Background
In heavy-duty forging operations, dies are exposed to extreme thermal stress, impact, and wear.
This often leads to:
- Cracking
- Surface wear
- Reduced dimensional accuracy
- Frequent replacement and high cost
This case study demonstrates how repair welding significantly extends die life and reduces production costs.
Problem Analysis
In this case, a forging die used in diesel engine crankshaft production experienced:
- Severe wear on working surfaces
- Cracks in high-stress zones
- Reduced service life
Material hardness: approx. HRC 39
Frequent replacement caused:
- High annual tooling cost
- Production downtime
- Reduced efficiency
Repair Solution
CAVITEX applied a multi-layer repair welding process:
Based on the actual working condition of the die, a multi-layer repair welding process was applied using different functional alloys.
- For the transition and buffer layer, higher hardness was required. Therefore, 3247-FCG, a high-strength alloy mainly composed of high-hardness alloying elements, was selected.
- For areas with cracks, it was necessary to enhance the toughness of the surface layer. 3235-FCG, a tough iron-based alloy, was used to improve resistance to cracking.
- Finally, 3245-FCG was applied as the surface layer to ensure overall stability and wear resistance.
Selected welding alloys:
- High-strength repair alloy
- Wear-resistant surfacing alloy
This combination of materials ensures proper hardness distribution, improved crack resistance, and stable long-term performance.
Results
After repair:
- Die life increased by 2–2.8×
- Service life significantly extended
- Stability improved
Cost Comparison
| Item | Original Die | Repaired Die |
|---|---|---|
| Service Life | 13,800 pcs | 16,300 pcs |
| Cost per Unit | 14.49 RMB | 7.19 RMB |
| Annual Cost | 289,800 RMB | 143,800 RMB |
Cost reduction: over 50%
Conclusion
By using CAVITEX repair welding solutions:
- Mold life is significantly extended
- Production downtime is reduced
- Total manufacturing cost is lowered
Looking to extend your die life and reduce production cost?
Contact CAVITEX for a customized repair solution.