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Eureka Welding Alloys

2000 E. Avis Drive

Madison Heights, MI 48071

TOOL STEEL WELDING REPORT

Phone: 248/588 0001 (800) 962-8560 FAX: 248/585 7711


E-Mail: eurekagm@compuserve.com
Web Site: www.eurekaweldingalloys.com
TABLE OF CONTENTS

SECTION PAGES

Forward 3

Product Information A 4–5

Trimming Steels – Blanking Steels B 6 – 13

Flanging Steel C 14 – 18

Cast Iron Draw Dies, Punches, Binders D 19 – 25

Tempering and Preheat Information E 26 – 32


Tool Steel Welding Equipment F 33 – 34

Welding Terms G 35

Summary H 36

Composite Fabrication/Case Histories I 37 – 40

A Technical Report by Eureka


Page 2 of 40
Forward

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.

The Eureka Tool Steel Welding Program places heavy emphasis on


trouble shooting. Both management and hourly personnel will be trained to
recognize the four major factors that are responsible for repetitious tool failure
and subsequent down time.

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.

From the standpoint of return on investment, the modernization of your


Tool and Die Welding Program and facilities have limitless potential. Down
time due to tool failure is extremely expensive. Any reduction in this area has a
profound effect on plant profitability.

A Technical Report by Eureka


Page 3 of 40
SECTION A

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.

The Eureka products that are recommended herein are available in


S.M.A.W., G.T.A.W., and G.M.A.W. Our technical people know that this is
absolutely imperative for corporate consistency.

II. PRODUCT DESCRIPTION

EUREKA EXP-10 – Automotive Cast Iron


Developed by Eureka engineers to:
Adhesion to automotive cast iron

Comparable wear resistance value to parent casting

Machinable deposits – 36/38 RC

Color Match

Forming an austenitic barrier on high carbon ferrous metals

EUREKA NO. 74 -- Shock Resisting Tool Steel (A.I.S.I. S-7)


Recommended by A.I.S.I. for cold shearing of steel

Deposits a tough chip resistant alloy 54/57 RC

Which is desirable for blanking and trimming up to .250” thick.

A Technical Report by Eureka


Page 4 of 40
SECTION A

PRODUCT DESCRIPTION
(continued)

EUREKA NO. 1216 – High Speed Tool Steel (A.I.S.I. M-1/M-2)


High Speed tops the list of premium air hardening steels
Hardness 59/62 RC

Abrasion resistance – Best

Density – Resist metal or zinc pick up

High polish

Lubricity

EUREKA NO. 350


Super Joining Alloy
Tensile – 170,000

Hardness – 36/38 RC

Heat Treatable

Compression strength for cushion passes

Join dissimilar metals

EUREKA NO. 72
Hardness – 54/56 HRC

Abrasion resistance – Good

Low Crack Sensitivity

Excellent weldability

A Technical Report by Eureka


Page 5 of 40
SECTION B

TRIMMING STEELS – BLANKING STEELS


Trouble Shooting

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)

I. PARTIAL REPAIR – Figure 1 – 2, page 11

Prepare the Section


Remove all chips by grinding at 45° angle ¼” X ¼” (See Figure 1, page 11 )

Be sure to form a radius as shown in Figure 1. (Partial Repair)

Prepare the Section


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-6
Air 650°F. Examples: A.I.S.I. A-2, A-6, A-10
Air 950°F. Examples: A.I.S.I. D-2, D-5

Start the Welding

Employ the G.T.A.W. or S.M.A.W. process

One inch stringer beads maximum

Peen thoroughly

3/32” maximum clean up

Peen weld metal over radius in plastic state (See Figure 2, Page 11)

A Technical Report by Eureka


Page 6 of 40
SECTION B

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

II. COMPOSITE FABRICATION


Full Repair of Cutting Edge
Figures 3 – 4, page 12

Prepare the Section


Remove the entire cutting edge 3/8” X 3/8”

J Groove – See Figure 3, Page 12

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

Employ the G.M.A.W. or S.M.A.W. process

Start the Welding


Short stringer beads 2-1/2” maximum

Peen each pass

Allow 3/32” maximum clean up. Watch heat build up

Do not allow water-hardening steels to exceed 500°°F.

