Forging Industry

鍛造行業(yè)維護(hù)與維修焊接解決方案

Heat and Impact -MWA International Ltd. has worked alongside the forging industry for many years gaining invaluable experience throughout the various processes. From this we have developed a unique range of welding electrodes to combat the wear elements predominant in Die Shops and supporting Maintenance Departments.

熱與沖擊 -MWA國際有限公司多年來一直與鍛造行業(yè)合作，在各個流程中都積累了寶貴的經(jīng)驗(yàn)。由此，我們開發(fā)了一系列獨(dú)特的焊條，以對抗模具車間和輔助維修部門中主要的磨損因素。

MWA International Ltd. -Our aim is always to save companies money, we do this by reducing down-time and increasing the life of worn parts. This guide will isolate some of the more common problem areas withinyourindustry, (see list below). Using our specialist knowledge we are able to provide a solution, minimising wear and in doing so generate large cost savings for your company.

MWA公司 -我們的目標(biāo)始終是為客戶節(jié)省資金，我們通過減少停機(jī)時間和延長磨損零件的使用壽命來實(shí)現(xiàn)這一目標(biāo)。本文將列出鍛造行業(yè)中一些非常常見的問題領(lǐng)域（見上表）。利用我們的專業(yè)知識，我們能夠提供有針對性的解決方案，盡可能地減少磨損，從而為客戶節(jié)省大量成本。

Team Work- We look upon ourselves as an extension to your maintenance department or workshop. We try to understand your needs and adapt ourselves accordingly. We hope that by working together we can help improve the performance of your maintenance department and ultimately save you money.

團(tuán)隊(duì)合作 - 我們將自己視為客戶維護(hù)部門或車間的延伸。我們努力了解客戶的需求，并相應(yīng)地調(diào)整自己。我們希望通過共同努力，可以幫助客戶提高維護(hù)部門的績效，并最終為客戶節(jié)省資金。

Processes

鍛造過程

Forging is fundamentally a process of forming metal, under impact or pressure, to economically produce a desired shape with improved properties. This can be accomplished by any of several forging methods that are basically related to extruding, upsetting and pressing. These methods are performed hot, warm or cold.

鍛造從根本上是一種在沖擊或壓力下金屬成形的過程，經(jīng)濟(jì)地生產(chǎn)出具有改進(jìn)性能的所需形狀的零部件。這可以通過擠壓、鐓粗和壓制等幾種基本鍛造方法中的任何一種來實(shí)現(xiàn)。這些方法可以在熱的、溫的或冷的條件下進(jìn)行。

Hammer Forging (Open or Closed Die) -A number of blows are usually required to achieve the desired configuration. In open die forging, the same die is used for all or part of the required blows. In closed die forging, generally one or more blows is struck for each of several die cavities.  Operator skill plays a major role in product quality.

錘鍛（開式或閉式模具） -通常需要多次錘擊才能達(dá)到所需的外型配置。在開式模鍛中，同一個模具用于所有或部分所需的錘擊。在閉式模鍛中，通常對幾個模腔進(jìn)行一次或多次錘擊。鍛工技能對產(chǎn)品質(zhì)量起著重要作用。

Press Forging -The forging sequence in a press is block and finish, sometimes with a preform, pierce, or trim operation. The piece is usually only hit once in each die cavity. Dies become more important and operator skills less critical.

機(jī)鍛 -壓力機(jī)中的鍛造順序?yàn)榇皱懞途?，有時采用預(yù)成型、穿孔或修整操作。工件通常在每個模具型腔中只打擊一次。模具變得更加重要，鍛工技能變得不那么重要。

Open dies which can be flat, half round, or V-shaped and are used in hydraulic presses for rough shaping of the work piece. Closed  die forging is more complex and is done on a variety of different press types.

