D-M-E Pro Weld User manual

D-M-E
Pro Weld™
USER GUIDE

D-M-E Company
29111 Stephenson Highway
Madison Heights, MI 48071
Phone:
[phone] [phone]
Fax:
[phone]
D-M-E ProWeld™User Guide
PREFACE
Please read this instruction manual thoroughly before using
your 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.
Applications
♦Welding can be made to steel molds and dies for plastics,
rubber, die casting, and compression molds.
♦Welds can be applied on as-rolled steel, pre-hardened
steel, quenched and tempered steel, free cutting steel,
stainless steel, and others.
♦To build up parting lines, mold seams, 3-point corners
and edges.
♦To fill in pores, repair of pinholes.
♦To repair wear, worn areas on slides, ejector pins,
sharp edge molds, and thin core parts.
♦To design modification of inserts and cores.
♦To add a radius to an inner corner due to a
design change.
♦To repair the shrinkage that occurs after argon arc
and TIG welding.
♦To repair damage due to overgrinding, from an
end mill or EDM process.

D-M-E
Pro Weld™
Model No. UMW0001
USER GUIDE

2
TABLE OF CONTENTS
Applications
I. Introduction............................................................................5
Advantages 5
II. Specifications........................................................................7
Standard Accessories for Pro Weld™UMW0001 7
Additional Welding Materials 9
III. Parts Nomenclature for Pro Weld UMW0001....................11
IV. General Description of Use................................................13
IV.1 Function 13
IV.2 Attachment of Electrodes 13
IV.3 Usage of Electrodes 13
➤Operational Tip 14
IV.4 Start-Up Procedure 14
➤Operational Tip 16
V. Operation ............................................................................17
V.1 Cautions in Welding Work 17
V.2 Discharge of Stored Energy 18
VI. Welding ................................................................................19
VI.1 Workpiece, Electrode, Welding Materials 19
VI.2 Pro Weld Control Features 20
➤Operational Tip 21
VI.3 Shaping Electrodes 22
VI.4 Recommended Current Output Levels 23
VI.5 Mold Material/Welding Material 25
VI.6 Pro Weld Welding Process 27
➤Operational Tip 28
VI.7 Roll Welding Technique 29
Table of Contents

3
Table of Contents
VII. Examples of Welding ........................................................ 31
VII.1 Focalization of Current, Electrode Shape 31
and Formation of the Weld Spot
VII.2 Powder Metal Application 32
Welding to a 3-Point Corner, Parting Line, Edge 33
Welding to a Flat Surface 34
Welding an Inner Corner 35
Welding a Pinhole 35
Welding a Crack 36
Welding in a Rib 37
➤Operational Tip 37
VII.3 Welding of Sheet Material 38
Proper Electrode Contact 38
Positioning of the Sheet Material 38
Welding to a Flat Surface 39
Sheet Material Recession 39
Repair of a 3-Point Corner Collapse 40
Repair of a Parting Line or Edge 41
Repair of a Scratch or V-Notched Flaw
and Pinhole 42
Multi-Layer Padding 43
Repair of Base Metal Impurities 45
Repair of an Inner Corner 45
Welding to a Rising Wall 46
Welding to a Narrow or Concave Mold Section 46
VIII. Examples of Bad Welding Work ........................................47
VIII.1 Unconnected Weld Spots 47
VIII.2 Improperly Shaped Electrodes 47
VIII.3 Oxidized Base Metal or Electrodes 48
VIII.4 Bad Conductivity 48
IX. Maintenance Guarantee ....................................................49

