Optimized Mold Repair Process for Forging Production

Forging dies operate continuously under high temperature and pressure, making wear and deformation inevitable over time. The quality of mold repair directly impacts forging production efficiency and the dimensional accuracy of finished forgings. Recently, Qingliang Mould has optimized its mold repair process to enhance the stability and precision of refurbished dies.

As those in the forging industry know, replacing dies at the first sign of wear is costly, but poorly executed repairs lead to premature failure and dimensional inaccuracies in forgings. Previously, our mold repair process was limited to basic welding and grinding, which often resulted in rapid re-wear and welding-induced deformation that compromised forging dimensions. The optimized process is a collaborative effort between welders, forgers, and machinists:

Material Matching: We select welding materials specifically formulated for forging die steels, ensuring the welds deliver high strength and wear resistance.

Controlled Welding: A "staged welding + controlled cooling" method is adopted to minimize thermal deformation.

Precision Machining: Post-repair, dies are precision-machined to restore their dimensions and tolerances to match new dies.

Wear Enhancement: For high-wear critical areas, we add a wear-resistant hardfacing alloy layer during repair to extend service life.

Initial trials show significant improvements: the average service life of repaired dies has increased by nearly 50%. This not only reduces die replacement costs but also minimizes production downtime caused by mold changes. Refurbished dies now reliably meet all forging production requirements, making this optimization highly practical for daily operations.