Abstract
Dies, molds and gears are very expensive and difficult-to-manufacture components which develop some repairable damages during their use. These damages do not render them to be rejected due to various industrial and economic reasons but affect their proper functioning. Timely and economic repairing or remanufacturing of these components can greatly extend their life without compromising their functional and quality aspects thus yielding rich financial and productivity benefits. This chapter describes various repair processes for different types of damages that occur in the dies, molds and gears with major focus on laser-based repair processes. It also defines various types of damages and discusses possible causes of their occurrence. This will help users in selecting the most appropriate repair process for the damaged industrial dies, mold, and gear depending upon availability of the resources and various constraints.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
He B (2011) Research on the Damage and material selection of Plastic mold. Proc Eng 23:46–52
Jhavar S, Paul CP, Jain NK (2013) Causes of damage and repairing options for dies and molds: a review. Eng Fail Anal 34:519–535
Cosenza C, Fratini L, Pasta A, Micari F (2004) Damage and fracture study of cold extrusion dies. Eng Fract Mech 71:1021–1033
The tool and die industry: contribution to us manufacturing and federal policy considerations. CRS Report for Congress. Congressional Research Service 7–5700
Timothy A (2003) With foreign rivals making the cut, toolmakers dwindle, Indian edn. The Wall Steel J
Pantazopoulos G, Zormalia S (2011) Analysis of the failure mechanism of a gripping tool steel component operated in an industrial tube draw bench. Eng Fail Anal 18:1595–1604
Grum J, Slabe JM (2003) A comparison of tool-repair methods using CO2 laser surfacing and arc surfacing. Appl Surf Sci 208–209:424–431
Pleterski M, Tuek J, Kosek L, Muhi M, Muhi T (2010) Laser repair welding of molds with various pulse shapes. METABK 49(1):41–44
Rao I (2012, May–June) Casting dies for a sustainable future. Eff Manuf (EM) Mag
Shi J, Bai SQ (2013) Research on gear repairing technology by laser cladding. Key Eng Mater 546:40–44
Garat V, Bernhart G, Hervy L (2004) Influence of design and process parameters on service life of nut hot forging die. J Mater ProcessTechnol 147:359–369
Moura GCR, Aguilar MTP, Pertence AEM, Cetlin PR (2007) The materials and the design of the die in a critical manufacturing step of an automotive shock absorber cap. Mater Des 28:962–968
Sun Y, Hanaki S, Uchida H, Sunada H, Tsujii N (2003) Repair effect of hot work tool steel by laser-melting process. J Mater Sci Technol 19:91–93
Pereira MP, Yan W, Rolfe BF (2012) Wear at the die radius in sheet metal stamping. Wear 274–275:355–367
http://looktech.en.ec21.com/Mold_Doctor–1605536_2399545.html
http://www.tractorbynet.com/forums/john-deere-lawn-garden/295609-metal-cam-gear-failure.html
Stavridis N, Rigos D, Papageorgiou D, Chicinas I, Medrea C (2011) Damage analysis of cutting die used for the production of car racks. Eng Fail Anal 18:783–788
Alaneme KK, Adewuyi BO, Ofoegbu FA (2009) Damage analysis of mould dies of an industrial punching machine. Eng Fail Anal 16:2043–2046
http://www.empiredie.com/empire-die-casting/resource-center/faq/q7-table.html
http://www.novexa.com/en/intervention/gears/defects-treated.html
Ebara R, Takeda K, Ishibashi Y, Ogura A, Kondo Y, Hamaya S (2009) Microfractography in Damage analysis of cold forging dies. Eng Fail Anal 16:1968–1976
Choi C, Groseclose A, Altan T (2012) Estimation of plastic deformation and abrasive wear in warm forging dies. J Mater Process Technol 212:1742–1752