I
I. Introduction
Please read this instruction manual thoroughly before using your
Pro Weld™system.
Pro Weld is a newly developed resistance-type welder. It effectively
builds up material to repair or redesign molds and dies. [Note: It is
not recommended for use on press dies, blow molds (usually made
from aluminum) or aluminum molds.]
The resistance welding method creates high energy discharges in
very short cycles through a capacitance circuit. Almost no heat is
created and, therefore, the base mold material is not altered or
damaged.
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.
Advantages
♦No scaling or flaking occurs after welding as the sheet, wire and
powder metals used are free from impurities, and because the
weld has high strength, homogeneity and reliability.
♦Easy to operate, no special training necessary.
♦Hand and machine finishing is easier as the amount of weld
metal is not excessive.
♦As the process emits almost no heat, there will be no shrinkage,
distortion, deformation or discoloration of the mold.
♦No welding fumes or toxic gases are emitted.
5
Introduction

6
Introduction
I
♦The process is optimally suited for small areas and micro
welding.
♦Hardening and plating can be done after welding.
♦Welding work time is greatly reduced. Roll welding a 3/8" (10mm)
long parting line can be done in 1 minute, treating a pinhole in
30 seconds.
♦As the capacitor system charges slowly and unloads quickly, an
input power can be used with low loading capacity.
♦A built-in microprocessor allows stored energy to be easily
adjusted.
♦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.

7
II. Specifications
II
Standard Accessories for Pro Weld UMW0001
Specifications
Power pack with welding cord, grounding
cord and plate, power cord, foot switch and
all accessories listed below
N51–Standard SKH-51 steel powder (50 grams)
(63 Rc; for D-2/M-2/S-7 steels)
N80–Standard NAK80 steel powder (50 grams)
(38-40 Rc; for P-20/P-21 steels)
NAK80–Standard steel sheet (10 sheets,
0.1T x 5W x 100L) (38-40 Rc; for P-20/P-21 steels)
NTA1–Ni Alloy sheet (10 sheets, 0.1T x 30W x 70L)
(135HV; for all steels)
NTA2–Ni Alloy sheet (10 sheets, 0.2T x 30W x 70L)
(135HV; for all steels)
Protective glasses
Catalog No. Description
Complete Pro Weld system includes: (Dimensions in millimeters)
UMW0001
UMW0002
UMW0003
UMW0004
UMW0005
UMW0006
UMW0007
Model Pro Weld UMW0001
Input Voltage 120 VAC
Consumable Power 600 VA
Output Power 700W
Output Voltage 0 - 9V
Output Current 0 - 1100 Amps
Control System SCR Switching System
Auto Timer On 0.5 sec.
Dimensions (inches) W6.5 x D17.75 x H16
Weight 62 lbs

Catalog No. Description
II
Specifications
8
Protective gloves
Magnet electrode (2 dia. x 50L)
Magnet electrode (3 dia. x 50L)
Magnet electrode (4 dia. x 60L)
Magnet electrode (4 dia. x 50L)
Standard electrode (2 dia. x 50L)
Standard electrode (3 dia. x 50L)
Standard electrode (4 dia. x 50L)
Standard electrode (1.2T x 5W x 35L)
Standard electrode holder (black)
(used with UMW0015)
Magnet electrode holder (brown)
(used with UMW0011 and UMW0012)
Standard electrode holder (black)
(used with UMW0016)
Standard electrode holder (black)
(used with UMW0013)
Standard electrode holder (black)
(used with UMW0014)
Magnet electrode holder (brown)
(used with UMW0009 and UMW0010)
Tool box
Sheet metal shears
Screw and wrench set
Fuse (2A)
Insulation tape
UMW0008
UMW0009
UMW0010
UMW0011
UMW0012
UMW0013
UMW0014
UMW0015
UMW0016
UMW0017
UMW0018
UMW0019
UMW0020
UMW0021
UMW0022
UMW0023
UMW0024
UMW0025
UMW0026
UMW0027
Standard Accessories for Pro Weld UMW0001 (continued)
Complete Pro Weld system includes: (Dimensions in millimeters)