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

A Technical Report by Eureka


Page 7 of 40
SECTION B

II. COMPOSITE FABRICATION


Full Repair of Cutting Edge
Figures 3 – 4, page 12
(continued)

Composite Fabrication – Trimming and Blanking Steels


Base Metal
S.A.E. 1020 hot rolled. Acceptable for up to .250” thick stock

Cutting Edge – A.I.S.I. S-7

Eureka No. 74 A.C.W. – G.M.A.W. process -- .045” diameter wire maximum

Prepare the Section

Grind or flame cut a 3/8” X 3/8” – J Groove


See Figure 3, Page 12 on the entire cutting edge

Preheat Base Material

S.A.E. 1020 -- 150°F. minimum

Employ the G.M.A.W. Process

Skip weld 2-1/2” maximum stringer beads, move quickly

Peen each pass while in plastic state

Allow 3/32” maximum clean up

Post Heat – All Sections

500°F. for one hour at temperature – slow cool

A Technical Report by Eureka


Page 8 of 40
SECTION B

III. REPAIR FRACTURE


See Figure 5 – 6, Page 13

Prepare the Section


Grind all cracks completely out forming a “U” groove. Avoid 90° corners.

If the section is broken into pieces, clamp them together tightly then tack weld
with Eureka No. 350.

Clamp or tack weld section to a heavy plate or strong back

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

Start the Welding


Employ the S.M.A.W. or G.M.A.W. process

Use short stringer beads (move around quickly)

Peen thoroughly

3/32” maximum clean up

NOTE: If a fracture runs through cutting edge,


allow 5/16” for cap of Eureka No. 74

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

A Technical Report by Eureka


Page 9 of 40
SECTION B

IV. EUREKA NO. 74 WELDING PARAMETERS

Electrodes
Size Amps D.C.R.P.
3/32” 85/100
1/8” 115/125
5/32” 135/160

Alloy Cored Wire


Size D.C.R.P. Amps Volts
.045” 120/140 17/19
.063” 135/165 20/22

Gas Coverage

75 percent Argon, 25 percent CO2 (C-25)

A Technical Report by Eureka


Page 10 of 40
SECTION B

BLANKING TRIMMING STEELS


I. PARTIAL REPAIR

Figure #1

As Prepared

Figure #2

Eureka #74
Peen weld over edges while
in plastic state

Watch heat build-up here

G.T.A.W. Recommended for Partial Repairs

A Technical Report by Eureka


Page 11 of 40
SECTION C
Blanking & Trimming Steels
II. COMPOSITE FABRICATION & FULL REPAIR

Figure #3

As Prepared
3/8" X 3/8"
J Groove Construction

Eureka #74
Build-up Entire Edge
Allow 3/32" Cleanup

Use Skip Welding Technique


2-1/2" Stringer Beads

G.M.A.W. Recommended For Composite Fabrication and Full Repair

A Technical Report by Eureka


Page 12 of 40
SECTION C
III. REPAIR FRACTURE

Figure #5

If the cracks runs through


the cutting edge
Allow 3/16" cap of Eureka #74

Figure #6

Eureka #350 -- Underlay


Eureka #74 -- Cap on trim edge

Grind out entire crack


Use short stringer beads
Peen thoroughly
Allow 3/32" clean up

G.M.A.W. S.M.A.W. G.T.A.W.


Depending on Size of Section

A Technical Report by Eureka


Page 13 of 40
SECTION C

FLANGING STEELS
Trouble Shooting
The welder and foreman should recognize the two major causes of failure:

1. Galling on the work surface of the section.


2. Metal or zinc oxides collecting on draw or wiping
surface scoring subsequent panels.

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:

1. Check hardness. If the section is under 59 HRC, he should consider


replacing the entire work surface with Eureka No. 1216 High Speed Tool
Steel.

2. Consider building a complete fabrication utilizing S.A.E. 1020 hot rolled as


the base and Eureka No. 1216 HSTS as the work surface.