開式模具可以是平的、半圓的或V形的，用于液壓機(jī)中對工件進(jìn)行粗成形。閉式模鍛更為復(fù)雜，可在各種不同類型的壓力機(jī)上進(jìn)行。

Upset Forging -This process can produce a wide variety of parts in many different configurations such as bolts, sockets and axles. It can be used for preforming jet engine blades and secondary operations for products such as crankshaft flanges.

鐓粗 -該過程可生產(chǎn)多種不同形狀配置的零件，如螺栓、套筒和軸。它可用于預(yù)成型噴氣發(fā)動機(jī)葉片和曲軸法蘭等產(chǎn)品的二次操作。

The process is very versatile and lends itself to automation. An upset forge can work in both longitudinal and transverse directions, either simultaneously or sequentially.

這一過程用途廣泛，易于自動化。鐓鍛可以在縱向和橫向同時進(jìn)行，也可以按順序進(jìn)行。

Upsetting can be performed in a single blow or a series of blows utilising multiple-pass tooling.

鐓粗可采用多道次工具在一次或一系列錘擊中進(jìn)行。

Roll Forging -This process is capable of producing many shapes required for preforming or finish forging, it is economical and offers high productivity. The process resembles a rolling mill operation in that it reduces the cross-sectional area of a heated bar or billet. The work-piece is squeezed by two powered rolls that rotate in opposite directions.

輥鍛 -該過程能夠生產(chǎn)預(yù)成型或終鍛所需的多種形狀，經(jīng)濟(jì)且生產(chǎn)率高。該過程類似于軋鋼機(jī)操作，因?yàn)樗鼫p少了加熱棒材或鋼坯的橫截面積。工件被兩個反向旋轉(zhuǎn)的動力輥擠壓。

Ring Rolling -This process offers homogeneous circumferential grain flow, ease of manufacture and versatility in material, size, mass and geometry. A preform is heated to forging temperature and placed over the idler roll of the rolling machine. Pressure is applied to the wall by the main roll as the ring rotates. The cross-sectional area is reduced as the I.D. and O.D. is expanded. With modern ring rolling, equipment can be fully automated to produce rings, from billet heating through post forge handling.

環(huán)鍛 -該過程提供了均勻的周向晶粒流、易于制造性以及材料、尺寸、質(zhì)量和幾何形狀的多功能性。將預(yù)制件加熱至鍛造溫度，并放置在軋制機(jī)的托輥上。環(huán)旋轉(zhuǎn)時，主輥向壁面施加壓力。橫截面積隨著時間的推移而減小內(nèi)徑和外徑都擴(kuò)大了。隨著現(xiàn)代環(huán)件軋制，設(shè)備可以完全自動化生產(chǎn)環(huán)件，從鋼坯加熱到鍛造后處理。

Precision Forging - This process is designed to eliminate or minimise machining. Precision forging uses conventional techniques that  are refined to tight tolerances and low draft angles through improved die sinking and close process controls. Control of the forging process, die temperatures, forging pressures, and die lubrication are among the parameters that are very critical to successful precision forging.

精密鍛造 - 該過程旨在消除或減少加工。精密鍛造使用傳統(tǒng)技術(shù)，通過改進(jìn)的開模和精確過程控制，將其細(xì)化到精密公差和低拔模角度。鍛造過程的控制、模具溫度、鍛造壓力和模具潤滑是精密鍛造成功的關(guān)鍵參數(shù)之一。

Isothermal Forging - In this process the material and die are heated to about the same temperature. Isothermal forging of high temperature alloys is a well proven and accepted production process, which requires special tooling materials that retain their strength at these elevated temperatures.

恒溫鍛造 -在這個過程中，材料和模具被加熱到大約相同的溫度。高溫合金的恒溫鍛造是一種經(jīng)過充分驗(yàn)證和認(rèn)可的生產(chǎn)工藝，需要特殊的模具材料，以在這些高溫下保持其強(qiáng)度。

By eliminating die chilling closer tolerances can be achieved. Slower ram speeds of hydraulic presses can be used, lowering the strain rate and flow stress of the forged material. The forging pressure is thus reduced and larger parts can be forged in lower tonnage hydraulic presses than applicable mechanical presses.