II
9
Specifications
N-11 UMP0067 SKD-11 50 grams Rc 50-60 Min. A-2, D-2
All Die Steels
N-38 UMP0072 HPM38 50 grams Rc 30 Max. 420SS
(Prehardened)
N-39 UMP0073 PD555 50 grams Rc 50-52 STAVAX
N-40 UMP0060 Ni-Cr Alloy 50 grams Rc 36-42 All Mold Steels
N-50 UMP0062 Ni Alloy 50 grams Rc 47-53 All Mold Steels
N-61 UMP0068 SKD61 50 grams Rc 40-53 Max. H-13, 420SS
N-13 UMP0063 Ni Alloy 50 grams Rc 10-15 All Mold Steels
N-90 UMP0061 Ni Alloy 50 grams Rc 16-20 All Mold Steels
SCM, Good Choice
N-14 UMPS017 PHM-2 50 grams Rc 30-35 for P-20
SNCM, Good Choice
N-15 UMPS018 HPM17 50 grams Rc 30-35 for P-20
SNCM, Good Choice
N-16 UMPS019 2767 50 grams Rc 30-35 for P-20
N-55 UMP0071 NAK55 50 grams Rc 38-41 P-21
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
SP-11 UMPS011 SKH-11 50 grams Rc 50 Min. A-2, D-2
SP-61 UMPS012 SKD-61 50 grams Rc 53 Max. H-13
Welding Material: Powder
Welding D-M-E Japanese Quantity Hardness U.S. Mold Steel
Materials Catalog No. Mold Steel Rockwell C Equivalent
Additional Welding Materials for Pro Weld UMW0001

10
Specifications
II
Additional Welding Materials for Pro Weld UMW0001
Welding Material:Wire
Welding D-M-E Japanese Hardness U.S. Mold Steel
Materials Catalog No. Mold Steel Quantity / Size Rockwell Equivalent
Welding Material: Sheet (Dimensions in millimeters)
NT-6 UMA0001 10 / 0.2T x 5w x 100L Rc 30 All Mold Steels
NS-1 UMA0054 SS Alloy 10 / 0.1T x 30w x 70L Rb 90 All Mold Steels
NS-2 UMA0055 SS Alloy 10 / 0.2T x 30w x 70L Rb 90 All Mold Steels
HPM-50 UMD0102 HPM50 10 / 0.2T x 5w x 100L Rc 38-40 P-21 Improved
HPM-38 UMD0107 HPM38 10 / 0.2T x 5w x 100L Rc 30-33 420SS
STAVAX UMD0104 STAVAX 10 / 0.2T x 5w x 100L Rc 50-52 STAVAX,420SS
SCM440,
HPM-2 UMD0101 IMPAX, 10 / 0.2T x 5w x 100L Rc 30-50 P-20
HPM-2
MAS1 UMD0103 10 / 0.2T x 5w x 100L Rc 50-53 P-20
NAK-55 UMD0106 NAK55 10 / 0.2T x 5w x 100L Rc 38-40 P-21
Welding D-M-E Japanese Hardness U.S. Mold Steel
Materials Catalog No. Mold Steel Quantity / Size Rockwell Equivalent
S2 UMA0056 SS Alloy 1 / 0.2 dia. x 5m Rb 90 All Mold Steels
S3 UMA0057 SS Alloy 1 / 0.3 dia. x 5m Rb 90 All Mold Steels
S4 UMA0058 SS Alloy 1 / 0.4 dia. x 5m Rb 90 All Mold Steels
S5 UMA0059 SS Alloy 1 / 0.5 dia. x 5m Rb 90 All Mold Steels

11
III
III. Parts Nomenclature for Pro Weld™UMW0001
Parts Nomenclature for
Pro Weld™ UMW0001
D-M-E Pro Weld™
Carrying Handle
Amp Output Meter
Slidac Amp
Output Control
Automatic/Manual
Function
Main Power
Switch
Output for
Grounding
Cord
Output for
Electrode
Holder Cord
Power Indicator
Lamp
Timer
Input for Foot Switch
Operation
Mode Lamp

III
12
Parts Nomenclature for
Pro Weld™ UMW0001
Carrying Handle
Fan
Specifications and
Serial Number
Plate
Fuse Holder/Fuse
Input Power
Socket
Pro Weld UMW0001 Back Panel

