Professional Documents
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SECTION PAGES
Forward 3
Flanging Steel C 14 – 18
Welding Terms G 35
Summary H 36
Full implementation of the four alloy programs spelled out herein has
resulted in a substantial decrease in the number of tool failures that occurs
daily in the production of pressed metal components.
1. Chipping
2. Metal Pick Up
3. Galling
4. Improper Temper
Metal stamping tools and dies can then be effectively repaired, upgraded,
or replaced with a high efficiency composite fabrication that is specifically
designed for the applications. This decision will be made on the basis of cause
and effect only.
I. PRODUCT INFORMATION
Eureka recommends that four alloys be used for the repair and
maintenance of metal stamping tools. This recommendation is made on the basis
of technical data furnished by the American Iron and Steel Institute and almost
63 years of experience and direct involvement. Minimizing the number of alloys
available to the welders also reduces confusion in the plant.
Color Match
PRODUCT DESCRIPTION
(continued)
High polish
Lubricity
Hardness – 36/38 RC
Heat Treatable
EUREKA NO. 72
Hardness – 54/56 HRC
Excellent weldability
The welder should recognize that cutting steels fail mostly due to
chipping on the cutting edge. He should check the hardness. Cutting tools run
best about 54/58 RC. If the section is over 59 RC, the operator should temper it
back to at least 54/58 RC. (See tempering information)
Peen thoroughly
Peen weld metal over radius in plastic state (See Figure 2, Page 11)
Post Heat
Water 500°F. Examples: A.I.S.I. W-1, W-2
Oil 500°F. Examples: A.I.S.I. O-1, O-2, O-6
Air 700°F. Examples: A.I.S.I. A-2, A-6, A-10
Air 1000°F. Examples: A.I.S.I. D-2, D-5
Preheat
Water 400°F. Examples: A.I.S.I. W-1, W-2
Oil 450°F. Examples: A.I.S.I. O-1, O-2, O-6
Air 600°F. Examples: A.I.S.I. A-2, A-6, A-10
Air 950°F. Examples: A.I.S.I. D-2, D-5
Post Heat
Water 500°F. Examples: A.I.S.I. W-1, W-2
Oil 500°F. Examples: A.I.S.I. O-1, O-2, O-6
Air 700°F. Examples: A.I.S.I. A-2, A-6, A-10
Air 1000°F. Examples: D-2, D-5
If the section is broken into pieces, clamp them together tightly then tack weld
with Eureka No. 350.
Preheat
One hour per inch of thickness at temperature
Water 400°F. Examples: A.I.S.I. W-1, W-2
Oil 450°F. Examples: A.I.S.I. O-1, O-2, O-6
Air 600°F. Examples: A.I.S.I. A-2, A-6, A-10
Air 950°F. Examples: A.I.S.I. D-2, D-5
Peen thoroughly
Post Heat
One hour per inch of thickness at temperature
Water 500°F. Examples: A.I.S.I. W-1, W-2
Oil 500°F. Examples: A.I.S.I. O-1, O-2, O-6
Air 700°F. Examples: A.I.S.I. A-2, A-6, A-10
Air 1000°F. Examples: A.I.S.I. D-2, D-5
Electrodes
Size Amps D.C.R.P.
3/32” 85/100
1/8” 115/125
5/32” 135/160
Gas Coverage
Figure #1
As Prepared
Figure #2
Eureka #74
Peen weld over edges while
in plastic state
Figure #3
As Prepared
3/8" X 3/8"
J Groove Construction
Eureka #74
Build-up Entire Edge
Allow 3/32" Cleanup
Figure #5
Figure #6
FLANGING STEELS
Trouble Shooting
The welder and foreman should recognize the two major causes of failure:
These are the two major reasons for failure and subsequent down time.
Galling suggests that the surface is too soft. Pick up indicates that the surface is
too porous allowing iron or zinc oxide to get trapped. The welder should:
Preheat
Water 400°F. Examples: A.I.S.I. W-1, W-2
Oil 500°F. Examples: A.I.S.I. O-1, O-2, O-6
Air 600°F. Examples: A.I.S.I. A-2, A-6, A-10
Air 950°F. Examples: A.I.S.I. D-2, D-5
S.A.E. 10120 150°F.