I. COMPOSITE FABRICATION – FULL REPAIR


Figures 1-2, Page 17

Prepare the Section


Remove all cracks entirely

Undercut 3/8” minimum the entire work surface.

Use carbon arc (preheat first) or grind to facilitate weld deposit.

(Carbon Arc Electrodes, 1/4” maximum)

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

A Technical Report by Eureka


Page 14 of 40
SECTION C

Start the Welding


1. Use the G.M.A.W. or G.T.A.W. process if possible.

Stick electrodes (S.M.A.W.) are also acceptable but careful attention


should be paid to inner-pass temperature.

Do not allow section to exceed 150°F. – more than there preheat


temperature.

2. Use short stringer beads 1-1/2” to 2” long.

Move around the section, stopping only to peen.

Try to distribute heat exposure evenly.

It is important to move quickly and keep welding until the section is


finished.

Final passes can be peened in the plastic state.

This promotes harder, more dense weld metal at the surface.

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.

This can only be achieved, however, with a second individual temper at


1025°F. at temperature for one hour per inch of thickness at the thickest point.
See Tempering Information, Section E, Eureka No. 1216, page 29

Cooling Down
Keep the cooling rate slow

Cover with Kaowool

A Technical Report by Eureka


Page 15 of 40
SECTION C

II. PREPAIR FRACTURES AND CRACKS


Figures 3 – 4, Page 18

Note: In that most wiping and flanging steels are made with
D-2 through D-7, the following procedure should be followed:

Prepare the Section

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.

a. Apply short stringer beads 3” maximum.


b. Peen each pass thoroughly
c. Employ the skip welding method to minimize heat sink as much as
possible. Move quickly.

Note: Maintain preheat. Don’t rush anything.

Apply the Cap


Eureka No. 1216 H.S.T.S.
Fill the 5/16” balance plus 3/32” for clean up maximum.

Use 2” stringer beads maximum.

Peen each pass thoroughly and wire brush as necessary.

Post Heat
Replace the section on the furnace for 2 – 3 hours at 1000°F. maximum,
(or other depending upon base material)

Cover with Kaowool. Slow cool in still air to room temperature

To obtain a secondary hardness of 63/66 RC, temper at 1025°F. for one


hour per inch of thickness at temperature -- Slow cool

A Technical Report by Eureka


Page 16 of 40
FLANGING STEELS
I. Composite Fabrication & Full Repair
SECTION C

Figure #1
As Prepared
Remove 3/8" Stock
Radius All 90 Degree Corners

Figure #2
Eureka #72 or
Eureka #1216

Buildup entire face


Allow 3/32" cleanup
Peen thoroughly

G.M.A.W. Recommended for Composite


Fabrication & Full Repair

A Technical Report by Eureka


Page 17 of 40
SECTION C

Figure #3

Figure #4
Eureka EXP-10 - Underlay
Eureka #72 or #1216 cap

Grind out entire crack


Use short stringer beads
EXP-10 cap working area
with #1216

G.M.A.W. S.M.A.W. G.T.A.W.


Depending on size of Section

A Technical Report by Eureka


Page 18 of 40
SECTION D

Cast Iron Draw Dies, Punches, Binders

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

Prepare the Section


Undercut the entire areas enough to facilitate one pass of EXP-10 on the iron
and two passes of Eureka No. 1216 approximately 3/8” deep.

Wire brush and thoroughly inspect this area. See Figure No. 1, Page 23

Preheat -- 750°°F. - 950°°F.


Cast iron dies are usually too big to get into a furnace so local preheat
is acceptable.

Use natural gas blowers to heat the area being overlayed.

Cover adjacent areas with Kaowool to minimize heat loss.

See Section F for information on natural gas blowers.

Start the Welding


Use G.M.A.W. or S.M.A.W. process

Always use the smallest diameter wire suitable for the job.

Apply short stringer beads of EXP-10 on the entire surface.

Employ the skip welding technique.

Peen each pass lightly while in the plastic state.


Cover the entire area; move around quickly.

