Repair of a forging die with a gouged surface
Repairing forging dies manually introduces the possibility of human error, particularly when dealing with uneven surfaces. In the case of this particular forging die, the surface was gouged in preparation for repair. To enhance both quality and efficiency, MaxQ Repair was utilized as the solution for repairing this forging die.
The Challenge
In prepartation for the repair process, the surface of this die was manually gouged, creating an uneven substrate for welding operations. Fortunately, MaxQ Repair provides a solution through its pose projection feature. This advanced feature utilizes 3D scanning technology to analyze the part before and during the repair process. It automatically plans toolpaths and projects them onto the surface, effectively addressing the unevenness. By employing this method, MaxQ Repair guarantees a consistent stick-out of the wire, resulting in high-quality repairs.
The solution: Scan, plan, repair, repeat
MaxQ Repair utilizes a straightforward four-step process to repair metal parts. The die placed on the table was scanned using an integrated 3D camera in the weld cobot, capturing its dimensions. A comparison was made between the scan and an ideal die representation, generating tool paths automatically while considering torch tilting and collision checks. The repair job was then initiated with a button press, and real-time monitoring ensured quality control. This included geometry control with the 3D camera, interpass temperature control using a thermal camera, and anomaly detection with high-frequency current and voltage sensors. The process was automatically repeated for subsequent layers, ensuring efficient and reliable repairs.
The result
- Enhanced Welding Quality: MaxQ Repair delivers consistent, high-quality welds, also on an uneven surface. This improves product durability and reduces defects.
- Increased Production Efficiency: Automation minimizes delays, clears the backlog, and ensured timely deliveries, improving customer satisfaction.
- Cost Savings: MaxQ Repair reduces labor costs by eliminating the need to hire and train additional welders.
The stats
- 21 layers, 125 beads
- Total arc on time: 1 hr 39 min 58 sec
- Deposited weight: ~8.5 kg @ 8.2g/m @ 10.4m/min WFS
- Shielding gas used: ~2000 L @ 20L / min
- Pose projection (3D scanning process: Between 60 and 80 sec per projection, total = 21 to 28 min
- Welding Wire: UTP ROBOTIC 554
How it works
About MaxQ Repair
MaxQ Repair is an all-in-one automated solution for the repair of metal parts, such as rails, rotors, and dies, that are subject to wear in service.
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