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D-M-E Pro Weld User Manual

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USER GUIDE
D-M-E
™
Pro Weld

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  • Page 1 USER GUIDE D-M-E ™ Pro Weld...
  • Page 2 D-M-E Pro Weld ™ system. The D-M-E Pro Weld unit is a newly developed resistance- type micro-welding machine. It is powerful enough to weld 0.3mm thick metal sheets and has a wide selection of weld- ing materials in sheet, wire and powder form to choose from.
  • Page 3 USER GUIDE D-M-E Pro Weld ™ Model No. UMW0001...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Applications Introduction................5 Advantages Specifications ................7 Standard Accessories for Pro Weld ™ UMW0001 Additional Welding Materials III. Parts Nomenclature for Pro Weld UMW0001....11 General Description of Use..........13 IV.1 Function IV.2 Attachment of Electrodes IV.3 Usage of Electrodes Operational Tip IV.4...
  • Page 5 Table of Contents VII. Examples of Welding ............31 VII.1 Focalization of Current, Electrode Shape and Formation of the Weld Spot VII.2 Powder Metal Application Welding to a 3-Point Corner, Parting Line, Edge Welding to a Flat Surface Welding an Inner Corner Welding a Pinhole Welding a Crack Welding in a Rib...

  • Page 7: Introduction

    The Pro Weld micro welding technique is revolutionizing the repair of molds by keeping this work in-house. Pro Weld welds 0.1mm, 0.2mm and 0.3mm thick metal sheets or strips, metal wire and metal powder to the damaged area. It is extremely easy to use, reduces downtime and improves quality.
  • Page 8 High quality selection of welding materials in 0.1 and 0.2mm thick metal sheet, 0.2-0.5mm diameter wire and powder metal. After the initial weld, if more padding is required, re-welding can be done easily. Pro Weld is powerful enough to weld 0.3mm thick sheet.

  • Page 9: Specifications

    Dimensions (inches) W6.5 x D17.75 x H16 Weight 62 lbs Standard Accessories for Pro Weld UMW0001 Complete Pro Weld system includes: (Dimensions in millimeters) Catalog No. Description UMW0001 Power pack with welding cord, grounding cord and plate, power cord, foot switch and...
  • Page 10 Specifications Standard Accessories for Pro Weld UMW0001 (continued) Complete Pro Weld system includes: (Dimensions in millimeters) Catalog No. Description UMW0008 Protective gloves Magnet electrode (2 dia. x 50L) UMW0009 UMW0010 Magnet electrode (3 dia. x 50L) Magnet electrode (4 dia. x 60L) UMW0011 Magnet electrode (4 dia.

  • Page 11: Additional Welding Materials

    Specifications Additional Welding Materials for Pro Weld UMW0001 Welding Material: Fine Powder – Precision Work Welding D-M-E Japanese Quantity Hardness U.S. Mold Steel Materials Catalog No. Mold Steel Rockwell C Equivalent SP-51 UMPS010 SKH-51 50 grams Rc 63 Min. D-2, M-2, S-7...
  • Page 12 Specifications Additional Welding Materials for Pro Weld UMW0001 Welding Material: Sheet (Dimensions in millimeters) Welding D-M-E Japanese Hardness U.S. Mold Steel Materials Catalog No. Mold Steel Quantity / Size Rockwell Equivalent NT-6 UMA0001 10 / 0.2T x 5w x 100L...

  • Page 13: Parts Nomenclature For Pro Weld Umw0001

    Parts Nomenclature for Pro Weld™ UMW0001 III. Parts Nomenclature for Pro Weld™ UMW0001 Carrying Handle D-M-E Pro Weld ™ Power Indicator Operation Lamp Mode Lamp Amp Output Meter Slidac Amp Output Control Output for Automatic/Manual Electrode Function Holder Cord Timer...
  • Page 14 Parts Nomenclature for Pro Weld™ UMW0001 Pro Weld UMW0001 Back Panel Carrying Handle Specifications and Serial Number Plate Input Power Fuse Holder/Fuse Socket...

  • Page 15: 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 of current causes the welding material to melt and fuse with the base metal.

  • Page 16: Operational Tip

    Connect the Electrode Holder Cord to (+) Output, the Grounding Cord to (-) Output, and Foot Switch to Foot Switch Input on the Pro Weld according to Parts Nomenclature diagrams (see III). Check to ensure correct single phase voltage available is the same as that marked on the specifications plate located on the rear panel.
  • Page 17 Welding material is bonded to the base metal by pressing down firmly on the repair area with the Electrode, then triggering the Pro Weld with the Foot Switch, in either the Manual or Auto setting, while slowly rolling the Electrode across the repair area.

  • Page 18: Operational Tip

    General Description of Use 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.

  • Page 19: Operation

    Operation 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: Discharge Of Stored Energy

    Except at the time of welding (which is done by the discharge of stored voltage), Pro Weld has a special circuit which discharges the stored voltage automatically 10 minutes after the machine’s Main Power Switch is...

  • Page 21: Welding

    Welding 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, Electrode, Welding Materials...

