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Steve Thompson, "Handbook of Mold, Tool and Die Repair Welding"

This book covers an important and frequently overlooked area of welding - the repair of molds, tools and dies. Because two rather different trades overlap in this process - welding and tool making, the materials and techniques involved have tended to be obscured. For many years, toolmakers and tool users have had to rely on the small number of specialist welders who do understand exactly what welding repair involves and have the skills to carry it out. Understanding the technical side of tool steels is frequently a problem for welders and understanding the practical side of welding can be a problem for machinists. This book has been written so that specialists from both sides can get to grips with the techniques and procedures involved.

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Contents

Preface

Acknowledgements

Introduction

1 How to use this book

Can you TIG weld?

Weld procedure

Review

2 Writing your weld procedure

Why you may need a weld procedure

Collecting your information

Weld procedure 1

Weld procedure 2

Weld procedure 3

Weld procedure 4

3 Identification of material

Tool steels

HRC file check

Tool coppers

Tool aluminum

4 Choosing your filler wire

Buying filler wires

Choosing filler wires

General color match

Photo/acid etch

Cheapest filler

Hardness (HRC)

Butter/crack repair

Filler wires for tool coppers

Tab testing on aluminum and copper tools

5 Heat control

Pre-heats

Cooling

Heat sources

Pre-heating

Oven heating

Heating larger tools

Post-heat treatment

Pre-heating aluminum and copper

Minimizing pre-heats on aluminum and copper

6 Weld techniques

Weld procedures

Cracking

Previous bad weld repairs

Sink

Under cut (notches)

Building pads of weld

Preparing a tool for a pedestal pad

Porosity (pin/blow holes)

Arc marks (earthing and protecting sensitive areas)

Using heat soaks and flood supports

Getting around bad access

Bending tungsten

Controlling distortion

Welding without full pre-heat

Welding case-hardened tools

Welding photo/acid etched and polished tools

Using base metal as filler wire

Welding fine details

Filler wire

7 Equipment

Safety

Safety wear

Keeping your work place tidy

Power tools

Welding equipment

Setting up your equipment

Control panels

Other equipment

8 Basic TIG welding for beginners

Holding your torch

Torch angles

Striking your arc

Using your filler wire

Welding exercises

Appendix I

Appendix II

Appendix Ill

Appendix IV Temperature conversion table

Appendix V Hardness conversion chart

Other steels and tool steels

Elements and their symbols

Millimeters to inches conversion table

Weld procedure sheet

Index

Thank you!

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