Note to Operator: Air hardening steels require a thorough soaking—
short cutting is counter productive in the final analysis
Allow a full 3/32” for clean up – touch ups are counter productive.
Post Heat
Air hardening sections welded with Eureka No. 1216 should be posted heat at
950°F. - 1000°F.
The purpose of the tempering is to relieve stress and temper the weld
deposit to 59/62 RC.
This weld deposit has a secondary hardening range of 63/66 RC.
Cooling Down
Keep the cooling rate slow
Note: In that most wiping and flanging steels are made with
D-2 through D-7, the following procedure should be followed:
Grind all cracks completely out leaving a smooth “U” shaped groove.
Tightly clamp broken sections together before tack welding with Eureka 350.
Preheat the entire section to 950°F. minimum, 1000°F. maximum for one hour
per inch of thickness at temperature. (If other than D-2 – D-7 series, refer to
appropriate preheat temperature).
Fill the “U” groove using Eureka EXP-10 all the way leaving only 5/16” for
Eureka 1216 cap.
Post Heat
Replace the section on the furnace for 2 – 3 hours at 1000°F. maximum,
(or other depending upon base material)
Figure #1
As Prepared
Remove 3/8" Stock
Radius All 90 Degree Corners
Figure #2
Eureka #72 or
Eureka #1216
Figure #3
Figure #4
Eureka EXP-10 - Underlay
Eureka #72 or #1216 cap
Trouble Shooting
The panel tells the story – iron dies mark the panel while drawing over the
beads or in deep or reverse draw areas. This generally indicates that the draw
surface is either too soft, too porous, or both. The welder should consider the
underlay/overlay method as follows:
I. DRAW RADIUS
Figure 1 –2, Page 23
Wire brush and thoroughly inspect this area. See Figure No. 1, Page 23
Always use the smallest diameter wire suitable for the job.
Post Heat
After welding, cover with Kaowool and keep gas belchers
on low for at least eight hours.
Preparation
Unlike steel trimmers, cast iron requires an underlayment of EXP-10
and a different preparation. See Figure 5, page 25
The “U” groove facilitates both the EXP-10 underlay and the tool steel,
Eureka No. 74, cap.
Prepared in this fashion, the trim edge will also be supported mechanically.
Preheat -- 750°°F.
Use Tempil Sticks
Apply the tool steel trim edge. Maintain the same preheat, apply three passes of
Eureka No. 74. Use skip welding technique 2-1/2” to 3” stringer beads. Allow
3/32” maximum for clean up. Square corners as you go by peening the final pass
while still in the plastic state. Again, it is important to move quickly and distribute
the heat as evenly as possible.
Post Heat
Cover the welded section of the punch with Kaowool.
Decrease the heat from the gas blowers but leave them on the section
somewhere below the welded trim edge for eight hours.
Remove the blowers but leave the section covered until it is room temperature.
Preparation
Keller a “U” groove approximately 3/8” deep, 3/8” wide to facilitate two underlay
passes of Eureka EXP-10. See Figure No. 3, page 25
Preheat
750°F. - 900°F.
Apply the tool steel cap. (G.M.A.W., Eureka No. 1216). Using the filled groove as
base, apply short stringer beads to form draw bead. Peen each pass (again
lightly) while in the plastic state, forming the bead radius as you go. Skip weld
and move around quickly to avoid heat build up. Keep welding until you finish.
Post Heat
Cover with Kaowool. Cut the blowers down and keep hot for eight (8) hours.
Remove the blowers and slow cool in still air to room temperature.
Gas Coverage
75 percent Argon, 25 percent CO2 (C-25)
Figure #1
As prepared
Remove 3/8" stock
X
X
X
XX
XX
Figure #3
As Prepared
3/8" "U" Groove
Fill Groove
Figure #4 with EXP-10
Figure #5
As Prepared
Remove 3/8" stock use
"U" or "J" Groove
Figure #6
The tempering information in this section should be referred to on every job. The
tempering curves tell the operator how to raise and lower the hardness of the
weld deposit.
Trimming and blanking steels perform best at about 54/57 RC. Excessive
hardness results in chipping and breaking.
Flanging steels perform best at 60/62 RC. Higher hardness can be reached for
problem sections, but the higher the hardness, the lower the ductility.
Improper tempering is one of the four major causes of failure. Properly tempered
tools consistently perform better.
