Introduction – Precision Repair Welding

We recognise the challenges of precision repair welding. Specifcally on Injection Mould tooling.  We have many customers who have small cracks or breaks in their plastic injection moulding and struggle to carry out the detailed repair required.

Finally, at Moleroda we have the solution and we are offering all our customers the chance for us to demo this at your premises.

This blog details the challenges of precision repair welding and our powerful, versatile solution which comes in the form of the Eneskaimpulse 230. We will detail the benefits, applications and reasons we rate this system above all others for precision repair welding.

Challenges of repair welding on Plastic Injection Moulds

Repair welding on plastic injection moulds presents several challenges due to the precision, material properties, and intricate nature of the moulds. These challenges can affect the success of the repair and the longevity of the mould.

Here are some of the key challenges:

1. Material Compatibility:

• Hardness Matching: Plastic injection moulds are often made from hardened tool steels like H13, P20, or D2, which have specific hardness levels. Matching the hardness of the filler material with the base metal is crucial. Mismatched materials can lead to issues like uneven wear, cracking, or failure of the repaired area.
• Thermal Sensitivity: Tool steels can be sensitive to the heat generated during welding. If not managed carefully, the heat can cause changes in the steel’s microstructure, leading to soft spots, warping, or cracking.

2. Distortion and Warping:

• Heat Input: The high heat from welding can cause thermal expansion and contraction, leading to distortion or warping of the mould. This is especially problematic for large or complex moulds where dimensional accuracy is critical.
• Maintaining Tolerances: Injection moulds often have tight tolerances and precise geometries. Any distortion from welding can result in the mould no longer producing parts within specification, leading to costly rework or scrapping of the mould.

3. Cracking and Brittle Welds:

• Stress Concentration: The heat from welding can introduce residual stresses into the mould. If not properly managed, these stresses can lead to cracking, especially in high-stress areas of the mould.
• Cold Cracking: This can occur if the mould is not preheated or cooled properly after welding. Hardened tool steels are particularly prone to cold cracking due to the formation of brittle martensite.

4. Small and Intricate Repairs:

• Precision Requirements: Injection moulds often have intricate features, such as fine cavities, sharp edges, or small details. Repairing these areas requires precision welding techniques, such as laser or micro welding. Even minor errors can result in significant defects in the moulded parts.
• Access to Repair Areas: Some damage may occur in hard-to-reach areas of the mould, making it difficult to access the area for welding. This can complicate the repair process and increase the risk of incomplete or faulty repairs.

5. Surface Finish Restoration:

• Maintaining Surface Quality: The surface finish of the mold is critical for producing high-quality parts. After welding, the repaired area must be ground, polished, and textured to match the original surface. Achieving a uniform finish can be challenging, especially in complex areas or with fine details.
• Avoiding Over-Polishing: Over-polishing can alter the dimensions of the repaired area, leading to problems with part fit or finish.

6. Heat Treatment and Material Properties:

• Post-Weld Heat Treatment: After welding, some moulds may require heat treatment to restore their hardness and relieve residual stresses. Incorrect heat treatment can lead to further distortion or changes in material properties, affecting the mould’s performance.
• Carbide Precipitation: During welding, tool steels can experience carbide precipitation, leading to a brittle weld area. Controlling this requires precise welding parameters and, in some cases, specialized filler materials.

7. Repair Longevity:

• Wear Resistance: The repaired area must withstand the same wear and tear as the original mould. Ensuring that the repair is durable and does not wear out prematurely is a challenge, especially if the filler material does not perfectly match the base material.
• Frequent Repairs: Some moulds may require frequent repairs due to recurring damage. This can weaken the mould over time, as repeated welding and heat treatments can degrade the material.

8. Time and Cost:

• Minimizing Downtime: Injection moulds are critical to production, and downtime for repairs can be costly. The repair process must be quick and efficient without compromising quality, which can be difficult to achieve.
• Cost of Specialized Equipment and Skills: Precision welding techniques like laser welding require specialized equipment and highly skilled welders. This adds to the cost of repairs and can make it difficult for smaller operations to afford the necessary resources.

9. Non-Destructive Testing and Verification:

• Detecting Hidden Defects: After the repair, ensuring that there are no hidden defects like internal cracks or porosity is challenging. Non-destructive testing (NDT) methods, such as ultrasonic testing or dye penetrant inspection, are often required, adding another layer of complexity to the process.
• Ensuring Consistent Quality: Ensuring that the repair meets the original specifications and will perform reliably in production is a significant challenge. Quality control must be rigorous to avoid failures during operation.

10. Repeatability of Repair Quality:

• Consistency in Results: Achieving consistent repair quality across multiple moulds or multiple repairs on the same mould can be challenging. Variations in material, welding conditions, or operator skill can result in inconsistencies that affect the performance of the mould.

