Before starting a zinc alloy die casting plant, it is necessary to have the appropriate welding materials, welding power supply, welding auxiliary equipment, crown block, and electric furnace on hand. Use the proper welding procedure, which is described below.

The first step is to thoroughly clean and inspect the mold.
When it comes to determining the most appropriate welding repair method, it all starts with cleaning and inspecting the mold that is going to be repaired. Following the cleaning process, the zinc alloy die casting factory must determine the welding repair process based on the inspection results, including the model and quantity of welding materials used, and achieve the repair goal by combining welding materials in the appropriate combination based on the mold conditions, according to the mold conditions. Also read 5 methods to overcome defects in electroplating of zinc alloy die castings.


2. Thoroughly clean the interior of the cavity.
To ensure that the crack, scaling, and fatigue layer are completely removed as well as that sufficient openness is maintained prior to welding, a number of cleaning steps must be completed. The angle between 40 and 60 degrees is generally required to ensure that the welding rod or welding wire is properly deposited during the welding process.

The third step involves pre-weld heating.
The process of heating the mold prior to welding is critical to completing a successful mold repair project. The temperature of the heating element is between 800 and 900 degrees Fahrenheit. It is taken into account when calculating and insulating the structure how much time it takes to cover one inch of thickness. The calorific value of the heating flame used in the welding process, as well as the quality of the insulating material used, determine the total number of hours spent welding in the heating furnace or in the heating flame during the welding process.

4. The location of the weldment on the structure
In order for the welder to be able to operate in the area where it is required, the weldment must be straightforward. Sometimes the position of the weldment must be adjusted continuously throughout the welding process; however, the center line of the cavity to be welded must remain perpendicular to the ground throughout the welding process at all times. In order to ensure that the welding wall is tightly integrated with the welding material, a short arc must be used during welding, and the welding wall must be visible to the welder. The welding wall must also be visible to the welder from his or her position.

5. After the welds have been completed, they should be inspected.
It is necessary to knock each weld bead with an air pick or mechanical method after it has been formed in order to achieve the best crystal structure of the cladding layer and to prevent the weldment from shrinking along the center line during cooling.

6. After welding, heat treatment and normalization are performed.
It is necessary to maintain a post-weld heating and normalizing temperature of 800-900 ° F, which is calculated as one hour per inch of thickness of the workpiece and cladding, in order to prevent them from cooling too quickly.

7. The cooling process is cumbersome and time-consuming.
When we speak of slow cooling, we're talking about the process by which a weldment is gradually cooled to room temperature over time in an air-static environment. If you're going to use slow cooling, the goal is to achieve a balanced microstructure and toughness so that you can get the best possible effect during the forging process.

8. Stress-relief that is more moderate in intensity
Final goal is to eliminate the stress generated during welding and to achieve the toughness required by the die as well as the hardness necessary for the cladding layer. The amount of time required for tempering is calculated as 1 hour per inch of thickness of the material.

9. Concluding the cooling process
Finally, the weldment is gradually cooled to room temperature in an air static environment as the welding process is completed. Weldment insulation materials can be used to cover the weldment, thereby increasing its effectiveness during the slow cooling process.

In a zinc alloy die casting factory, repairing the mold is a routine part of the manufacturing process that takes place every day. If the mold is properly repaired, mass production can be restarted in order to achieve the cost-saving effect that has been sought by the company.