Always keep in mind that you are tempering the weld deposit, not the base
material. If the base material needs to be tempered down before welding to lend
ductility to the section, refer to the manufacturer’s technical data sheet.
RT
EUREKA #74
70
65
60
55
50
45
40
35
30
25
20
RT 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
HRC
2. The dotted vertical line indicates the ideal post heat for sections welded
with Eureka #74 on Blank and Trim Steels 54 -–57 RC.
Eureka 1216
70
65
60
55
50
45
40
35
30
25
20
HRC 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
RT
2. The dotted vertical line indicates the secondary hardness range of Eureka
#1216. Obtaining this hardness (63/66 RC) requires a second and separate
temper at 1025°F. for one hour per inch of thickness at temperature.
PREHEAT INFORMATION
1000°°F.
950°°F.
900°°F.
850°°F.
800°°F.
750°°F.
700°°F.
650°°F.
600°°F.
550°°F.
500°°F.
450°°F.
400°°F.
350°°F.
1020 W-1 P-20 6150 4130 H-12 D-5 M-1
1045 W-5 O-6 6145 4140 H-13 D-7 M-2
S.A.E. 1050 O-1 O-7 S-1 4340 A-7 D-2 M-36
A.I.S.I. O-5 S-7 A-2 A-10 M-42
A-6
Low Chrome 2% Cr 1/2% Mo. Up to .15 2.0 0.5 2% Cr 1/2% Mo 400°F. - 600°F.
Moly 2% Cr 1/2% Mo. .15 -.25 2.0 0.5 2% Cr 1/2% Mo 500°F. - 800°F.
Steels 2% Cr 1% Mo Up to .15 2.0 1.0 2% Cr 1% Mo 500°F. - 700°F.
2% Cr 1% Mo .15 - .25 2.0 1.0 2% Cr 1% Mo 600°F. - 800°F.
Medium 5% Cr 1/2% Mo Up to .15 5.0 0.5 5% Cr 1/2% Mo 500°F. - 800°F.
Chrome 5% Cr 1/2 % Mo .15 - .25 5.0 0.5 5% Cr 1/2% Mo 600°F. - 900°F.
Moly Steels 8% Cr 1% Mo .15 max. 8.0 1.0 8% Cr 1% Mo 600°F. - 900°F.
Plain High 12–14% Cr Type 410 .10 13.0 12-14% Cr Type 410 300°F. - 500°F.
Chromium 16-18% Cr Type 430 .10 17.0 16-18% Cr Type 430 300°F. - 500°F.
Steels 23-30% Cr Type 446 .10 26.0 23-30% Cr Type 446 300°F. – 500°F.
High 18% Cr 8% Ni Type 304 .07 18.0 8.0 18% Cr 8% Ni Type 304 Usually Do Not
Chrome 25-12 Type 309 .07 25.0 12.0 25-12 Type 309 Require
Nickel Preheat But
Stainless 25-20 Type 310 .10 25.0 20.0 25-20 Type 310 It May Be
Steel 18-8 Cb Type 347 .07 18.0 8.0 Cb10X 18-8 Cb. Type 347 Desirable To
C Remove Chill
18-8 Mo Type 316 .07 18.0 8.0 2.5 18-8 Mo. Type 316
18-8 Mo Type 317 .07 18.0 8.0 3.5 18-8 Mo. Type 316
I. Tempering Furnace
(Eureka Mod. No. M.S.T.F.)
The tempering furnace recommended for metal stamping dies should be big
enough to facilitate every section in the plant with the exception of large cast iron
draw dies and punches which call for local preheat with gas belchers. Eureka
suggests that a Pyrometer controlled recirculating gas furnace be considered.
(1200°F. maximum). Inside dimensions of the furnace will be determined by the
individual requirements of each plant.
T.I.G. machines are a must for small repairs tough-up work and partial repairs.
Low heat input and precise control are required on small tool steel sections.
M.I.G. welding power source is used for full repairs and composite fabrication of
sections.
This dual wire feeder is excellent for upgrading cast iron draw dies, punches, and
trimmers. Both the underlay wire and the tool steel cap can be applied without
changing spools.
IV. S.M.A.W.
V. Accessories
Welding Terms
Preheat
Preheating tool steel before welding reduces the quench rate of the molten weld
metal. This minimizes stress and equalizes the shrink rate.
