools.
Hot forming: 1050 - 850 C slow cooling in
vermiculite or in the oven
Soft annealing: 830 - 860 C / 4 h oven cooling annealing
hardness max. 250 HB
Hardening: 1000 -1050 C/warm bath 550 C/air
Hardness after quenching: 63 HRC
Tempering C: 100 200 300 400 500 525 550 600
Hardness after tempering HRC: 63 61 58 58 58 60 56 50
INDEX

Cutting jaw with partial edge repair

Punching die with build up cutting edge

INDEX

6.4 Appropriate UTP welding consumables for cold working tools

Coated TIG rod Application Hardness

electrode M I G /MAG wire weld deposit

UTP 665 UTP A 66 Cutting edge build up on approx. 55 HRC

annealed Cr-cutting tools.
Crack resistant tough, for
one or max. two layers
(quick repair)

UTP 67 SST Multi layer build up on soft 40 HRC

annealed Cr steel, colour and untreated
structure match.

UTP 67 S UTP A DUR 600 Universal build up alloy for 56 - 58 HRC

tempered cold steel and untreated
unalloyed base steel. Natural
hardness for multi layer build
up
UTP 673 UTP A 673 Multi layer build up on 58 - 60 HRC
annealed cold working tools untreated
and unalloyed base material,
natural hardness
UTP 65 D UTP A 651 High tensile and tough joints approx. 220 HB
on cracked and broken cutting
tools. On cutting edges
overlay with hard deposit.
INDEX

Welding preparation and seam build up on cutting edges

a) Low cutting pressure (bevelled edge preparation)

b) High cutting pressure (saddle preparation with rounded edges and corners)
INDEX

7. Welding of hot working tool steel

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

Filling of a defect with UTP 73 G 3

Partial repair of an Al-injection mould

INDEX

For build up welding on injection tools the use of age

hardenable martensitic material (Maraging Steel) is
recommended, due to its high wear resistance. For
this repair the tool is pre-heated to approx. 150 C
and welded by maintaining this temperature. The
deposited material has a hardness of approx. 37 HRC.
Age hardening at 480 C / 3 - 4 h will bring
the tool to a hardness of 53 HRC.

On forging tools, very good results are obtained

by using work hardening high Ni- and Co-base
alloys. These alloys have an initial hardness after
deposition of approx. 240 and 320 HB respectively.
Build up of the whole die pattern with Ni-alloy

In operation, due to impact and pressure the hardness

will increase to approx. 45 HRC. The available welding
consumables can be used for partial repairs, for
complete reconditioning, or for filling whole defects.
For their particulars see table 7.3.
INDEX

Build up welding on an axial roller

with UTP AF CELSIT 721

Build up welding on a mandril

with UTP A 73 G 3
 Material No DIN-Design. Chemical composition in %
INDEX
C Si Mn Cr Mo Ni V W

