Preparation before patching:

 

I. Power on (220V, single-phase 50HZ)

 

2. Connect the magnet:

 

1. Tighten the magnet wire firmly to the negative output terminal of the host.

 

2. Two magnets must be attached to the mold at the same time. If the mold volume is too small, it should also try to absorb at the same time.

 

3. Keep the contact surface between the magnet and the mold clean to ensure good conduction. Impurities adsorbed on the copper surface should be removed, and oil or oxides on the surface of the mold should be cleaned with kerosene or abrasive cloth.

 

4. Selection of magnet attraction point: as close as possible to the straight line of the defect, and flat and large contact area with the magnet.

 

Three, welding head:

 

1. Tighten the welding head connection wire firmly to the positive output terminal of the host.

 

2. According to the actual situation of the defect surface, choose different shapes of copper welding heads, and you can process the shape of the copper welding heads appropriately. Pay attention not to make the contact area between the shape and the mold too large after processing. (Refer to mold repair attention problem 2)

 

Caution: During the work, the movement of the magnet wire and the welding torch wire will loosen the tightened terminal posts, which will cause the terminal posts to ablate and affect the repairing effect. They should be checked and tightened frequently.

 

四. Plug in the foot control switch

 

5. Adjust the power and select supplementary materials:

 

调节 Adjust the power of the host according to the power data shown for each supplementary material shell. The power of the sheet material refers to the alloy steel of the same thickness.

 

选择 Select different supplementary materials according to different mold steel materials (see the supplementary material table for details)

 

26. Mold repair:

 

Basic process:

 

1) Press the welding gun on the surface of the supplementary material.

 

2) Depress the foot switch.

 

3) Roll welding torch.

 

4) Release the foot control switch.

 

5) Detach the welding head from the mold.

 

Note: If the order is wrong, the machine will alarm and protect, but it may occasionally burn out pits on the mold surface!

 

  Precautions:

 

⑴ Cleanup: Simple cleanup at the place where repair is needed to remove oil and impurities, otherwise there will be poor power and sparks during the repair process.

 

(2) Rolling speed: It is advisable that the welding gun's rotation speed is closely aligned with the welding output to form fusion points on the supplementary material. The rotation speed should not be too fast, otherwise there will be a small amount of supplementary material peeling and fine porosity after repair and polishing.

 

(3) Welding gun and mold contact point: The smaller the contact area between the welding gun and the supplementary material, the better the sticking is, the greater the current density passed in the moment (the more concentrated the current), the greater the heat of the welding point, and the relative degree of supplementary material combination. better. The power data shown in the shell of the supplementary material is the power requirement when the standard welding gun electrode rod of φ5mm is in contact with the flat supplementary material. The larger the contact area of ​​the welding head with the same power, the larger the current spread, and the effect after replenishment is not ideal. Otherwise, the contact area is too small, and repair In the process, it is easy to cause the melting of the supplement material and the surface of the potholes.

 

(4) Posture and pressure: It is better that the welding torch and the mold face are at 45 degrees during repair, and a certain pressure is applied to the welding torch. The pressure depends on the roughness of the defect surface, and is not smooth. The surface with more impurities should be strong.

 

5 (5) Complex cavity: precise, multi-angled, and complex surfaces are repaired with precision power. Thin materials are better for multiple repairs. The normal state is suitable for defects with relatively large repairs.

 

(6) Oxidized surface repair:

 

Process: clean up impurities ---> remove oxide layer ---> edge repair with low power ---> fill out ---> polishing

 

1) Before repairing the oxidation mold, the nitrided layer must be removed with a power tool, and the supplementary material should be directly welded to the steel substrate, otherwise there is an oxide layer between the supplementary material and the substrate, which is easy to peel off.

 

2) Use small power and thin materials to repair the edge part as much as possible, which can reduce and reduce the edge traces caused by the heat generated by the repair.

 

(7) After the repair point is polished, there are light protrusions on the outer ring. The reason is that the workpiece is hardened by the heat generated during repair. The material with good quenching characteristics is particularly obvious. The edge part uses low power. Thin materials can avoid this phenomenon ( The method refers to the oxidation mold repair).

 

(8) The indentation after repairing and polishing is caused by the fact that the supplementary material is harder than the base material. It can be avoided by using a supplementary material with a hardness similar to the base material.

 

七. Routine maintenance

 

In order to make your machine better serve you, you should do daily maintenance of the machine, which has a great impact on the quality of welding. Because the working pulse current is low voltage and large current, special attention should be paid to the terminals, cables, welding guns and copper magnets. Be sure to maintain good electrical contact between them and the mold.

 

1) Replace the magnet copper in time.

 

2) If the cable is obviously broken, it should be replaced or repaired.

 

3) The inside of the welding torch should be kept clean, and impurities should be cleaned frequently.

 

4) Check the positive and negative terminals, tighten them tightly, and replace them in time if they are ablated.

 

5) It is normal for the welding gun to heat up during the repair process. Two welding guns should be used alternately during continuous repairing. Do not wrap the welding gun with insulation material, otherwise the welding gun will be damaged.