通過消除模具冷卻，可以實(shí)現(xiàn)更接近的公差?？梢允褂靡簤簷C(jī)較慢的沖壓速度，降低鍛造材料的應(yīng)變率和流動應(yīng)力。因此，鍛造壓力降低，與適用的機(jī)械壓力機(jī)相比，更大的零件可以在噸位較低的液壓機(jī)中鍛造。

Cold Forging - This process is defined as forging at ambient temperature without exceeding yield strength limits. Advantages offered with this process are improved strength, closer tolerences, less draft angles and almost no shrinkage. Due to no preheating of the material being required, lubrication, handling and post treatments differ dramatically from hot forging.

冷鍛 - 該工藝定義為在環(huán)境溫度下鍛造，且不超過屈服強(qiáng)度極限。這種工藝的優(yōu)點(diǎn)是提高了強(qiáng)度、更緊密的公差、更小的拔模角度和幾乎沒有收縮。由于不需要對材料進(jìn)行預(yù)熱，潤滑、搬運(yùn)和后處理與熱鍛有很大不同。

As no preheating is used uniform forming pressures work best. Generally, symmetrical or hollow parts are best suited for cold forging. There are three types of extrusion processes; forwards, backwards and side extrusion. Many of the cold processes can be combined in a single operation, though in most instances parts cannot be completely forged in one stroke. The number of materials suitable for cold forging is very large, ranging from low, medium-carbon steels to aluminium alloys to some stainless steels and titanium alloys. With increased alloying elements, the amount of deformation possible in a single step is generally reduced.

由于不需要預(yù)熱，可以得到均勻的成型壓力效果。通常，對稱或空心零件最適合冷鍛。有三種類型的擠壓工藝：向前、向后和側(cè)向擠壓。許多冷加工過程可以在一次操作中結(jié)合在一起，盡管在大多數(shù)情況下零件不能完全一次就鍛造出來。適合冷鍛的材料數(shù)量非常多，從低、中碳鋼到鋁合金，再到一些不銹鋼和鈦合金。隨著合金元素的增加，單個步驟中可能發(fā)生的變形量通常會減少。

Warm Forging - The engineering definition of warm forging is forging below the material’s critical point but high enough to significantly lower the material’s yield strength. The practical explanation is to gain some of the advantages of cold forging without some of the problems associated with hot forging. In warm forging, the material retains much of the improved physical condition and strength gained from hot forging, while achieving part tolerances and finishes similar to those obtained in cold forging. Parts produced with warm forging include aerospace components, gears, splines, farm implements and  medical instruments. As warm forging is better engineered, the number of parts forged warm is expected to increase substantially.

溫鍛 -溫鍛的工程定義是低于材料臨界點(diǎn)但足以顯著降低材料屈服強(qiáng)度的鍛造。實(shí)際的解釋是獲得冷鍛的一些優(yōu)點(diǎn)，而不存在與熱鍛相關(guān)的一些問題。在溫鍛中，材料保留了從熱鍛中獲得的大部分得到改善的物理?xiàng)l件和強(qiáng)度，同時實(shí)現(xiàn)了與冷鍛中獲得的零件公差和光潔度相似的零件公差和光潔度。溫鍛生產(chǎn)的零件包括航空航天組件、齒輪、花鍵、農(nóng)具和醫(yī)療器械等。隨著溫鍛工藝的改進(jìn)，溫鍛零件的數(shù)量有望大幅增加。

Die Shop Maintenance

模具車間維護(hù)

Tools and Diesin the forging industry are normally repaired and maintained in a Die Shop separate to general plant and machinery maintenance. There are numerous types and variations of tools and dies, however, these can generally be separated into three different categories :

工具和模具在鍛造行業(yè)，通常在模具車間進(jìn)行維修和維護(hù)，與一般設(shè)備和機(jī)械維護(hù)分開。工具和模具有多種類型和變體，但通?？煞譃槿悾?