1.2311 40 CrMnMo 7 0,4 0,3 1,5 1,9 0,2 - - -

1.2312 40 CrMnMoS 8-6 0,4 0,4 1,5 1,9 0,2 - - S 0,7
1.2323 48 CrMoV 6-7 0,45 0,3 0,8 1,5 0,8 - - -
1.2343 X 38 CrMoV 5-1 0,38 1,0 0,4 5,3 1,3 - 0,4 -
1.2344 X 40 CrMoV 5-1 0,4 1,0 0,4 5,3 1,4 - 1,0 -
7.1 Summary of
1.2362 X 63 CrMoV 5-1 0,6 1,0 0,4 5,3 1,2 - 0,3 -
hot working 1.2365 X 32 CrMoV 3-3 0,32 0,3 0,3 3,0 2,8 - 0,5 -
tool steels 1.2367 X 40 CrMoV 5-3 0,4 0,4 0,5 5,0 3,0 - 0,9 -
1.2564 X 30 WCrV 4-1 0,3 0,9 0,4 1,0 - - 0,2 3,8
1.2567 X 30 WCrV 5-3 0,3 0,2 0,3 2,4 - - 0,6 4,3
1.2581 X 30 WCrV 9-3 0,3 0,2 0,3 2,6 - - 0,4 8,5
1.2606 X 37 CrMoW 5-1 0,37 1,0 0,5 5,3 1,5 - 0,3 1,3
1.2678 X 45 CoCrWV 5-5-5 0,45 0,4 0,4 4,5 0,5 2,0 Co 4,5 4,5
1.2710 45 NiCr 6 0,45 0,3 0,8 1,4 - 1,7 - -
1.2713 55 NiCrMoV 6 0,55 0,3 0,8 0,7 0,3 1,7 0,1 -
1.2714 55 NiCrMoV 7 0,56 0,3 0,8 1,1 0,5 1,7 0,1 -
1.2744 57 NiCrMoV7-7 0,57 0,3 0,8 1,1 0,8 1,7 0,1 -
1.2764 X 19 NiCrMo 4 0,2 0,3 0,3 1,2 0,2 4,0 - -
1.2767 X 45 NiCrMo 4 0,45 0,3 0,3 1,3 0,3 4,0 - -
1.2082 X 20 Cr 13 0,2 0,5 0,7 13 - - - -
1.2787 X 22 CrNi 17 0,22 0,4 0,5 16,5 - 1,7 - -
1.2792 X 30 CrNiMoV 3-1 0,3 0,3 0,7 2,8 0,6 1,0 0,4 -
1.2731 X 50 NiCrWV 13-13 0,5 1,3 0,8 13 - 13 - 1,3
1.2885 X 32 CrMoCoV 3-3-3 0,32 0,3 0,3 3,0 2,8 Co 2,8 0,5 -
1.2888 X 20 CoCrWMo 10-9 0,2 0,25 0,5 8,5 2,2 Co 9,5 - 6,8
1.2889 X 45 CoCrMoV 5-5-3 0,45 0,4 0,4 4,5 3,0 Co 4,5 2,0 -
1.2898 X 30 CoCrMoV 3-3-3 0,3 - - 3,0 2,8 Co 2,8 0,5 -
1.2709 X 3 NiCoMoTi 18-9-5 0,03 < 0,1 < 0,15 - 5,0 18 Co 10 Ti 1
INDEX
BHLER W500
INDEX

7.2 Data for hot working tool steel 1.2714

DIN Designation: 56 NiCrMoV 7

Chemical composition: C Cr Mn Mo V
0,55 1,1 1,7 0,5 0,1

Properties Die steel with high toughness and

excellentthrough hardening

Application Forging dies of all kinds, forming dies shear

knives, extruder screws, cutting blades

Hot forming: 1100 - 850 C slow cooling in

vermiculite or in the oven

Soft annealing: 650 - 700 C / 4 h oven cooling annealing

hardness max. 250 HB

Hardening: 830 - 870 C / oil

860 900 C / air

Hardness after quenching: Oil 58 HRC

Air 56 HRC

Tempering: 300 350 400 450 500 550 600 650

Hardness after tempering
HRC Oil 52 51 50 48 46 43 40 36
HRC Air 50 49 48 46 43 40 36 33
INDEX
BHLER W302
INDEX

7.2.1 Data for hot working tool steel 1.2344

DIN Designation: X 40 CrMoV 5 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.

Application: Universally suitable, particularly for injection- and continuous

cast moulds for AI-alloys, for forging tools and dies and hot
shear knives.

Hot forming: 1100 - 900 C slow cooling in vermiculite

or in the oven

Soft annealing: 750 - 800 C / 4 h oven cooling annealing

hardness max. 230 HB

Hardening: 1020 -1050 C oil / air or

500 - 550 C hot bath

Hardness after quenching: 54 HRC (1910 N/mm)

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)

New engraving in forging die

INDEX Coated TIG rod Application Hardness
electrode MIG /MAG wire weld deposit

73 G 4 A 73 G 4 Single- and multi-layer build 38 - 42 HRC

up on similar CrMo- and
73 G 3 A 73 G 3 45 - 48 HRC
NiCrMo steels for shear
73 G 2 A 73 G 2 blades, moulds, dies,
trimming dies, rolls fill welding

7.3 Appropriate 702 A 702 Build up on CrMo steels in 37 - 40 HRC

particular injection moulds untreated
UTP welding (Maraging steel) 51 - 54 HRC
aged 4 h / 480 C
consumables for
hot working tools Celsit 706 A Celsit 706 V Heat resistant Co-alloys for 40 - 43 HRC
AF Celsit 706 applications involving thermal
Celsit 712 A Celsit 712 SN shock such as hot shear 48 - 53 HRC
AF Celsit 712 blades, hot punching- and
Celsit 701 A Celsit 701 N trimming tools. Partial build up 52 - 57 HRC
AF Celsit 701 welding.

