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MEACM IOP Publishing
IOP Conf. Series: Materials Science and Engineering 307 (2018) 012011 doi:10.1088/1757-899X/307/1/012011
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Increasing of the lifetime of large forging dies by

repairwelding

M Duchek1, Koukolikova M2 , J Kotous3, M Majer4

1 Head of Department Metallurgical Technologies, COMTES FHT a.s., Dobřany, CZ

2 R&D engineer Mechanical Testing, COMTES FHT a.s., Dobřany, CZ
3 R&D engineer Metallurgical Technologies, COMTES FHT a.s., Dobřany, CZ
4 Head of Technical Department, CZECH PRECISION FORGE a.s., Plzeň, CZ
E-mail: Michal.duchek@comtesfht.cz, martina.koukolikova@comtesfht.cz,
jakub.kotous @comtesfht.cz, miroslav.majer@cpforge.com

Abstract. Repair welding is often used for rebuilding discarded or failed forging dies. It saves
the cost of new tools. Increased useful life of repaired dies is another motivation for repair
welding. This article focuses on the development of new filler materials for this purpose. The
main goal was to prolong the life of tools of DIN 1.2714 material. Filler wires of two
chemistries were made and several samples were experimentally welded. Metallographic and
tribological analyses were carried out.

1. Introduction
Most forge shops face the issue of worn forging dies and their repair welding or rebuilding. However,
those dies are typically small-size tools which are easy to pre-heat for better outcomes of repair
welding. Pre-heating of large forging dies is a rather complicated operation with greater demands on
the process route and, consequently, on the experience of the engineers involved. [1]
Hot-forming dies are most often scrapped after reaching the maximum permitted wear (approx. 70 %
of cases), followed by those affected by mechanical fatigue (25 %) [2]. The factors which play a major
role in the die life include the die design, the heat treatment, and the materials used (i.e. both the base
material and the filler material). The design of a forging die is dictated by the shape of the forged part
and by the capabilities of the forming machine. Special software tools are available for optimizing the
impression to achieve the best possible cavity filling [8]. There are many heat treatment and
thermochemical treatment routes for extending the die life. In each case, the method chosen must be
appropriate for the material in question. For instance, plasma nitriding improves wear resistance but
the product becomes more prone to cracking. Such cracks are caused by thermal shock and mechanical
loads [3]. Recently, deep cryogenic treatment has been receiving renewed attention – as a process
which can provide full martensitic transformation, and therefore eliminates retained austenite from the
product. Deep-cryogenic-treated dies show approximately 30% longer life than conventionally-treated
tools [4].
Base materials with the right chemistry can provide improved utility properties. Finding the optimal
chemical composition is a demanding endeavour that entails numerous trial heats and testing of
properties. Modification of chemical composition can deliver the life improvement of 10-20% at
considerably increased costs of the material [5]. However, there is also a more affordable variant
which involves hardfacing the base material with special materials. Various ordinary filler materials

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IOP Conf. Series: Materials Science and Engineering 307 (2018) 012011 doi:10.1088/1757-899X/307/1/012011
1234567890‘’“”

and special hardfacing materials can be used. Another advantage of this method is that it enables
discarded dies to be rebuilt or repaired [2], [9]. In practice, all these methods are applied to small and
medium-sized dies, i.e. those with weights of around 100 kg. By contrast, the dimensions of large dies
that weigh several tonnes make it almost impossible to use and combine heat treatment and
thermochemical treatment. Their hardfacing is complicated as well because they are difficult to pre-
heat. Repair welding of sizable forging dies has been embarked upon by CZECH PRECISION
FORGE, a forging company which intends to use it to rebuild damaged dies. One advantage is that
repair-welded dies have longer life than new dies. A consortium of companies has been formed to
pursue this research. The consortium members are COMTES FHT, a research organisation, DG Weld,
an Italian company engaged in welding which has extensive experience in die rebuilding, and CZECH
PRECISION FORGE, a forge shop and the main user of the results. The main objective is to develop a
new material for welding large dies.

2. Experimental programme
The basic principle of the experiment was to vary the levels of the key alloying elements in such a way
that the effects of such variation could be identified. Two materials were developed in this manner:
CPF and N31 materials. In CPF, the carbon and chromium levels were reduced, whereas the nickel
content was increased. In N31, the amount of manganese was reduced and more chromium was added.
Details of their chemical compositions cannot be published at this time because their legal protection
is under discussion.