1. Dies 模具

2. Shear Blades and Saws 剪切刀片和鋸

3. Punches and Clipping Tools 沖頭和剪切工具

Due to the high carbon contents and subsequent high hardenability the weldability of tool steels is poor. This hardenability occurs both in the weld and in the heat affected zone (HAZ) immediately after welding. This in turn will increase the chance of stress cracks. It is therefore vital that not only the correct specification of weld material is used but also the correct welding techniques are followed.

由于高碳含量和隨后的高淬透性，工具鋼的焊接性較差。這種淬透性發(fā)生在焊接和焊后的熱影響區(qū)（HAZ）中。這反過來會增加應(yīng)力裂紋的可能性。因此，不僅要使用正確規(guī)格的焊接材料，而且要遵循正確的焊接技術(shù)。

The first stage of the welding procedure is to isolate the type of tool steel to be welded. While there are hundreds of different tool steels produced throughout the world, many of which may carry their own individual code number, they can generally be grouped under one of the five sections below：

焊接工藝的第一階段是明確待焊接工具鋼的類型。雖然全世界生產(chǎn)了數(shù)百種不同的工具鋼，其中許多可能帶有各自的代碼，但它們通?？梢詺w為以下五個部分之一：

1.Water Hardening Steels 水淬硬鋼
2.Air Hardening Steels 空氣淬硬鋼
3.Oil Hardening Steels 油淬硬鋼
4.Hot working Steels 熱作鋼
5.High Speed Steels 高速鋼

Water Hardening Steels 水淬硬鋼

Application : Where design or shape is not intricate. Blanking dies, Shears, Trimming Dies.

應(yīng)用 :  設(shè)計或形狀不復(fù)雜。沖裁模、剪切機(jī)、切邊模。

Preheat Temperature : 200°C min.

預(yù)熱溫度 : 200°C min.

MWA Products : Mac Hica E3074, Mac HSS E3062
MWA 產(chǎn)品 : 工模具鈷基焊條Mac Hica E3074(獨(dú)有設(shè)計) ，工模具焊條Mac HSS E3062(高速鋼)

Post Weld Treatment : Slow Cool

焊后處理 : 緩慢冷卻

Air Hardening Steels空氣淬硬鋼

Application: Due to their high resistance to abrasion, air hardenable steels are most suitable for large dies where the blank traverses across the die face in an abrasive manner. 

應(yīng)用:由于其高耐磨性，空氣淬硬鋼最適合大型模具，其中坯料橫過模具表面具有磨蝕性。

Preheat Temperature: 250°C min.

預(yù)熱溫度: 250°C min.

MWA Products:Mac Trode E630, Mac Hica E3074

MWA產(chǎn)品:特種鋼焊條Mac Trode E630，工模具鈷基焊條Mac Hica E3074(獨(dú)有設(shè)計)

Post Weld Treatment: Furnace cool (where possible)

焊后處理:爐冷 (如有可能)

Oil Hardenable Steels油淬硬鋼

Applications: Used where finaldimensional accuracy is required. This type of steel is particularly suitable due to its stability during heat treatment. Used for intricate dies,punches  and trimming tools.

應(yīng)用:用于有最終尺寸精度要求的。由于這種鋼在熱處理過程中的穩(wěn)定性，特別適用于復(fù)雜的模具、沖頭和修整工具。

Preheat Temperature: 250°C min.

預(yù)熱溫度: 250°C min.

MWA Products:Mac Hica E3072, Mac Hica E3074
MWA產(chǎn)品:工模具鈷基焊條Mac Hica E3072(Stellite 6號)，工模具鈷基焊條Mac Hica E3074(獨(dú)有設(shè)計)
Post Weld Treatment: Slow cooling

焊后處理:緩慢冷卻

Hot Working Steels熱作鋼

Application: Hot working steels possess a combination of toughness and red hardness. Such steels are used for punches, billet shears, forging dies and aluminium diecasting dies.