700 A 776 High heat resistant Ni-alloy for 220 HB (400 K)

7000 A 776 tools having to support very
240 HB (400 K)
high pressure and thermal
7008 A 776 shock such as forging tools, 260 HB (450 K)
Celsit 721 A Celsit 721 mandrils, shear blades. 320 HB (450 K)
AF Celsit 721 Machinable with cutting tools (Co-alloy)

65 D A 651 Buffer layers, welding of 220 HB (350 K)

653 A 651 cracks, joining, as well as 240 HB (350 K)
7015 Mo A 068 HH easy machinable, high heat 190 HB (350 K)
resistant build up.
6218 Mo A 6222 Mo 230 HB (450 K)
INDEX

Hot cutting blade of a billet shear

Cutting edge build up with Ni-alloy

INDEX

8. Welding of steels for plastic injection moulds

Steels are selected for plastic moulds according to the operating conditions and for economical purposes. Depending
on the working process we can differentiate between

Press- and injection tools

for hardenable plastics (Duroplast)

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

Heat treatable steel

8.1 Summary of steels 1.2311 40 CrMnMo 7 0,4 0,3 1,5 1,9 0,2
1.2312 40 CrMnMoS 6-8 0,4 0,4 1,5 1,9 0,2 0,07
for plastic moulds
1.2347 X 40 CrMoVS 5-1 0,4 1,0 - 5,2 1,3 1,0 0,1
1.2378 40 CrMnNiMo 8-6-4 0,4 0,3 1,5 2,0 0,2 1,0
1.2766 35 NiCrMo 16 0,35 0,3 0,5 1,3 0,3 4,0

Corrosion resistant steel

1.2082 X 21 Cr 13 0,2 0,4 0,4 13,0 -
1.2083 X 40 Cr 13 0,42 0,4 0,3 13,0 -
1.2316 X 36 CrMo 17 0,36 0,4 0,4 17,0 1,2
1.4120 X 20 CrMo 13 0,2 0,4 0,4 13,0 1,2

Through hardening steel

1.2713 55 NiCrMoV 6 0,55 0,3 0,8 0,7 0,3 1,7 0,1
1.2343 X 38 CrMoV 5-1 0,38 1,0 0,4 5,3 1,3 0,4
1.2767 X 45 NiCrMo 4 0,45 0,3 0,3 1,4 0,3 4,0
1.2842 90 MnCrV 8 0,9 0,3 2,0 0,4 - 0,1
1.2080 X 210 Cr 12 2,0 0,3 0,3 12 -

Nitriding steel
1.2895 34 CrAINi 7 0,35 0,5 1,7 0,2 1,0 Al 1,0

Age hardening steel

1.2709 X 3 NiCoMoTi 18-9-5 0,03 0,1 0,15 Ti 1,0 5,0 18,0 Co 10,0

Block steel
1.1730 C45W 0, 45 0, 3 0, 7 - -
INDEX

8.2 Data for plastic mould steel 1.2312

DIN Designation: 40 CrMnMoS 8 6

Chemical composition: C Si Mn Cr Mo S
0,4 0,4 1,5 1,9 0,2 0,07

Properties: Through heat treatable, good machinability also in

heat treated condition, polishable

Application: Plastic forms and - moulds, form holding blocks,

receiver coatings

Hot forming: 1050 - 850 C slow cooling in vermiculite

or in the oven

Soft annealing: 710 - 740 C / 4 h oven cooling / 235 HB

Hardening: 840 - 870 C oil / air or

180 - 220 C hot bath

Hardness after quenching: 51 HRC (1730 N/mm)

Tempering C 100 200 300 400 500 600 700

Hardness after 51 50 48 46 42 36 28
tempering HRC
N/mm 1730 1670 1570 1480 1330 1140 920
INDEX

Die cast form for plastic made from material No. 1.2312
INDEX

8.3 Appropriate UTP welding consumables for steels for injection moulds

Coated TIG rod Application Hardness

electrode MIG /MAG wire weld deposit

641 Kb A 641 Build up and joints on case approx. 200 HB

hardening and heat treatable
steel
73 G 4 A 73 G 4 Build up on similar heat treatable 38 - 42 HRC
73 G 3 A 73 G 3 and through hardened steel with 45 - 48 HRC
73 G 2 A 73 G 2 corresponding hardness 55 - 58 HRC
65 A 651 Build up welding on corrosion approx. 220 HB
665 A 66 resistant steels with high approx. 350 HB
C-content
63 A 63 Crack resistant and tough approx. 180 HB
630 joints and build up,
6302 stainless
6025 A 6025 Build up and joints on Ni-containing approx. 180 HB
case hardening- and heat treatable
steel
702 A 702 Build up on nitriding and aged approx. 37 HRC
steels
INDEX

Plastic press die lower and upper part

made from material 1.2162
INDEX

9. Welding of cast iron

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

Substantial change of the form of a cast iron press tool

INDEX

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

reduce welding stress.