Post Heat
Post heating equalizes the temperature throughout the section to allow the weld
deposit and base metal to cool at an equal rate when removed from the furnace.
This helps to reduce shrinkage stress that may promote cracking.
Peening
Mechanically relieves locked up stress, done in the plastic state, peening forges
the weld metal and promotes a very dense grain structure.
Stringer Beads
S.M.A.W.
G.M.A.W.
G.T.A.W.
Porosity
Pyrometer
Inner-Pass Temperature
The upper limit of the tempering range. Exceeding this temperature will sharply
reduce the hardness of tool steel.
SUMMARY
The tool and die welding resources that are in your plant today can be utilized to
save and earn the corporation a great deal of money. The case histories on the
pages that follow represent thousands of dollars that G.M. and others have
saved in the past.
2. Properly welded tools allow for optimum production runs (Parts produced)
4. Tools and dies fail consistently for the same reason over and over again.
Proper welding corrects this problem.
5. The tool bill is reduced – less tool steel, less tool maintenance
Tool steels, particularly the premium air grades, are expensive. Buying it in wire
form and applying it only where it is needed is rapidly becoming the modern way
of building tools. Everything considered, tool steel welding may be the only way
to reduce tool cost and down time in the metal stamping industry.
The concept of composite tool construction will then be examined from several
different vantage points. The statistical information presented will represent cross
sectional analysis of case histories assembled over the past ten year.
COST
Composite tools, constructed utilizing conventional M.I.G. equipment, appear to
cost within 5 percent of those tools constructed out of solid tool steel. Certain
variables influence this percentage:
Compositely fabricated dies were first used in the forging industry. Hammer dies,
used for hot forging, were constructed by utilizing a tough low alloy base
material. In the area where the impression is sunk, a massive tool steel weld
deposit is applied. The tool steel weld deposit and the low alloy base material
delivered a perfect balance of heat, impact, and abrasion resistance. The
combination of physical and mechanical properties is otherwise unobtainable.
Today, the forging industry uses composite dies almost exclusively. The same
results can be obtained in the Metal Stamping Industry. Although production
results vary according to the part being made, the average increase will range
from 30 to 50 percent more parts per tool.
Compositely fabricated tools and dies are constructed from steels selected on
the basis of their weldability. Therefore, when repairs are necessary, they can be
made both quickly and effectively. The complicated procedures that are normally
required on air hardening tools are minimized substantially.
PRODUCTION
Uninterrupted production is the single biggest advantage that composite
fabrications deliver. The reasons of this are as follows:
CASE HISTORIES
General Motors
A. Chevrolet Metal Fab., Flint, Michigan
Tool Camero Frame Rail Flanging Section -- .100” stock
Original Tool D-2 Construction
Production Runs Approximately six weeks before replacement or repair
Subsequent tools constructed from AMPCO with same results
Fabricated Tool 4130 base material overlay with M-2 HSTS (Eureka No.
1216). Die was set in May 1981 and ran until July 1982.
Approximately 500,000 parts
CHRYSLER CORPORATION
A. Toledo Machine
Tool Torque converter – coining and forming tool -- .500” stock
Original Tool D-2 – constant breakage and scoring
Fabricated Tool Base 4340 – overlay M-2 high speed tool steel. Eliminated
scoring and breaking. Still in service
B. Twinsburg Stamping
Tool Inner door crash bar trim -- .125” stock
Original Tool W-2, O-6 – Daily edge chipping
Fabricated Tool Base W-2 tempered to 40 RC. Overlay with S-7 shock
resisting tool steel (Eureka No. 74)
Eliminated Chipping Die still running, no production interruptions after six
weeks
A.
Tool Trim steel detail for L.H. ranger – “I” beam .127” stock
Original Tool A-2, A-10, D-2 – constant chipping and breaking
Fabricated Tool 1020 base, S-7 (Eureka No.74) cutting edge
Production 63,000 pieces versus 10,000 pieces maximum
conventional tool
B.
Tool Brake back up plate, Form -- .125” stock
Original Tool A-2 – nine dies per month, breaking
Fabricated Tool S.A.E. 1020 (Eureka No. 1216)
Production One die ran over three months – minor touch up required
with grinder