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D-M-E Pro Weld User Manual - Operation

Summary of Pro Weld

  • Page 1

    D-m-e pro weld ™ user guide.

  • Page 2: D-M-E Pr

    D-m-e company 29111 stephenson highway madison heights, mi 48071 phone: (800) 626-6653 (248) 398-6000 fax: (248) 398-6174 d-m-e pr o w eld ™ user guide preface please read this instruction manual thoroughly before using your d-m-e pro weld ™ system. The d-m-e pro weld unit is a newly developed resis...

  • Page 3

    D-m-e pro weld ™ model no. Umw0001 user guide.

  • Page 4: Table of Contents

    2 table of contents applications i. Introduction............................................................................5 advantages 5 ii. Specifications ........................................................................7 standard accessories for pro weld ™ umw0001 7 additional welding mat...

  • Page 5

    3 table of contents vii. Examples of welding ........................................................ 31 vii.1 focalization of current, electrode shape 31 and formation of the weld spot vii.2 powder metal application 32 welding to a 3-point corner, parting line, edge 33 welding to a flat surface 34 ...

  • Page 7: Introduction

    I i. Introduction please read this instruction manual thoroughly before using your pro weld ™ system. Pro weld is a newly developed resistance-type welder. It effectively builds up material to repair or redesign molds and dies. [note: it is not recommended for use on press dies, blow molds (usually ...

  • Page 8

    6 introduction i ♦ the process is optimally suited for small areas and micro welding. ♦ hardening and plating can be done after welding. ♦ welding work time is greatly reduced. Roll welding a 3/8" (10mm) long parting line can be done in 1 minute, treating a pinhole in 30 seconds. ♦ as the capacitor ...

  • Page 9: II.

    7 ii. Specifications ii standard accessories for pro weld umw0001 specifications power pack with welding cord, grounding cord and plate, power cord, foot switch and all accessories listed below n51 – standard skh-51 steel powder (50 grams) (63 rc; for d-2/m-2/s-7 steels) n80 – standard nak80 steel p...

  • Page 10

    Catalog no. Description ii specifications 8 protective gloves magnet electrode (2 dia. X 50l) magnet electrode (3 dia. X 50l) magnet electrode (4 dia. X 60l) magnet electrode (4 dia. X 50l) standard electrode (2 dia. X 50l) standard electrode (3 dia. X 50l) standard electrode (4 dia. X 50l) standard...

  • Page 11

    Ii 9 specifications n-11 ump0067 skd-11 50 grams rc 50-60 min. A-2, d-2 all die steels n-38 ump0072 hpm38 50 grams rc 30 max. 420ss (prehardened) n-39 ump0073 pd555 50 grams rc 50-52 stavax n-40 ump0060 ni-cr alloy 50 grams rc 36-42 all mold steels n-50 ump0062 ni alloy 50 grams rc 47-53 all mold st...

  • Page 12

    10 specifications ii additional welding materials for pro weld umw0001 welding material: wire welding d-m-e japanese hardness u.S. Mold steel materials catalog no. Mold steel quantity / size rockwell equivalent welding material: sheet (dimensions in millimeters) nt-6 uma0001 10 / 0.2t x 5w x 100l rc...

  • Page 13: III

    11 iii iii. Parts nomenclature for pro weld™ umw0001 parts nomenclature for pro weld™ umw0001 d-m-e pro weld ™ carrying handle amp output meter slidac amp output control automatic/manual function main power switch output for grounding cord output for electrode holder cord power indicator lamp timer ...

  • Page 14: III

    Iii 12 parts nomenclature for pro weld™ umw0001 carrying handle fan specifications and serial number plate fuse holder/fuse input power socket pro weld umw0001 back panel.

  • Page 15

    13 iv iv. General description of use iv.1 function electric power is supplied from an ac120v source. As a resistance- type micro-welding machine, pro weld stores current in a capacitance circuit. Current is released by the foot switch and sent to the electrode in the electrode holder. This release o...

  • Page 16

    Iv operational tip when using magnetic electrodes apply less pressure to the workpiece. Do not exceed the amp output guidelines (see vi.4). To do so could cause the electrode to de- magnetize. Apply more pressure to the work surface when using non-magnetic electrodes. Again, follow the amp output gu...

  • Page 17

    Electrode selected and by the type of repair to be performed (see amp output guidelines, vi.4). ♦ with the amperage output selected, connect an electrode holder with electrode fixed to the electrode holder cord by sliding it on to the end of the cord until snug (it need not be perfectly flush). ♦ re...

  • Page 18

    Operational tip be sure the electrode holder cord and grounding cord are fully tightened in their respective sockets. If not completely tight, conductivity will be lost resulting in bad welding. 16 general description of use iv.

  • Page 19: Operation

    17 v v. Operation v.1 cautions in welding work each pro weld has a caution sticker applied to the top of the unit. Please follow these guidelines before operation: ♦ wear the supplied goggles during operation. ♦ both the pro weld and its associated cables create strong mag- netic fields around them....

