Introduction – Precision Repair Welding

We recognise the challenges of precision repair welding. Specifically 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:

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.

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.

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.

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.

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.

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.

Benefits of ENESKAimpulse 230

High Precision and Control:

• Pulse Functionality: The ENESKAimpulse 230 system features pulse technology, which allows for extremely precise control. This is especially useful for detailed working on edge repair and filling.

Versatility:

• 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 welder for different industries.

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.

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.

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!