A Technical Report by Eureka


Page 19 of 40
SECTION D

Apply the Cap – Eureka No. 1216


Follow the above procedure to apply the cap.
Remember to move quickly and peen lightly.

Post Heat
After welding, cover with Kaowool and keep gas belchers
on low for at least eight hours.

Gradually decrease heat until section is room temperature.

II. WELD TRIM EDGE


Figures 5 – 6, Page 25

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

Start the Welding


Apply one pass of EXP-10 on the entire surface of the “U” groove. Be sure to
leave room for the tool steel cap. Peen each pass lightly. Maintain heat
temperature throughout entire welding process.

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.

A Technical Report by Eureka


Page 20 of 40
SECTION D

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.

III. DRAW BEADS


Figures 3 – 4, Page 25

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

This method provides additional mechanical strength to the underlay.

Preheat
750°F. - 900°F.

Start the Welding


G.M.A.W. Process Only
Using short stringer beads, fill the entire groove flush with the draw surface of the
die. Skip weld and peen lightly. Move quickly and keep welding until the entire
groove is filled.

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.

A Technical Report by Eureka


Page 21 of 40
SECTION D

IV. WELDING PARAMETERS

Eureka EXP-10 / Eureka No. 1216


Electrodes
Size Amps D.C.R.P.
3/32” 85/110
1/8” 115/125
5/32” 135/160

Eureka EXP-10 / Eureka No. 1216


Alloy Cored Wire
Size D.C.R.P. Amps Volts
.045” 120/140 17/19
.063” 130/165 20/22

Gas Coverage
75 percent Argon, 25 percent CO2 (C-25)

A Technical Report by Eureka


Page 22 of 40
SECTION D

CAST IRON DRAW DIE


I. DRAW RADIUS

Figure #1

As prepared
Remove 3/8" stock

Underlay with EXP-10


Cap with #1216
Figure #2 Peen each pass
Allow 3/32" cleanup

X
X
X
XX
XX

G.M.A.W Recommended for Welded Draw Radius


A Technical Report by Eureka
Page 23 of 40
SECTION D

CAST IRON DRAW DIE


II. Draw Die/Draw Bead

Figure #3

As Prepared
3/8" "U" Groove

Fill Groove
Figure #4 with EXP-10

Cap with 1216


xxxx
xxx

G.M.A.W. Recommended for Welded Draw Bead


A Technical Report by Eureka
Page 24 of 40
SECTION D

CAST IRON TRIM POST


III. Welded Trim Edge

Figure #5

As Prepared
Remove 3/8" stock use
"U" or "J" Groove

Figure #6

Underlay with EXP-10


Cap with #74
Peen each pass
Allow 3/32" cleanup

G.M.A.W. Recommended for Welded Trim Edge

A Technical Report by Eureka


Page 25 of 40
SECTION E

Tempering and Preheating Information

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.

The preheat tables on pages 27 thru 29 can be referred to as a guide.

A Technical Report by Eureka


Page 26 of 40
SECTION E

TEMPERING DATA FOR WATER HARDENING TOOL


STEEL A.I.S.I. W-1, W-2

A.I.S.I. W-1, W-2


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

Tempering Temperature -- °F.

Tempering data for Water Hardening Steel has been included as a


reference. Prior to welding on water hardening sections, it is best to check
the hardness. Sections over 59 RC should be tempered back to 54/57 RC to
minimize the reoccurrence of chipping on the cutting edge. Sections that are
having the cutting edge fully welded can be tempered back to 42/44 RC prior
to welding. This gives the base material added ductility during and after the
S-7 application.

A Technical Report by Eureka


Page 27 of 40
SECTION E

Tempering Procedure for Section Welded with

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

Tempering Temperature -- °F.


1. Sections welded with Eureka #74 should be post heated to 500°F. for
one hour per inch of thickness at temperature

2. The dotted vertical line indicates the ideal post heat for sections welded
with Eureka #74 on Blank and Trim Steels 54 -–57 RC.

A Technical Report by Eureka


Page 28 of 40
SECTION E

Tempering Procedure for Sections Welded With

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

Tempering Temperature -- °F.


