D-M-E Pro Weld Manuel utilisateur
D-M-E
Pro Weld™
USER GUIDE
D-M-E Company
29111 Stephenson Highway
Madison Heights, MI 48071
Phone:
(800) 626-6653 (248) 398-6000
Fax:
(248) 398-6174
D-M-E ProWeld™User Guide
PREFACE
Please read this instruction manual thoroughly before using
your D-M-E Pro Weld™system.
The D-M-E Pro Weld unit is a newly developed resistance-
type micro-welding machine. It is powerful enough to weld
0.3mm thick metal sheets and has a wide selection of weld-
ing materials in sheet, wire and powder form to choose from.
Applications
♦Welding can be made to steel molds and dies for plastics,
rubber, die casting, and compression molds.
♦Welds can be applied on as-rolled steel, pre-hardened
steel, quenched and tempered steel, free cutting steel,
stainless steel, and others.
♦To build up parting lines, mold seams, 3-point corners
and edges.
♦To fill in pores, repair of pinholes.
♦To repair wear, worn areas on slides, ejector pins,
sharp edge molds, and thin core parts.
♦To design modification of inserts and cores.
♦To add a radius to an inner corner due to a
design change.
♦To repair the shrinkage that occurs after argon arc
and TIG welding.
♦To repair damage due to overgrinding, from an
end mill or EDM process.
D-M-E
Pro Weld™
Model No. UMW0001
USER GUIDE
2
TABLE OF CONTENTS
Applications
I. Introduction............................................................................5
Advantages 5
II. Specifications........................................................................7
Standard Accessories for Pro Weld™UMW0001 7
Additional Welding Materials 9
III. Parts Nomenclature for Pro Weld UMW0001....................11
IV. General Description of Use................................................13
IV.1 Function 13
IV.2 Attachment of Electrodes 13
IV.3 Usage of Electrodes 13
➤Operational Tip 14
IV.4 Start-Up Procedure 14
➤Operational Tip 16
V. Operation ............................................................................17
V.1 Cautions in Welding Work 17
V.2 Discharge of Stored Energy 18
VI. Welding ................................................................................19
VI.1 Workpiece, Electrode, Welding Materials 19
VI.2 Pro Weld Control Features 20
➤Operational Tip 21
VI.3 Shaping Electrodes 22
VI.4 Recommended Current Output Levels 23
VI.5 Mold Material/Welding Material 25
VI.6 Pro Weld Welding Process 27
➤Operational Tip 28
VI.7 Roll Welding Technique 29
Table of Contents
3
Table of Contents
VII. Examples of Welding ........................................................ 31
VII.1 Focalization of Current, Electrode Shape 31
and Formation of the Weld Spot
VII.2 Powder Metal Application 32
Welding to a 3-Point Corner, Parting Line, Edge 33
Welding to a Flat Surface 34
Welding an Inner Corner 35
Welding a Pinhole 35
Welding a Crack 36
Welding in a Rib 37
➤Operational Tip 37
VII.3 Welding of Sheet Material 38
Proper Electrode Contact 38
Positioning of the Sheet Material 38
Welding to a Flat Surface 39
Sheet Material Recession 39
Repair of a 3-Point Corner Collapse 40
Repair of a Parting Line or Edge 41
Repair of a Scratch or V-Notched Flaw
and Pinhole 42
Multi-Layer Padding 43
Repair of Base Metal Impurities 45
Repair of an Inner Corner 45
Welding to a Rising Wall 46
Welding to a Narrow or Concave Mold Section 46
VIII. Examples of Bad Welding Work ........................................47
VIII.1 Unconnected Weld Spots 47
VIII.2 Improperly Shaped Electrodes 47
VIII.3 Oxidized Base Metal or Electrodes 48
VIII.4 Bad Conductivity 48
IX. Maintenance Guarantee ....................................................49
I
I. Introduction
Please read this instruction manual thoroughly before using your
Pro Weld™system.
Pro Weld is a newly developed resistance-type welder. It effectively
builds up material to repair or redesign molds and dies. [Note: It is
not recommended for use on press dies, blow molds (usually made
from aluminum) or aluminum molds.]
The resistance welding method creates high energy discharges in
very short cycles through a capacitance circuit. Almost no heat is
created and, therefore, the base mold material is not altered or
damaged.
