Tool & Die Welding Repair

Learn the process for welding and repair of draw, trim/ pierce, flange and cam dies. Also learn to repair defects on panels using various welding and grinding methods. Emphasis is placed on proper techniques for tool steel welding and the ins-and- outs of press repair methods. Students will learn and practice proper techniques for welding and repair using MIG, TIG, and Stick applications. 

Course Outline:  

1.0 Welding Overvie
1.1 Types of Welding and Equipment
GTAW Gas Tungsten Arc Welding (TIG), SMAW Shielded Metal Arc Welding (Stick)
GMAW Gas Metal Arc Welding (MIG), Choosing the proper equipment
1.2 Welder Settings for Different Types of Die Steels
1.3 Pre-Heating and Steel Preparation
Estimating temperature change by color
1.4 Welding Rod Types
0-1, A-2, D-2C, Cast Steel, Aluminum

2.0 Draw Die Weld Repair 
2.1 Draw Bead Repair 
Fixing a Bead by Welding, Grinding, and Polishing 
2.2 Repairing a Welded Flat Surface 
Steps to Welding, Grinding, and Stoning a Flat Surface by Hand 
2.3 Repairing a Welded Curved Surface 
Steps to Welding, Grinding, and Stoning a Curved Surface by Hand 
2.4 Repairing a Welded Feature Line 
Steps to Successfully Blend a Welded Feature Line

3.0 Trim Die Weld Repair  
3.1 Punch Trim Line Repair 
Fixing Cutting Problems Associated with Burrs by Welding 
3.2 Die Trim Line Repair
Fixing Cutting Problems Associated with Burrs by Welding 
3.3 Trim Line Change to Reduce Panel Size 
How to Successfully Move a Trim Line by Welding 
3.4 Trim Line Change to Increase Panel Size 
How to Successfully Move a Trim Line by Welding 
3.5 Scrap Cutter Repair 
Steps to Grinding a Welded Inserted Cutter

4.0 Pierce Die Weld Repair
4.1 Pierce Die Repair
How to Grind Welded Cutting Edges
4.2 Pierce Punch Repair
How to Grind Welded Cutting Edges

5.0 Flange Die Weld Repair
5.1 Verifying Flange Clearance
Steps to Successfully Establish Proper Clearances
5.2 Flange Line Change to Reduce Panel Size
Using Plotted Points to Successfully Grind a Welded Bend Line
5.3 Flange Line Change to Increase Panel Size
Using Plotted Points to Successfully Grind a Welded Bend Line

6.0 Production Die Repair & Welding  
6.1 Cracking and Wrinkling 
What to look for and ways of fixing Panel Conditions during Production 
6.2 Panel Stoning and Deforms 
Identifying the Common Types of Deforms by Panel Stoning 
6.3 Emergency Repairs for Negative Deforms 
Temporary Time Saving Repairs for Draw Dies that can Reduce Press Downtime 
6.4 Emergency Trim Line Repairs 
Temporary Time Saving Repairs for Draw Dies that can Reduce Press Downtime 

7.0 Hands-On Welding Applications- 8 Hours 
7.1 GTAW-TIG Welding 
Students perform a variety of welding applications 
7.2 SMAW- Stick Welding 
Students perform a variety of welding applications 
7.3 GMAW- MIG Welding 
Students perform a variety of welding applications 

 

Who should attend?
Tooling Supervisors, Process, Manufacturing and Tooling Engineers, Tool and Die Makers and Plant Welding Personnel