1. Sections welded with Eureka #1216 should be post heated to 950°F. for
one hour per inch of thickness at temperature.

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.

3. Composite fabrications that are double tempered perform extremely well


due to the ductile base material.

A Technical Report by Eureka


Page 29 of 40
SECTION E

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

A.I.S.I. TOOL STEEL DESIGNATIONS


• W-1 -- W-6 Water Hardening
• O-1 – O-6 Oil Hardening
• A-2 – A-10 Air Hardening
• M-1 – M-42 Molybdenum High Speed
• S-1 – S-7 Shock Resisting
• L-1 – L-7 Special Purpose
• P-1 – P-21 Mold Steel
• D-1 – D-7 High Carbon / High Chrome
• H-10 – H-43 Hot Work
• T-1 – T-15 Tungsten High Speed

A Technical Report by Eureka


Page 30 of 40
Preheat Temperatures for Metal Alloys
Metal Metal Recommended
Group Metal Approximate Composition – Percent Designation Preheat
Designation C Mn Si Cr Ni Mo Cu
Plain Plain Carbon Below .20 Plain Carbon Up to 200°F.
Carbon Plain Carbon .20-.30 Plain Carbon 200°- 300°F.
Steel Plain Carbon .30-.45 Plain Carbon 300°- 500°F.
Plain Carbon .45-.80 Plain Carbon 500°- 800°F.
Carbon Carbon Moly .10-.20 .50 Carbon Moly 300°- 500°F.
Moly Steels Carbon Moly .20-.30 .50 Carbon Moly 400°- 600°F.
Carbon Moly .30-.35 .50 Carbon Moly 500°- 800°F.

Silicon Structural .35 .80 .25 Silicon Structural 300°- 500°F.


Manganese Medium Manganese .20-.25 1.0-1.75 Medium Manganese 300°- 500°F.
Steels
SAE T1330 .30 1.75 SAE T 1330 400°- 600°F.
SAE T 1340 .40 1.75 SAE T 1340 500°- 800°F.
SAE T 1350 .50 1.75 SAE T 1350 600°- 900°F.
12% Manganese 1.25 12.0 12% Manganese USUALLY NOT
REQUIRED
Manganese Moly .20 1.65 .20 .35 Manganese Moly 300°F.- 500°F.
Jalten Steel .35 max. 1.50 .30 .40 Jalten Steel 400°F.- 600°F.
Manten Steel .30 max. 1.35 .30 .20 Manten Steel 400°F.- 600°F.
Armco High Tensile .12 max. .50 min .05 min .35 min Armco High Tensile Up to 200°F.
High
Double Strength #1 .12 max. .75 .50-1.25 .10 min .50-1.50 Double Strength #1 300°F. - 600°F.
Tensile
Steels Double Strength #1A .30 max. .75 .50-1.25 .10 min .50-1.50 Double Strength #1A 400°F. - 700°F.
Mayari R Steel .12 max. .75 .35 .2 –1.0 .25-.75 .60 Mayari R Steel Up to 300°F.
(See Otiscoloy Steel .12 max. 1.25 .10 max .10 max .50 max Otiscoloy Steel 200°F. - 400°F.
also Nax High Tensile .15 - .25 .75 .60 .17 .15 max .25 max Zr .12 Nax High Tensile Up to 300°F.
steels Cromamsil Steel .14 max. 1.25 .75 .50 Cromansil Steel 300°F. - 400°F.
below) A.W. Dyn-El Steel .11-.14 max .40 A.W. Dyn-El Steel Up to 300°F.
Corten Steel .12 max. .25-1.0 .5-1.5 .55 max .40 Corten Steel 200°F. - 400°F.
Chrome Copper Ni .12 max. .75 .75 .75 .55 Chrome Copper Ni 200°F. - 400°F.
Chrome Manganese .40 .90 .40 Chrome Manganese 400°F. - 600°F.
Yoloy Steel .05-.35 .3-1.0 1.75 1.0 Yoloy Steel 200°F. - 600°F.
Hi-Steel .12 max. .6 .3 max .55 .9-1.25 Hi-Steel 200°F. - 500°F.
SAE 2015 Steel .10 -.20 .50 SAE 2015 Steel Up to 300°F.
Nickel
SAE 2115 Steel .10-.20 1.50 SAE 2115 Steel 200°F. - 300°F.
Steel 2-1/2% Nickel Steel .10-.20 2.50 2-1/2% Nickel Steel 200°F. - 400°F.
SAE 2315 Steel .15 3.50 SAE 2315 Steel 200°F. - 500°F.
SAE 2320 Steel .20 3.50 SAE 2320 Steel 200°F. - 500°F.
SAE 2330 Steel .30 3.50 SAE 2330 Steel 300°F. - 600°F.
SAE 2340 Steel .40 3.50 SAE 2340 Steel 400°F. - 700°F.