Table 1. Material: DIN 1.2714, chemical composition [%]

C Si Mn P S Cr Mo Ni V Fe
0.50 0.30 0.50 0.90 0.30 1.50 0.10
balance
0.60 0.60 0.90 0.030 0.030 1.30 0.50 1.90 0.25

Table 2. Material: N3, chemical composition [%]

C Mn Si Cr Ni Mo V P S Fe
0.106 1.162 0.5 0.131 4.3 1.87 0.128 0.01 <0.15 91.4

Samples were cut from a discarded die. Their shapes were chosen to enable the same hardfacing
process as the actual die. Having the dimensions of 180×90×150 mm, the samples were provided with
a V-notch of 80 mm depth, Figure 1. Each sample was hardfaced according to specified welding
procedure, table 3. The samples were then examined by metallographic techniques, their hardness was
measured and their wear resistance tested by the pin-on-disc method.

Figure 1. In Macrophotograph of weld, N31 – Etching revealed the heat-affected zone (HAZ)
and the boundary of the weld

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IOP Conf. Series: Materials Science and Engineering 307 (2018) 012011 doi:10.1088/1757-899X/307/1/012011
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Table 3. Welding parameters

Welding Welding Heat

position parameters treatment
Stress-
290 A
Horizontal relieving
28 V
575°C

3. Metallographic examination
Metallographic examination was carried out on all samples to verify the quality of the weld joint.
HV10 hardness numbers were determined using STRUERS DuraScan 50 laboratory tester. The
indents were spaced at 1 mm. The locations of the indents are indicated in the macrographs.
Metallographic specimens were ground. Their microstructures were brought out by etching with 3%
nital and documented using NIKON Eclipse MA200 optical microscope. Macrographs of the locations
with indents were taken using a CARL ZEISS Observer Z1m microscope. The macrostructure was
revealed by etching with aqua regia. A close-up view of a weld joint and a hardness profile for the
CPF material is shown in Figure 2. In the heat-affected zone (HAZ), adjacent to the weld metal, there
was coarse tempered martensite and bainite. The base material consisted of bainite (tempered lower
and upper bainite). The variation within the hardness profile was acceptable: in the range of 125 HV10.

Figure 2. A close-up view of the weld joint and a hardness profile for the CPF material.
The weld metal of the N31 material in the region under examination consisted of a highly-tempered
hardening microstructure with minute oxide inclusions. In the heat affected zone, adjacent to the base
material, there was fine tempered bainite. The variation in hardness was in the range of 150 HV10.

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MEACM IOP Publishing
IOP Conf. Series: Materials Science and Engineering 307 (2018) 012011 doi:10.1088/1757-899X/307/1/012011
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Figure 3. A close-up view of the weld joint and a hardness profile for the N31 material.

4. Mechanical testing
Impact toughness testing was chosen for comparing fundamental mechanical properties of the
specimens. Samples for making impact toughness test pieces were taken from four locations, Figure 1.
The test pieces had the standard size of 10×10×55 mm and contained a V-notch. The results achieved
with optimum welding parameters for both newly-developed materials are given in table 4.

Figure 5. Locations of samples for impact toughness testing (W–Weld, HAZ-Heat Affected Zone,
R-Root, BM–Basic Material)
Table 4. Impact toughness test values
KCV Note
Specimen
J/cm2
13.2 HAZ
N3 8.6 R
8.5 W
47.0 HAZ
CPF 8.0 R
31.6 W
12.2 HAZ
N31 15.5 R
6.8 W
1.2714 20.8 BM

5. Tribological testing– PIN-ON-DISC test

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MEACM IOP Publishing
IOP Conf. Series: Materials Science and Engineering 307 (2018) 012011 doi:10.1088/1757-899X/307/1/012011
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To study the life of the newly-created surfaces on specimens, the PIN-ON-DISC test was chosen. As
the materials were intended for hot-working operations, the tests were carried out at 150 °C and
300 °C.
The purpose of the test was to determine the wear resistance of materials under operating conditions.
The test consisted in forcing a ball indenter into the surface of a rotating flat specimen. The indenter
was loaded by a prescribed force (exerted by a weight) and attached to a rigid arm. Strain gauges fitted
to the arm recorded the resulting friction force. Wear data was found by measuring the resulting tracks
in test specimens. The measured parameters included the actual amount of wear (material loss) and the
impressions (deformation) in the test specimen. The readings are given in figure 5 and table 5.
Average values obtained from three readings are shown.

