Forging Die Repair Process: Restoring Die Cavities Step by Step
According to standard mold welding procedures, proper die repair requires a systematic process including cleaning, inspection, welding, and heat treatment .
In this case study, we demonstrate a real forging die repair process, showing how severely worn cavities can be restored using welding and hardfacing techniques.
Step 1: Worn Die Condition (Before Repair)
The forging die shows severe cavity wear and deformation caused by long-term high-temperature and high-impact operation. Such damage leads to reduced forging accuracy and increased defect rates.
Step 2: Cavity Cleaning (Carbon Arc Gouging)
Before welding, all cracks, fatigue layers, and impurities must be completely removed to ensure proper bonding of the weld layer
Step 3: Inspection and Damage Assessment
Inspection ensures that hidden cracks and internal defects are identified before welding. This step is critical to avoid failure after repair.
Step 4: Welding Repair and Hardfacing
Different welding consumables are applied in layers (buttering layer, transition layer, and top layer) to achieve optimal hardness, toughness, and thermal fatigue resistance
Step 5: After Welding Completion
After welding, the cavity geometry is restored. Proper stress relief and heat treatment are required to ensure durability and prevent cracking.
Step 6: Final Result After Treatment
After machining and surface treatment, the die cavity achieves improved dimensional accuracy and extended service life.
Step 6: Final Result After Treatment
After welding, the cavity geometry is restored. Proper stress relief and heat treatment are required to ensure durability and prevent cracking.
This case demonstrates that a structured welding repair process can significantly extend forging die life and reduce production downtime.
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