A Technical Report by Eureka Page 31 of 40


Preheat Temperatures for Metal Alloys
Metal Metal Recommended
Group Metal Approximate Composition – Percent Designation Preheat
Designation C Mn Si Cr Ni Mo Cu
SAE 3115 Steel .15 .60 1.25 SAE 3115 Steel 200°F. - 400°F.
SAE 3125 Steel .25 .60 1.25 SAE 3125 Steel 300°F. - 500°F.
SAE 3130 Steel .30 .60 1.25 SAE 3130 Steel 400°F. - 700°F.
Medium SAE 3140 Steel .40 .60 1.25 SAE 3140 Steel 500°F. - 800°F.
Nickel SAE 3150 Steel .50 .60 1.25 SAE 3150 Steel 600°F. - 900°F.
Chromium
Steel SAE 3215 Steel .15 1.00 1.75 SAE 3215 Steel 300°F. - 500°F.
SAE 3230 Steel .30 1.00 1.75 SAE 3230 Steel 500°F. - 700°F.
SAE 3240 Steel .40 1.00 1.75 SAE 3240 Steel 700°F. - 1000°F.
SAE 3250 Steel .50 1.00 1.75 SAE 3250 Steel 900°F. - 1100°F.
SAE 3315 Steel .15 1.50 3.50 SAE 3315 Steel 500°F. - 700°F.
SAE 3325 Steel .25 1.50 3.50 SAE 3325 Steel 900°F. - 1100°F.
SAE 3435 Steel .35 .75 3.00 SAE 3435 Steel 900°F. - 1100°F.
SAE 3450 Steel .50 .75 3.00 SAE 3450 Steel 900°F. - 1100°F.
Moly SAE 4140 Steel .40 .95 .20 SAE 4140 Steel 600°F. - 800°F.
Bearing SAE 4340 Steel .40 .65 1.75 .35 SAE 4340 Steel 700°F. - 900°F.
Chromium &
SAE 4615 Steel .15 1.80 .25 SAE 4615 Steel 400°F. - 600°F.
Chromium
Nickel SAE 4630 Steel .30 1.80 .25 SAE 4630 Steel 500°F. - 700°F.
Steels SAE 4640 Steel .40 1.80 .25 SAE 4640 Steel 600°F. - 800°F.
SAE 4820 Steel .20 3.50 .25 SAE 4820 Steel 600°F. - 800°F.

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

A Technical Report by Eureka Page 32 of 40


SECTION F

Tool Steel Welding Equipment


Most of the equipment that is required for effective tool steel welding may already
be in the plant. Some, however, will have to be purchased by each plant to meet
the requirements.

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.

The tempering furnace is used to:

A. Temper sections after welding


B. Retemper sections prior to upgrading
C. Preheat
D. Post Heat
E. Stress Relieve

Improper temper is a major cause of chipped or fractured sections, both welded


and unwelded.

II. G.T.A.W. Power Source


(Miller ABP 330)

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.

III. G.M.A.W. Power Source


(Miller Delta Weld 450)

M.I.G. welding power source is used for full repairs and composite fabrication of
sections.

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Page 33 of 40
SECTION F

III. G.M.A.W. Power Source


(continued)

G.M.A.W. wire feeder (Miller No. D-52-A)

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.

