One of the first processes developed by Precision Joining Technologies during the start up phase of the company was the laser welding repair of molds. This was initiated by a call from a former co-worker who asked the question if the laser could be used to repair a broken corner of a mold. The answer was no problem. Using a wide selection of filler wire available the job was completed. After visual inspection by the mold company president he commented "you have something extremely unique to the industry here".

Since that call over 8,000 molds have been successfully repaired. Articles have been written on this unique application in the April 2003 edition of MoldMaking Technology Magazine entitled "Laser Weld Repair Of Molds"(1-3 minute download time on 56K modem) and EMTEC (Edision Materials Technology Center) Insider Magazine.

Process Used:
Nd:YAG pulsed laser welding is used. This is the lowest heat input fusion welding process in the industry and thus yields no/minimal distortion of the workpiece. The laser beam is focused down to a very small diameter onto the workpiece. Metal filler material is added between the laser beam and workpiece to build up the repair area.

Advantages:
- No/minimal undercut/sink of the weld or base metal surrounding the welded area.
- Minimal weld metal deposited resulting in minimal machining to restore the part to its original dimensions.
- Minimal heat input to the mold base metal resulting in no or the lowest possible distortion to precision features in close proximity to the weld repair area.
- Hard, tough resultant weld metal due to the fine grain structure of the weld metal which is a result of the extremely rapid solidification of the laser weld.
- Extremely precise control of the weld metal location which allows for welding within a few thousands of features which are not to be disturbed on the mold.
- Little to no discoloration of weld and the surrounding base material.

Mold Materials That Have Been Laser Weld Repaired:

S7	410SS	D2	Aermet	Aluminum
H13	420SS	A2	CPM9V	Copper-Beryllium
P20	440SS	A6		Amcoloy 940
NAK-55	Elmax	M2

Precision Joining Technologies, P.O. Box 531, Miamisburg, OH 45343-0531
Ph (937)865-4051 FAX (937)865-3666

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