  • Page 20

    18 v v.2 discharge of stored energy resistance type micro welding machines store voltage in condens- ers. It is important to discharge the stored voltage when the unit is not in use to avoid any danger and to save energy. Except at the time of welding (which is done by the discharge of stored voltag...

  • Page 21: VI. Welding

    19 vi vi. Welding in welding work using a pro weld unit, only the duration of each pulse (current discharge) is a constant. The variable factors are: ♦ the welding current ♦ electrode-applied pressure ♦ surface condition of the base metal, and ♦ selection of welding materials vi.1 workpiece, electro...

  • Page 22

    20 vi secured in a vise with the grounding plate close to the repair area. (fig. 1) ♦ cut the welding material to the proper size of the area to be repaired with supplied sheet metal shears. Place on workpiece. (fig. 2) vi.2 pro weld control features manual function 1. Select the manual function by ...

  • Page 23

    21 vi operational tip it is important when using the manual function to depress the foot switch correctly and in a timely fashion. Each time the foot switch is depressed, current is dis- charged to the electrode. If the foot switch is repeatedly depressed too fast (in quick succession), the unit wil...

  • Page 24

    22 vi timer 1. The timer will adjust the intervals at which the current is discharged. 2. The duration of each pro weld pulse (discharge) is 0.0040 second. 3. Turning the timer knob from slow to fast will increase the frequency at which each pulse is released. 4. Generally, the “slow” settings are u...

  • Page 25

    Cause excessive sparking. Standard electrodes are made of a silver alloy and can be easily shaped using diamond hard tools and emery paper. Shape examples of the flat electrode, fig. 4 vi.4 recommended current output levels amperage output levels used during welding will vary according to: – the typ...

  • Page 26

    Sheet mold electrode powder material wire repair type diameter 1-0.2mm 1-0.1mm material tack welding 2 200-300 300-500 roll welding with electrode 2 angled at 45° 3 200-400 400-600 4 5 300-500 500-700 700-900 roll welding with round 2 electrode angled at 10° 3 300-500 500-700 4 5 400-600 600-800 800...

  • Page 27

    Vi.5 mold material/welding material pro weld welding materials are in powder, sheet metal and wire form. Each has a different hardness and metal mold application. Generally, the powders, and sheets supplied standard with pro weld produce a strong homogenous weld on most large and small molds. Molds ...

  • Page 28

    26 vi welding welding d-m-e japanese hardness u.S. Mold steel materials catalog no. Mold steel quantity rockwell c equivalent n-11 ump0067 skd11 50 grams rc 50-60 min. A-2, d-2 all die steels n-38 ump0072 hpm38 50 grams rc 30 max. 420ss (prehardened) n-39 ump0073 pd555 50 grams rc 50-52 stavax n-40 ...

  • Page 29

    27 vi vi.6 pro weld welding process a. Having selected an electrode holder with electrode and set the amperage control knob to the desired output level (see iv.4), tack (fix) the weld material to the workpiece using the manual (single pulse) setting. Firmly push the electrode onto the weld material ...

  • Page 30

    B. Turn the auto(matic) function to on. Firmly push the electrode on the weld material. Depress the foot switch and keep it depressed while slowly rolling (see vi.7, roll weld- ing technique) the electrode along the length of the weld material. Pro weld will continually discharge and form overlappin...

  • Page 31

    Vi.7 roll welding technique a. With the pro weld micro welder, proper weld padding is obtained by rolling the electrode across all surfaces of the weld material. This technique may take some practice. B. It will be helpful to hold the electrode holder like a pencil with the forefinger or middle fing...

  • Page 32

    30 vi e. Proper roll welding is accomplished across a strip of weld material by holding the electrode holder as described above. Then, starting at one end of the weld material, turn your wrist as far as comfortable in one direction and roll turning the wrist as you roll as far as comfortable in the ...

  • Page 33: Vii

    31 vii vii. Examples of welding vii.1 focalization of current, electrode shape and formation of the weld spot examples of welding good o bad x fig. 8 electrode shape ra=0.2-0.5mm fig. 9 fig. 7 current dispersion good o bad x.

  • Page 34: Vii

    32 vii formation of the weld spot the size of the weld spot formed during roll welding will vary with amperage output value, the end-shape of an electrode and the applied pressure. Generally the spot formed will be 0.2~1.0mm in diameter per machine current discharge. Progression along the weld is ma...

  • Page 35: Vii

    33 vii welding to a 3-point corner, parting line, edge roll the electrode on a 3-point corner at various angles to ensure weld build-up at all points of the corner. Re-roll weld with a bare electrode after the first layer. If second or third layers are needed, also re-roll weld between layer applica...

  • Page 36: Vii

    Welding to a flat surface ♦ put a small amount of powder onto the part to be welded. Using a standard electrode with its end shaped like a ball point pen (magnetic electrodes cannot be shaped without their losing magnetism), weld the powder down spot by spot. ♦ with a round electrode whose edge has ...