13
IV
IV. 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.
IV.2 Attachment of Electrodes to the Electrode Holder
Electrodes are fixed in the Electrode Holders.To use the opposite
end of an Electrode or to replace an Electrode, use the supplied
Allen Head Wrenches. Do not over-tighten; leave approximately
25mm of the Electrode exposed.
IV.3 Usage of Electrodes
Electrodes are of two types: Magnetic Electrodes and Non-
magnetic Electrodes. Magnetic Electrodes are pre-mounted in the
brown Electrode Holders. Use these Electrodes to pick up metal
welding powders and for tacking powders on the mold repair area.
Non-magnetic Electrodes are fixed in the black Electrode Holders.
Use these to tack welding sheet and wire and to weld in place
powders, sheet and wire.
General Description of Use

IV
Operational Tip
When using Magnetic Electrodes apply less pressure to
the workpiece. Do not exceed the Amp output guidelines
(see VI.4).To do so could cause the Electrode to de-
magnetize.
Apply more pressure to the work surface when using
non-magnetic Electrodes. Again, follow the Amp output
guidelines.
Use only Pro Weld Electrodes.The manufacturer does
not accept liability for other manufacturers’ electrodes.
Do not use welding rods in the Electrode Holders
because they may weld to the work surface.
IV.4 Start-Up Procedure
♦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. Connect the power cable to the Main supply and put
Main power switch ON. In the ON position, the Power Indicator
Lamp will illuminate. Once the equipment has been connected as
directed, your Pro Weld is ready to operate.
♦In the Main ON position, you may select an amperage (power)
output setting. Amperage output setting will be displayed on the
Amp meter. Use the Slidac Amp Output Control knob to
increase/decrease amperage according to the type and size of
14
General Description of Use

Electrode selected and by the type of repair to be performed
(see Amp output guidelines, VI.4).
♦With the amperage output selected, connect an Electrode Holder
with Electrode fixed to the Electrode Holder Cord by sliding it on
to the end of the cord until snug (it need not be perfectly flush).
♦Release of amperage to the Electrode is accomplished by
depressing the Foot Switch on either the Manual or Auto
setting (10).
♦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.
All of the welding material must be covered
by the Electrode to ensure a 100% bond.
♦Rolling the Electrode slowly over the welding material forms
interconnecting scallop-shaped weld spots approximately 1 to
2mm (0.04"-0.08") in diameter.This is the type of weld needed
to ensure complete bonding.
♦If greater build-up is desired, repeat the process over the initial
build-up area, by applying another layer of powder, sheet or wire.
Pro Weld will weld 0.3mm thick metal sheet but best results are
achieved if the sheet is welded in 0.1mm thick increments.
♦No finishing is required between applied layers; an unlimited
number of layers can be applied.
♦Finishing of any repair area can be done by standard methods
including EDM, grinding, machining, plating, ultrasonic polishing,
or hand stoning and lapping. Diamond laps work well as all
repairs are in the hardened state.
15
IV
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.
16
General Description of Use
IV

17
V
V. 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.To avoid any problems, please ensure
that neither the mold welder or machine cables are used in close
proximity to:
–People with medical devices like Pacemakers.
– Magnetic products such as magnetic cards, floppy discs,
audio and video tapes.
– Electromechanical devices such as watches, clocks
and televisions.
♦Do not remove the mold welder cover.The unit’s transformer
carries high voltage.
♦Ensure the welder is properly grounded.
♦Main voltage must not exceed + or – 10% from the voltage stated
on the Specifications Plate on back panel.
♦Unit must be cooled for 20 minutes following 60 minutes of
continuous operation. Leave the unit ON while fan is running.
♦If the Electrodes become too warm while welding, use the
supplied gloves to protect fingers.
Operation

18
V
V.2 Discharge of Stored Energy
Resistance type micro welding machines store voltage in condens-
ers. It is important to discharge the stored voltage when the unit is
not in use to avoid any danger and to save 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
turned OFF.
Operation