The solution for detailed repair welding

The Eneskaimpulse 230 is the ultimate in detailed repair welding. We have tried and tested many systems over the years at Moleroda, and this is by far and beyond the best on the market.

The Eneskaimpulse 230 system is a high-precision polishing and repair tool, often used in mould and die repair, particularly in industries like plastic injection moulding. It is designed to provide fine control over the finishing process, allowing for precise work on intricate surfaces.

Benefits of Eneskaimpulse 230

1. High Precision and Control:

• Pulse Functionality: The Eneskaimpulse 230 system features pulse technology, which allows for extremely precise control of the polishing and finishing tools. This is especially useful for detailed work in small cavities and on complex geometries where traditional tools might struggle.
• Adjustable Speed: The system provides variable speed control, enabling users to adjust the tool’s speed according to the material being worked on and the desired finish. This flexibility ensures that the operator can achieve a high level of precision.

2. Versatility:

• Multi-Tool Compatibility: The system is compatible with a wide range of tools, such as electric and pneumatic handpieces, grinders, polishers, and micro-motors. This versatility makes it suitable for various tasks, including grinding, polishing, and finishing different materials.
• Broad Application Range: Whether you’re working on hardened steel moulds, soft metals, or even delicate surfaces, the Eneskaimpulse 230 can handle a wide range of materials, making it a versatile tool for different industries.

3. Improved Surface Quality:

• Fine Finishing: The precision of the Eneskaimpulse 230 ensures that you can achieve excellent surface finishes, reducing the need for additional manual polishing. This can improve the final product quality and reduce defects in moulded parts.
• Minimized Defects: With precise control over the tool’s movements and speeds, the system helps minimize common issues like scratches or uneven surfaces that can occur with less advanced equipment.

4. Enhanced Productivity:

• Efficient Workflow: The system’s advanced technology allows operators to work faster and more efficiently, reducing the time spent on manual polishing and finishing. This increased productivity can be a significant advantage in high-volume production environments.
• Quick Tool Changes: The system is designed for easy and quick tool changes, which minimizes downtime and allows for a more continuous workflow.

5. User-Friendly Interface:

• Intuitive Controls: The Eneskaimpulse 230 system is designed with user-friendly controls, making it accessible even to operators who may not have extensive experience with similar systems. The ease of use helps reduce training time and errors during operation.
• Ergonomic Design: The system’s design includes ergonomic features that reduce operator fatigue, allowing for extended use without discomfort. This is particularly important in industries where detailed work requires prolonged concentration and steadiness.

6. Reduced Thermal Impact:

• Cool Operation: One of the benefits of the Eneskaimpulse 230 is its ability to operate with minimal heat generation, especially during prolonged use. This reduces the risk of heat-related damage to sensitive mould surfaces, which is a common issue with other polishing systems.
• Thermal Management: The system’s design helps manage heat effectively, ensuring that the tool remains cool to the touch and safe to use even during extended periods of operation.

7. Durability and Reliability:

• Robust Construction: The Eneskaimpulse 230 is built for durability, ensuring that it can withstand the demands of industrial use. Its reliable construction means less downtime due to equipment failure, which is crucial in a production environment.
• Long Tool Life: The system’s efficient design contributes to a longer tool life, reducing the frequency of replacements and lowering overall operating costs.

8. Safety Features:

• Overload Protection: The system includes safety features like overload protection, which prevents damage to both the tool and the workpiece. This ensures that the equipment operates safely under various conditions.
• Stable Operation: The precision control and stable operation reduce the risk of accidents or mistakes, contributing to a safer working environment.

9. Compact and Portable:

• Space-Saving Design: The Eneskaimpulse 230 system is compact, making it easy to integrate into various workshop environments without taking up too much space.
• Portability: Its relatively lightweight and portable design allows it to be moved easily, making it convenient for use in different locations or for on-site repairs.

10. Cost Efficiency:

• Reduced Need for Manual Labour: By automating and refining many of the processes that would typically require manual labour, the system can reduce labour costs and increase overall efficiency.
• Lower Maintenance Costs: The system’s reliability and durability contribute to lower maintenance costs over time, making it a cost-effective solution for long-term use.

Conclusion

The Eneskaimpulse 230 system offers a combination of precision, versatility, and efficiency that makes it a valuable tool for mould and die repair, particularly in plastic injection moulding. Its advanced features and user-friendly design help improve productivity and reduce the risk of defects, making it an essential piece of equipment for professionals seeking high-quality results.

Contact us for a demo of the Eneskaimpulse 230

For demos of the Eneskaimpulse 230 give us a call – we  would be delighted to visit you and demo this outstanding tool.

And take a look at our You Tube page for videos of us hard at work finishing!