應(yīng)用:熱作鋼同時具有韌性和紅硬性。適用于沖頭、鋼坯剪切機(jī)、鍛模和鋁壓鑄模。

Preheat Temperature: 325°C

預(yù)熱溫度: 325°C

MWA Products:Mac  Hica E3072,  Mac  Hica E3074, Mac Nicro E215
MWA產(chǎn)品:工模具鈷基焊條Mac Hica E3072(Stellite 6號)，工模具鈷基焊條Mac Hica E3074(獨(dú)有設(shè)計)，鎳合金焊條Mac Nicro E215

Post Weld Treatment: Controlled cooling required

焊后處理:需要控制冷卻

High Speed Steels高速鋼

Applications: Used for cutting tools, drills broaches and milling cutters. Suitable for tools with a hardness range of 55-63 HRC.

應(yīng)用:用于切削工具、鉆頭、拉刀和銑刀。適用于硬度范圍55-63 HRC的工具。

Preheat Temperature: 250°C

預(yù)熱溫度: 250°C

MWA Products:Mac Hss E3062
MWA產(chǎn)品:工模具焊條Mac Hss E3062(高速鋼)

Post Weld Treatment: Controlled cooling required

焊后處理:需要控制冷卻

Works Maintenance Department

工程維修部

Whilst the importance of tool and die repairs can never be ignored, without a fully functional hammer or press to run them on, they are of little or no use.

雖然工具和模具維修的重要性不容忽視，但如果沒有功能齊全的錘子或壓力機(jī)，它們幾乎沒有用處。

MWA International Ltd. recognise the constant difficulty maintenance departments work under when presented with items to repair that may be as much as 50 years old. Spares are unlikely to be available and with replacement costs and delivery times completely unrealistic welding is often the only cost effective solution.

MWA公司認(rèn)識到，維修部門在面對可能長達(dá)50年之久的物品需要維修時，會面臨持續(xù)的困難。 備件不太可能得到，加上更換成本和交貨時間完全不現(xiàn)實(shí)，焊接修復(fù)往往是唯一的成本有效的解決方案。

Our aimis to offer you a complete back-up service where by you are able to use our wealth of experience within your industry. Our commitment to your repair is as follows:

我們的目標(biāo)是為客戶提供一個完整的支持服務(wù)，讓客戶能夠利用我們在行業(yè)的豐富經(jīng)驗(yàn)。我們對客戶的維修承諾如下：

1. To identify your problem and work with you to accomplish a cost effective solution.

找出問題，并與客戶一起完成一個經(jīng)濟(jì)高效的解決方案。

2. To recommend and provide the consumables required as well as explain in detail the welding procedures to be used.

建議并提供所需的焊材，并詳細(xì)解釋將使用的焊接工藝。

3. To cover the preparation, including cleaning and preheating, welding techniques and post welding procedures.

包括準(zhǔn)備工作，涉及清理和預(yù)熱、焊接技術(shù)和焊后處理。

4. If necessary to over see the work to ensure a successful result.

如有必要，仔細(xì)檢查工作，以確保取得成功。

Problems & Solutions

問題與解決方案

1.Hammer Leg - Replacement of hammer a leg is both impractical from a cost and delivery/down-time point of view. Cracking or breakage is usually caused by side blows. When this occurs the leg is often contaminated with oil etc.  It is vital that a high strength  repair is achieved. For this reason it is the techniques used which are as important as the welding material deposited.

鍛錘支柱 - 從成本和交貨/停工時間的角度來看，更換鍛錘支柱是不切實(shí)際的。開裂或斷裂通常是由側(cè)面撞擊引起的。發(fā)生這種情況時，鍛錘支柱經(jīng)常被油等污染。實(shí)現(xiàn)高強(qiáng)度修復(fù)至關(guān)重要。因此，采用的技術(shù)與熔敷的焊接材料一樣重要。

2.&3.Tups & Slides - Friction usually causes the tup and the slide to wear one another, resulting in the hammer to fall out of line. Repairs are very infrequent and therefore welding procedures critical. Once again replacement costs and delivery times mean welding is the only cost effective solution.