The Pro Weld micro welding technique is revolutionizing the repair
of molds by keeping this work in-house. Pro Weld welds 0.1mm,
0.2mm and 0.3mm thick metal sheets or strips, metal wire and
metal powder to the damaged area. It is extremely easy to use,
reduces downtime and improves quality.
Advantages
♦No scaling or flaking occurs after welding as the sheet, wire and
powder metals used are free from impurities, and because the
weld has high strength, homogeneity and reliability.
♦Easy to operate, no special training necessary.
♦Hand and machine finishing is easier as the amount of weld
metal is not excessive.
♦As the process emits almost no heat, there will be no shrinkage,
distortion, deformation or discoloration of the mold.
♦No welding fumes or toxic gases are emitted.
5
Introduction
6
Introduction
I
♦The process is optimally suited for small areas and micro
welding.
♦Hardening and plating can be done after welding.
♦Welding work time is greatly reduced. Roll welding a 3/8" (10mm)
long parting line can be done in 1 minute, treating a pinhole in
30 seconds.
♦As the capacitor system charges slowly and unloads quickly, an
input power can be used with low loading capacity.
♦A built-in microprocessor allows stored energy to be easily
adjusted.
♦High quality selection of welding materials in 0.1 and 0.2mm
thick metal sheet, 0.2-0.5mm diameter wire and powder metal.
♦After the initial weld, if more padding is required, re-welding
can be done easily.
♦Pro Weld is powerful enough to weld 0.3mm thick sheet.
7
II. Specifications
II
Standard Accessories for Pro Weld UMW0001
Specifications
Power pack with welding cord, grounding
cord and plate, power cord, foot switch and
all accessories listed below
N51–Standard SKH-51 steel powder (50 grams)
(63 Rc; for D-2/M-2/S-7 steels)
N80–Standard NAK80 steel powder (50 grams)
(38-40 Rc; for P-20/P-21 steels)
NAK80–Standard steel sheet (10 sheets,
0.1T x 5W x 100L) (38-40 Rc; for P-20/P-21 steels)
NTA1–Ni Alloy sheet (10 sheets, 0.1T x 30W x 70L)
(135HV; for all steels)
NTA2–Ni Alloy sheet (10 sheets, 0.2T x 30W x 70L)
(135HV; for all steels)
Protective glasses
Catalog No. Description
Complete Pro Weld system includes: (Dimensions in millimeters)
UMW0001
UMW0002
UMW0003
UMW0004
UMW0005
UMW0006
UMW0007
Model Pro Weld UMW0001
Input Voltage 120 VAC
Consumable Power 600 VA
Output Power 700W
Output Voltage 0 - 9V
Output Current 0 - 1100 Amps
Control System SCR Switching System
Auto Timer On 0.5 sec.
Dimensions (inches) W6.5 x D17.75 x H16
Weight 62 lbs
Catalog No. Description
II
Specifications
8
Protective gloves
Magnet electrode (2 dia. x 50L)
Magnet electrode (3 dia. x 50L)
Magnet electrode (4 dia. x 60L)
Magnet electrode (4 dia. x 50L)
Standard electrode (2 dia. x 50L)
Standard electrode (3 dia. x 50L)
Standard electrode (4 dia. x 50L)
Standard electrode (1.2T x 5W x 35L)
Standard electrode holder (black)
(used with UMW0015)
Magnet electrode holder (brown)
(used with UMW0011 and UMW0012)
Standard electrode holder (black)
(used with UMW0016)
Standard electrode holder (black)
(used with UMW0013)
Standard electrode holder (black)
(used with UMW0014)
Magnet electrode holder (brown)
(used with UMW0009 and UMW0010)
Tool box
Sheet metal shears
Screw and wrench set
Fuse (2A)
Insulation tape
UMW0008
UMW0009
UMW0010
UMW0011
UMW0012
UMW0013
UMW0014
UMW0015
UMW0016
UMW0017
UMW0018
UMW0019
UMW0020
UMW0021
UMW0022
UMW0023
UMW0024
UMW0025
UMW0026
UMW0027
Standard Accessories for Pro Weld UMW0001 (continued)
Complete Pro Weld system includes: (Dimensions in millimeters)
Table des matières
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