Thompson S (1999) Handbook of mold, tool and die repair welding. William Andrew Publishing
Preciado WT, Bohorquez CEN (2006) Repair welding of polymer injection molds manufactured in AISI P20 and VP50IM steels. J Mater Process Technol 179:244–250
Branza T, Duchosal A, Fras G, Beaume FD, Lours P (2004) Experimental and numerical investigation of the weld repair of superplastic forming dies. J Mater Process Technol 155–156:1673–1680
Horii T, Kirihara S, Miyamoto Y (2008) Freeform fabrication of Ti–Al alloys by 3D micro-welding. Intermetallics 16(11–12):1245–1249
Horii T, Kirihara S, Miyamoto Y (2009) Freeform fabrication of superalloy objects by 3D micro welding. Mater Des 30:1093–1097
Mizuta N, Matsuura K, Kirihara S, Miyamoto Y (2008) Titanium aluminide coating on titanium surface using three-dimensional microwelder. Mater Sci Eng A: 199–204
Xu FJ, Lv YH, Xu BS, Liu YX, Shu FY, He P (2013) Effect of deposition strategy on the microstructure and mechanical properties of Inconel 625 superalloy fabricated by pulsed plasma arc deposition. Mater Des 45:446–455
Wang W, Pinkerton AJ, Wee LM, Li L (2007) Component repair using laser direct metal deposition. In: Proceedings of 35th international matador conference 14:345–350
Borrego LP, Pires JTB, Costa JM, Ferreira JM (2009) Mould steels repaired by laser welding. Eng Fail Anal 16:596–607
Borrego LP, Pires JTB, Costa JM, Ferreira JM (2007) Fatigue behavior of laser repairing welded joints. Eng Fail Anal 14:1586–1593
Zhong M, Liu W, Ning G, Yang L, Chen Y (2004) Laser direct manufacturing of tungsten nickel collimation component. J Mater Process Technol 147:167–173
Lim JS, Ng KL, Teh KM (2008) Development of laser cladding and its application to mould repair. SIMTech Tech Rep 9(3):142–147
Capello E, Colombo D, Previtali B (2005) Repairing of sintered tools using laser cladding by wire. J Mater Process Technol 164–165:990–1000
Leunda J, Soriano C, Sanz C, Navas VG (2011) Laser cladding of vanadium–carbide tool steels for die repair. Phys Procedia 12:345–352
Mudge RP, Wald NR (2007) Laser engineered net shaping advances additive manufacturing and repair. Welding J:44–48
Zou JX, Grosdidier T, Zhang KM, Dong C (2009) Cross-sectional analysis of the graded microstructure in an AISI D2-steel treated with low energy high-current pulsed electron beam. Appl Surf Sci 255:4758–4764
Desale GR, Paul CP, Gandhi BK, Jain SC (2009) Erosion wear behavior of laser clad surfaces of low carbon austenitic steel. Wear 266(9–10):975–987
Srivastava A, Joshi V, Shivpuri R (2004) Computer modeling and prediction of thermal fatigue cracking in die-casting tooling. Wear 256:38–43
Paul CP, Alemohammad H, Toyserkani E, Khajepour A, Corbin S (2007) Cladding of WC–12 Co on low carbon steel using a pulsed Nd:YAG laser. Mater Sci Eng, A 464(1):170–176
Graf B, Ammer S, Gumenyuk A, Rethmeier M (2013) Design of experiments for laser metal deposition in maintenance, repair and overhaul applications. Proc CIRP 11:245–248
Graf B, Gumenyuk A, Rethmeier M (2012) Laser metal deposition as repair technology for stainless steel and titanium alloys. Phys Proc 39:376–381
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2017 Springer International Publishing AG
About this chapter
Cite this chapter
Nikam, S.H., Jain, N.K. (2017). Laser-Based Repair of Damaged Dies, Molds, and Gears. In: Gupta, K. (eds) Advanced Manufacturing Technologies. Materials Forming, Machining and Tribology. Springer, Cham. https://doi.org/10.1007/978-3-319-56099-1_6
Download citation
DOI: https://doi.org/10.1007/978-3-319-56099-1_6
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-56098-4
Online ISBN: 978-3-319-56099-1
eBook Packages: EngineeringEngineering (R0)