錘頭和滑塊 -摩擦通常會導(dǎo)致錘頭和滑塊相互間磨損，導(dǎo)致錘子不能正常工作。維修很少，因此焊接程序至關(guān)重要。再次說明，更換成本和交付時間意味著焊接是唯一具有成本效益的解決方案。

4.Lifting Drum -Normally made from cast iron and subject to friction, strict welding techniques need to be administered while repairing. A life increase of 200% can often be achieved using Mac Cast E407.

卷揚(yáng)機(jī)卷筒 -通常由鑄鐵制成，易受摩擦，維修時需要執(zhí)行嚴(yán)格的焊接技術(shù)。使用Mac Cast E407鑄鐵焊條通?？梢詫?shí)現(xiàn)200%的壽命增長。

5.Con Rods -Friction on the internal bores of con rods is the most common form of wear. Care needs to be taken to ensure distortion does not take place when welding.

連桿 -連桿內(nèi)孔上的摩擦是最常見的磨損形式。焊接時應(yīng)注意確保不發(fā)生變形。

6.&7.Wedge Keys & Poppets -Two applications which are seldom repaired despite the possibility of large savings against replacing with new parts.

楔鍵和提升閥 - 兩種應(yīng)用很少維修，盡管比更換新零件可能節(jié)省大量成本。

8. Drive Shafts - Can be easily repaired using the Powder Welding process. With the ability to apply deposits so accurately as to almost eliminate machining, cost of raw materials and labour can be as little as 5% compared to replacing with a new shaft.

驅(qū)動軸  -可使用粉末焊接工藝輕松修復(fù)。由于能夠精確地應(yīng)用熔敷物，幾乎可以消除加工，與更換新軸相比，原材料和勞動力成本僅為5%。

9. Spreaders -Wear is caused on the adjustment faces and by using Mac Trode E66a fast and cost effective repair can be achieved.

吊具 - Mac Trode E66鎳鉻合金特種鋼焊條可以對調(diào)整面上的磨損實(shí)現(xiàn)快速且經(jīng)濟(jì)高效的維修。

10. Bolsters -These are subject to massive impact forces with wear more prevalent on the dovetails. Bolsters can easily  be  repaired using either a special steel or cast iron electrode depending on the base material.

模枕 - 它們會受到巨大的沖擊力，燕尾榫磨損更為普遍。根據(jù)母材的不同，使用特殊的鎳鉻合金鋼焊條或鑄鐵焊條輕松地修復(fù)。

11. Furnace Repairs -With internal temperatures as high as 1400°C special electrodes that can withstand elevated temperatures, (Mac Stain E102), must be used. Applications such as heat treatment trays require electrodes that can combat constant thermal cycling, (Mac Nicro E215).

熔爐維修 -內(nèi)部溫度高達(dá)1400°C時，必須使用能夠承受高溫的特殊焊條（不銹鋼焊條Mac Stain E102）。熱處理托盤等應(yīng)用需要能夠抵抗恒定熱循環(huán)的焊條（鎳合金焊條Mac Nicro E215）。

12. Top Hat Bushes -These can often develop “flat spots”.  This  leads to potential problems on striking and in turn tup and slide wear. With the correct pre-heat and using special bronze electrodes (Mac Bronze E808) a repair costing a tenth of a new replacement can be achieved.

頂帽襯套 -這些通常會形成“平點(diǎn)”。這會導(dǎo)致潛在的打擊問題，進(jìn)而導(dǎo)致錘頭和滑塊磨損。通過正確的預(yù)熱和使用特殊的銅合金焊條（Mac bronze E808），可以實(shí)現(xiàn)僅需新更換件十分之一的修復(fù)成本。