(The Miller 330 ABP has stick welding capacity)

V. Accessories

A. Tempil Sticks 200° to 1050°F. (One set per welder)


B. Power Brush Air or electric (One per welder)
C. RC Hardness Testor One per plant
D. Ball Peen Hammer 1 to 1-1/2 pounds
E. Needle Scaler Air (three, one per shift)
F. Snag Grinder 10,000 R.P.M. – 1/3 H.P.
G. Kaowool or Refactory Blanket 4’ x 4’
H. Replacement Parts List provided

A Technical Report by Eureka


Page 34 of 40
SECTION G

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

Weld beads made without weaving the arc.

S.M.A.W.

Shielded metal arc welding – stick electrodes

G.M.A.W.

Gas metal arc welding – M.I.G. or wire welding

G.T.A.W.

Gas tungsten arc welding – T.I.G. or Heli-arc welding

Porosity

Holes in weld metal caused by trapped gases exploding

Pyrometer

Pyrometer is an instrument used to measure the temperature of a tempering


furnace.

Inner-Pass Temperature

The upper limit of the tempering range. Exceeding this temperature will sharply
reduce the hardness of tool steel.

A Technical Report by Eureka


Page 35 of 40
SECTION H

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.

The equipment and technology is available today. The decision to take


advantage of these resources must be made in light of several general facts.

1. Improperly welded tools may actually add to the problem.

2. Properly welded tools allow for optimum production runs (Parts produced)

3. Composite fabrications out perform conventional tools in troublesome


applications.

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.

A Technical Report by Eureka


Page 36 of 40
SECTION I

COMPOSITE FABRICATION/CASE HISTORIES

Our objective is to illustrate the feasibility and effectiveness of compositely


fabricated metal stamping tools. The concept will be demonstrated utilizing, for
the most part, equipment that is already in the plant. Our presentation will afford
you the opportunity to observe the basic mechanical sequence involved in
building a simple composite trim section.

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:

Sections that are normally constructed of expensive air


hardening grades could represent a broader cost differential
than those normally constructed of water hardening.

Accurate cost differentials are not easy to establish due to


the difficulty in obtaining documented information from the
plant.

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.

MAINTENANCE AND REPAIRABILITY


Every hour spent repairing or even dressing tools that are suppose to be
producing parts add to the tool cost per part. Stopping the press to repair trim
lines or draw radii is extremely costly due to the number of people that must be
involved.

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Page 37 of 40
SECTION I

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:

1. Composite tools won’t fracture – the base materials are extremely


resilient.

2. The hardness of the work surface or cutting edge is predetermined


and correct for the application. More important, the tool steel weld
metal has a forged grain structure that is far superior to
conventional tool steel.

3. Composite tools do not require heat treatment other than


tempering. Heat treated tools, especially air hardened draw die
inserts, require hours of stoning after heat treat due to distortion.
Tools cracked in heat treatment are also minimized.

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

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SECTION I

B. Buick Motor No. 12. Flint, Michigan


Tool Converter Pump Housing, .180” stock – 12” diameter
flanging
Original Tool D-2 / Constant breakage, scoring, metal pick-up, and
breakage due to metal thickness variance.
Fabricated Tool 1060 base material M-2 HSTS (Eureka No. 1216) on
flanging surface. Eliminated scoring and breakage. Ran for
one year.

C. Pontiac Motors, Plant 14


Tool Corporate Bumper Draw Die-D
Original Tool Cast iron GM-241 flame hardened RC 59/60; original
repaired with AMPCO No. 22 – severe scoring occurred
Eureka Repair Underlay, overlay
Procedure EXP-10 underlay, 1216 overlay. Reduced scoring
substantially

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 Technical Report by Eureka


Page 39 of 40
SECTION I

Bendix Brake and Steering Division

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

Eaton Corporation (MacIntosh Stamping)

Tool Trim Steel -- .250” stock


Original Tool A-2 – chipping
Fabricated Tool 1020 base – S-7 (Eureka No. 74) overlay
Production 40,000 versus 10,000 conventional

A Technical Report by Eureka


Page 40 of 40

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