Very large and substantial building up repairs can be done by using our Ferro- Nickel MIG wire UTP A 8051 Ti.
INDEX

Form change on a cast iron press tool

Micrograph of the transition zone

GGG 40 to UTP 86 FN
INDEX Material Mat. No. Structure Tensile Hardness Yield strength Elong.
typ strength HB (min) Rp0,2 (min) A5
N/mm N/mm %

GG 10 0.6010 ferritic 100 100 -150

GG 15 0.6015 150 140 -190
GG 20 0.6020 200 170 - 210
GG 25 0.6025 250 180 - 240
9.1 Summary of cast GG 30 0.6030 300 200 - 260
iron materials GG 35 0.6035 350 210 - 280
GG 40 0.6045 perlitic 400 230 - 300

GGG 35.3 0.7033 ferritic 350 - 400 110 -150 220 22

GGG 40.3 0.7043 400 - 450 120 -165 250 18
GGG 40 0.7040 400 - 550 135 -185 250 15
GGG 50 0.7050 500 - 650 170 - 220 320 7
GGG 60 0.7060 600 - 750 200 - 250 380 3
GGG 70 0.7070 700 - 850 235 - 285 440 2
GGG 80 0.7080 perlitic 800 -1000 270 - 335 500 2

GG - CrMo alloyed cast iron

GG - CrNi

Tensile strength values are minimum values in accordance with DIN 1691 and DIN 1693
INDEX

Edge build up on a cast iron

press tool with UTP 807
INDEX

9.2 Appropriate UTP products for cast iron welding

UTP Application Hardness Current

Electrodes

8C Buffer layer on joints and building up approx. 180 HB = - / -.

on large cast iron parts with lamellar
graphite structure.
Joint welds on thin walled cast iron parts

85 FN Joining and build up welding on GG approx. 190 HB =+/

and GGG cast iron parts, particularly
86 FN approx. 220 HB
for multi-layer welding and for wear
resistant building up on worn out tools.

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.

82 AS Electrode for gouging and chamfering - - / --

INDEX

9.3 Appropriate UTP TIG rods and MIG wires for cast iron welding

UTP type Application Hardness

A 80 Ni TIG rod with approx. 95 % Ni for build up and approx. 150 HB

joints

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 80 M Ni-Cu type TIG rod with approx. 70 % Ni and approx. 150 HB

30 % Cu (Monel) for joining and build up on all
kinds of cast iron.

A 068 HH Ni-Cr-Fe type rod with approx. 70 % Ni and approx. 180 HB

20 % Cr for joining and build up on all kinds of
cast iron, high 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

6025* 2,5 / 3,2 / 4,0

A 6025* 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6
INDEX UTP type Electrodes TIG rods MIG/MAG-wires
mm mm mm
8 2,5 / 3,2 / 4,0
8 C* 2,5 / 3,2 / 4,0
A 80 Ni 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

A 80 M 1,6 1,0/1,2/1,6

85 FN 2,5 / 3,2 / 4,0

86 FN 2,5 / 3,2 / 4,0
A 8051 Ti 2,4 0,8 / 1,2
10. Availability of the
A 387 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6
UTP Products for
700* 2,5 / 3,2 / 4,0
tool welding 7000 2,5 / 3,2 / 4,0
7008* 2,5 / 3,2 / 4,0
A 776 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6

6218 Mo* 2,5 / 3,2 / 4,0

A 6222 Mo 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6
7015 Mo
2,5 / 3,2 / 4,0
A 068 HH 1,6 / 2,0 / 2,4 0,8 / 1,0 / 1,2 / 1,6
Celsit 706 3,2 / 4,0
A Celsit 706 V 3,2 / 4,0
AF Celsit 706 1,2 / 1,6
Celsit 712 3,2 / 4,0
A Celsit 712 SN 3,2 / 4,0
AF Celsit 712 1,2 / 1,6
Celsit 701 3,2 / 4,0
A Celsit 701 N 3,2 / 4,0
AF Celsit 701 1,2 / 1,6
Celsit 721 3,2 / 4,0
A Celsit 721 3,2 / 4,0
AF Celsit 721 1,2 / 1,6

*) available on demand