Specimens taken from the welds were tested under the following conditions:
Test temperature: 150°C and 300 °C
Ball material: Si3N4, diameter 6 mm
Load: 10 N
Wear track diameter: 3 mm
Number of cycles: 5000
Linear travel speed: 2.5 cm/s
Rotation speed: 80 rev/mi

Table 5. Results of pin-on-disc testing

Designation Wear rate (10-6 mm3/Nm) Mean friction coefficient
N1 150°C 47 0.768
N31 150°C 88 0.721
CPF 150°C 74 0.768
N1 300°C 246 0.496
N31 300°C 175 0.490
CPF 300°C 181 0.504

Volume loss [μm3]

300

250

200

150

100

50

0
N1 150°C N31 150°C CPF 150°C N1 300°C N31 300°C CPF 300°C

Figure 5. Results of wear testing

6. Conclusion
In the project, two variants of filler material were proposed and compared with the N3 material. At
COMTES FHT, all materials were cast and converted into filler wires. Test samples were
manufactured at DG Weld. Upon metallographic examination, the weld joints were found to exhibit

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MEACM IOP Publishing
IOP Conf. Series: Materials Science and Engineering 307 (2018) 012011 doi:10.1088/1757-899X/307/1/012011
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good dilution. The microstructures were similar in both materials: tempered hardening microstructure.
The variation in the hardness profile was examined. The CPF material performed better because its
difference in hardness levels was 125 HV10. In the N31 material, the variation was 150 HV10. Both
profiles can be deemed very good. The comparison of impact notch toughness levels shows that the
CPF material is tougher than N3 and N31. In the HAZ, these values were 47 J/cm2 and 13.2 J/cm2. The
toughness of the N31 material is similar to that of N3. Only the toughness in the vicinity of the weld
root is twice as high.
The tribological test focused on wear at elevated temperatures to which dies are subjected during
forging. At 150°C, the performance of both newly-proposed materials was poorer than that of
the reference material N3. In N31, the wear rate was 88*10-6 mm3/Nm, in CPF it was 74*10-
6
mm3/Nm and in N3 it was 47*10-6 mm3/Nm. By contrast, at 300°C, both newly-proposed materials
performed better than the reference material. The performance of the N31 material was 29% better and
that of the CPF material was 27% better than in the reference material. These materials proved to be
more effective at higher operating temperatures of dies. At temperatures around 150°C, the N3
material is a more suitable choice.

7. References
[1] Duchek M, Šuchmann P, Majer M.: Development of New Welding Materials for Repair
Welding of Sizable Forging Dies. In: Kovárenství, 53/2015. Brno, 2015. p. 4/81-84. ISSN
1213-9289
[2] Dong-Gyu A: Hardfacing Technologies for Improvement of Wear Characteristics of Hot
Working Tools: A Review, International Journal Of Precision Engineering And
Manufacturing Vol. 14, No. 7, pp. 1271-1283,
[3] Paschkea H, Weber M, Braeuer G, Yilkiran T, Behrens B A, Brand H: Optimized plasma
nitriding processes for efficient wear reduction of forging dies, Archives Of Civil And
Mechanical Engineering 12, pp. 407–412, 2012
[4] Hauserova D, Dlouhy J, Novy Z, Zrnik J & Duchek M, Behrens B A, Brand H: Forming of C45
Steel at Critical Temperature, 11th Int. Conf. On the Mechanical Behavior of Materials
(icm11), 2011, 10
[5] Duchek M, Suchmann P, Reznar J, Krejcik J & Marek R, Behrens B A.; Brand, H.:
Development of Modified Versions of 1.2343 Tool Steel, 21st Int. Conf. On Metallurgy and
Materials (metal 2012), 2012, TANGER; VSB - TU, OSTRAVA
[6] Dzugan J, Konopik P., Rund M and Prochazka R 2015 ASME Pressure vessels and piping conf.
- 2015 Determination of local tensile and fatigue properties with the use of sub-sized
specimens, Volume 1A: Codes and Standards (New York: Amer. Soc. Mech. Eng.).
[7] Konopik P, Dzugan J, Rund M: Dynamic Tensile And Micro-Tensile Testing Using DIC
Method, Metal 2014, May 21st – 23rd 2014, Brno, Czech Republic, ISBN 978-80-87294-52-
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[8] PodanýP, Zemko M, Balcar M: Development of forging technology for microalloyed steel for
oil industry, (2010) Metal 2010 - 19th Int. Conf. on Metallurgy and Materials, Conf. Proc.,
pp. 287-292
[9] Duchek M, Koukolíková M, Nižňanská J, Majer M: Optimization Of Filler Materials For Large
Forging Dies, Materials Science and Technology Conf. and Exhibition 2016, MS and T 2016,
Association for Iron and Steel Technology, Warrendale (PA), USA

Acknowledgments
These results were created under the EUREKA - WELDWIRE project entitled “Development of
special welding wires for repair welding of large forging dies” financed by the Ministry of Education,
Youth and Sports of the Czech Republic and “Development of West-Bohemian Centre of Materials
and Metallurgy”, No.: LO1412, which financed by the Ministry of Education of the Czech Republic.