  • Page 22: Vi.2 Pro Weld Control Features

    Good Good Good Good VI.2 Pro Weld Control Features Manual Function Select the Manual Function by pushing the Automatic/Manual Function (10) so that the push button light does not illuminate. If this button light is illuminated, the unit is in the Automatic welding mode.

  • Page 23: Operational Tip

    Roll welding can be done with either magnetic or standard electrodes. In the Automatic mode, Pro Weld discharges current in constant intervals according to the Timer Function setting. For constant current discharges, depress the Foot Switch and leave depressed until a new wrist position must be started in the roll welding proc- ess (see VI.7 Roll Welding Technique).

  • Page 24: Vi.3 Shaping Electrodes

    Turning the Timer knob from Slow to Fast will increase the frequency at which each pulse is released. Generally, the “Slow” settings are used when the Pro Weld unit will be used to weld for a long time. The “Fast” settings are for short-term welding lasting for several minutes.

  • Page 25: Vi.4 Recommended Current Output Levels

    Welding cause excessive sparking. Standard Electrodes are made of a silver alloy and can be easily shaped using diamond hard tools and emery paper. Good FIG. 3 Ra = 0.2-0.5mm Shape examples of the Flat Electrode, Fig. 4 FIG. 4 VI.4 Recommended Current Output Levels Amperage output levels used during welding will vary according to: –...
  • Page 26 Welding Current (Amperage) Settings for Welding Sheet Mold Electrode Powder Material Wire Repair Type Diameter 1-0.2mm 1-0.1mm Material 200-300 300-500 Tack Welding Roll Welding with electrode 200-400 400-600 angled at 45° 300-500 500-700 700-900 Roll Welding with round 300-500 500-700 electrode angled at 10°...

  • Page 27: Vi.5 Mold Material/Welding Material

    Welding 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.
  • Page 28 UMPS019 2767 50 grams Rc 30-35 for P-20 N-55 UMP0071 NAK55 50 grams Rc 38-41 P-21 *Supplied with Pro Weld unit. Welding Material: Wire Welding D-M-E Japanese Hardness U.S. Mold Steel Materials Catalog No. Mold Steel Quantity / Size Rockwell...

  • Page 29: Vi.6 Pro Weld Welding Process

    NAK55 10 / 0.2T x 5w x 100L Rc 38-40 P-21 *Supplied with Pro Weld unit. VI.6 Pro Weld Welding Process 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.

  • Page 30: Operational Tip

    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 overlapping weld spots (FIG. 6). 0.1-0.2mm FIG.

  • Page 31: Vi.7 Roll Welding Technique

    Welding VI.7 Roll Welding Technique 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. It will be helpful to hold the Electrode Holder like a pencil with the forefinger or middle finger touching and pressing on the Electrode itself.
  • Page 32 Welding 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 opposite direction.

  • Page 33: Examples Of Welding

    Examples of Welding VII. Examples of Welding VII.1 Focalization of Current, Electrode Shape and Formation of the Weld Spot FIG. 7 Current Dispersion Good O Bad X FIG. 8 Electrode Shape Good O Bad X Ra=0.2-0.5mm FIG. 9...

  • Page 34: Vii.2 Powder Metal Application

    Examples of Welding 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.

  • Page 35: Welding To A 3-Point Corner, Parting Line, Edge

    Examples of Welding 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 applications.

  • Page 36: Welding To A Flat Surface

    Examples of Welding 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.

  • Page 37: Welding An Inner Corner

    Examples of Welding 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.
  • Page 38 Examples of Welding 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 FIG. 16 effective in filling and repairing cracks. Welding in a Rib The rib opening can be welded using a 2mm Electrode FIG.

  • Page 39: Welding In A Rib

    Examples of Welding (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.3 Welding Of Sheet Material

    Examples of Welding 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. Good Good FIG. 19 a = -0.5 -1.0mm b = 0 -1.0mm Positioning of the Sheet Material The sheet material should be slightly larger than the repair area...

  • Page 41: Sheet Material Recession

    Examples of Welding 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 0.1mmT sheet material.
  • Page 42 Examples of Welding 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.

  • Page 43: Repair Of A Parting Line Or Edge

    Examples of Welding 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...
  • Page 44 Examples of Welding 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.

  • Page 45: Multi-Layer Padding

    Examples of Welding 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.
  • Page 46 Examples of Welding 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.

  • Page 47: Repair Of Base Metal Impurities

    Examples of Welding 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. a=0.1mm FIG.

  • Page 48: Welding To A Rising Wall

    FIG. 35 Welding to a Narrow or Concave Mold Section Using the Pro Weld micro welder, repair welding into very small or very confined areas can be accomplished. It is unlikely welding of this nature can be done by argon arc, TIG or other types of welders.

  • Page 49: Examples Of Bad Welding Work

    VIII Examples of Bad Welding 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.

  • Page 50: Viii.3 Oxidized Base Metal Or Electrodes

    VIII Examples of Bad Welding 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.

  • Page 51: Maintenance Guarantee

    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 writing to D-M-E stating the date of purchase and serial number of the unit.
  • Page 52 D-M-E Company 29111 Stephenson Highway Madison Heights, MI 48071 Phone: (800) 626-6653 (248) 398-6000 Fax: (248) 398-6174...

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