Die Block Reclamation Cost Benefits
Die block weld reclamation of Hammer and Press forges can increase die life by more than 100% compared to conventional die block steels. The cost of tooling can add up to 15% to the cost of a forging. Indirect costs from premature die failure and scheduled die replacement can be even higher due to machine downtime.

 

Die Welding Process used A Key Differentiator
Optimising die life requires that tool design, tool steel selection, tool steel manufacture and heat treatment are all undertaken properly. Paralleling this, the potential benefits of weld reclamation can only be realised following accurate consumable selection, controlled weld deposition and proper heat treatment. Therefore, development of controllable and accurate die welding procedures has proven fundamental to the Forgeweld technology.

 

Limitations of Traditional Approach
Local welded repair of dies is a well-established way of reducing tool cost. However, this often utilizes only basic MIG welding equipment and consumables. Welding consumable are selected through a trade off between machining capability, cost, tradition and the availability of consumables. Because of this the full benefits and savings are not fully realised.

Intelligent material selection is important to improving the life of non-standard shaped forming components. Cost savings of around 62% have been realised through reclamation compared to new purchase. Moreover, the life of the reclaimed component exceeded that of the original  by ~200%.