  • Page 37: Vii

    ♦ put a small amount of powder onto an inner corner and use a flat electrode shaped like a spatula to weld the first layer down (fig. 14a). ♦ to add a second layer of powder material use an electrode with its end shaped like a ball point pen and weld spot by spot (fig. 14b). Also use this electrode ...

  • Page 38: Vii

    Welding. Fill and weld the crack in approximately 0.15mm thick layers. Weld one layer and then another and so on. Wire welding material is also effective in filling and repairing cracks. Welding in a rib ♦ the rib opening can be welded using a 2mm electrode 36 examples of welding vii fig. 16 fig. 17...

  • Page 39: Vii

    Vii (umw0013) or one shaped to a smaller diameter. ♦ for a flaw on the side of a rib, apply powder onto the area and use a flat electrode with its end thinned/dressed as necessary. ♦ for flaws at the bottom of a rib, apply powder as above and weld with a flat electrode with its end thinned as needed...

  • Page 40: Vii

    Proper electrode contact while welding sheet material, it is important to keep the electrode on the sheet to avoid sparking which could cause minor damage to the base material. Positioning of the sheet material the sheet material should be slightly larger than the repair area and extend beyond the e...

  • Page 41: Vii

    Vii the pro weld to manual function and tack the material in place (see fig. 19). Be sure the electrode end is in a rounded shape. ♦ using a round electrode, its edge shaped with a small radius, include the electrode and roll weld the sheet material. For best results, the first layer should be 0.1mm...

  • Page 42: Vii

    Described in vii.2 (see fig. 22). Repairing a 3-point corner with sheet material, use the profile (side) of a round electrode or the side of a flat square shaped electrode. Cover all of the weld material moving the electrode in various directions (see fig. 22 and 23 below). Re-roll weld the material...

  • Page 43: Vii

    Vii using the pro weld sheet metal shears, cut a strip of sheet materi- al large enough to cover the parting line or edge. Set the pro weld to manual function and tack the strip in place. Then, set pro weld to auto and, with the profile (side) of a round electrode, roll weld the material ensuring th...

  • Page 44: Vii

    Fig. 26 if the flaw to be repaired is more that 1mm in width or diameter, multiple layers of sheet material must be applied in the sequence shown in fig. 27 below. Fig. 27 a pinhole can be repaired using powder, sheet material or a combi- nation of both. When using sheet material, if the hole diamet...

  • Page 45: Vii

    Weld a small piece of material into the bottom of the pinhole and then a full-size piece of material over the first weld. Large diameter pinhole fig. 29 an alternate method of pinhole repair is done by hammering a cen- ter punch into the pinhole and onto the sheet material at the same time. Place th...

  • Page 46: Vii

    To ensure a good, strong weld on the first layer, roll weld with a 2mm or 3mm diameter tapered electrode with its end rounded like a ball-point pen. For the second layer, roll welding can be done with a round electrode, its edge shaped with a small radius. Fig. 30 when two pieces of sheet material a...

  • Page 47: Vii

    Vii repair of base metal impurities if the base metal surface is found to have impurities due to nitriding etc., grind the surface by 0.1mm and then weld sheet material onto it. Add another layer as needed. Fig. 33 repair of an inner corner to weld at an inner corner, use a length of wire material 0...

  • Page 48: Vii

    Welding to a rising wall in a confined area where a rising wall needs to have material build-up, it may not be possible to roll weld. In this case, pressing onto the weld material and triggering current discharge with the manual setting will be sufficient to properly weld the material in place. Use ...

  • Page 49: Viii

    Viii viii. Examples of bad welding viii.1 unconnected weld spots the worst kind of welding will result if the weld spots are arranged with any gap or clearance between them. Each weld spot must overlap the next by half its diameter. Subsequent weld material layers must be done in this same manner. F...

  • Page 50: Viii

    Viii.3 oxidized base metal or electrodes it is important that the mold surface and electrode be cleaned of any type of stain or contamination using sandpaper or alcohol absorbent. For full details, see vi.1 workpiece, electrode, welding materials. Fig. 39 viii.4 bad conductivity bad conductivity in ...

  • Page 51: Ix. Maintenance Guarantee

    Ix ix. Maintenance guarantee d-m-e guarantees the pro weld umw0001 free from defects in parts and workmanship for a period of one year from date of shipment of the unit. Within the guarantee period, d-m-e or the manufacturer will repair or replace defects free of any cost. All claims must be made in...

  • Page 52: D-M-E Pr

    D-m-e company 29111 stephenson highway madison heights, mi 48071 phone: (800) 626-6653 (248) 398-6000 fax: (248) 398-6174 d-m-e pr o w eld ™ user guide preface please read this instruction manual thoroughly before using your d-m-e pro weld ™ system. The d-m-e pro weld unit is a newly developed resis...