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Handbook of mould, tool and die repair welding

S Thompson

Woodhead Publishing Series in Welding and Other Joining Technologies No. 37

 - comprehensive tool metal welder's reference work
 - written for the shop floor, by the shop floor
 - practical, easy to understand techniques designed to save time and money
 - describes many 'tricks of the trade' and special techniques
 - useful training aid for both experienced and novice welders

This book covers an important and frequently overlooked area of welding - the repair of moulds, tools and dies. Because two rather different trades overlap in this process - welding and toolmaking, 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.

The Handbook of mould, tool and die repair welding is designed to save companies time and money by:

Acting as a training aid so that repairs can be carried out in-house
Reducing the need to send work out and the costs involved
Reducing the production time lost when repairs are required
Providing clear diagrams and a user-friendly style to make the techniques easily understood

It is an essential resource for Tool Room Managers and Foremen as well as maintenance and repair welding specialists.

ISBN 1 85573 429 X
ISBN-13: 978 1 85573 429 6
October 1999
224 pages  244 x 172mm  hardback  
£155.00 / US$265.00 / €185.00

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An e-book version of this title is available to purchase as part of a Collection or Pick n Mix or by Chapter. Visit Woodhead Publishing Online

About the author

Steve Thompson is a fully time-served welder with 25 years experience in all aspects of welding and a particular expertise working with exotic pipework such as stainless steels and copper alloys. In 1989 he joined a newly-formed company intending to specialise in mould, tool and die welding repairs. He found there was little information on the subject, so he started to collect together notes, materials and diagrams on the techniques which made the job easier. The book has grown out of this process and its practical and accessible style is a direct result of Steve's first hand experience.

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Contents

How to use this book
 - Can you TIG weld?
 - Weld procedure
 - Review

Writing your weld procedure
 - Why you need a weld procedure
 - Collecting your information
 - Weld procedure 1
 - Weld procedure 2
 - Weld procedure 3
 - Weld procedure 4

Identification of material
 - Tool steels
 - HRC file check
 - Tool coppers
 - Tool aluminium

Choosing your filler wire
 - Buying filler wires
 - Choosing filler wires
 - General colour match
 - Photo/acid etch
 - Cheapest filler
 - Hardness (HRC)
 - Butter/crack repair
 - Filler wires for tool coppers
 - Tab testing on aluminium and copper tools

Heat control
 - Pre-heats
 - Cooling
 - Heat sources
 - Pre-heating
 - Oven heating
 - Heating larger tools
 - Post-heat treatment
 - Pre-heating aluminium and copper
 - Minimizing pre-heats on aluminium and copper

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
 - Using base metal as filler wire
 - Welding fine details
 - Filler wire

Equipment
 - Safety
 - Safety wear
 - Keeping your work place tidy
 - Power tools
 - Welding equipment
 - Setting up your equipment
 - Control panels
 - Other equipment

Basic TIG welding for beginners
 - Holding your torch
 - Torch angles
 - Striking your arc
 - Using your filler wire
 - Welding exercises

Appendix 1

Appendix 2, 3, 4, 5