Tool Service

Welding consumables for toolmaking

 Tool Service Selection of welding consumables
Welding Alloys Consumable
Base materials and their typical mechanical properties in action
Field of application Wear pattern Chemistry similar to Based on functionality, Buffer layers/repair
Material base material dissimilar of base material
Short designation Strength (MPa) Hardness (HRC)
number
Hot working tools
ROBOTOOL 46 HARDFACE DCO
Since its foundation in 1966, 1.2343 X38CrMoV5-1 1450 45 ROBOTOOL 49W HARDFACE W
the Welding Alloys Group has Die-casting moulds, plastic moulds, punches, Thermal fatigue, cracks, grooves, ROBOTOOL 58 STELLOC C
mandrels, dies, die-holders friction, erosion ROBOTOOL KLMONI STELLOY Ni520
become the global specialist in 1.2344 X40CrMoV5-1 1500 46 - 47 HARDFACE WM STELLOY 6
ROBODUR KWM 56 STELLOY 21
the development of low and high GAMMA 625
TETRA/TRI S 307
alloyed cored wires. 1.2365 32CrMoV12-28 1400 44
Die-casting moulds, die inserts,
Grooves, edge wear
ROBOTOOL 40 HARDFACE WM
TETRA/TRI S 309 LMo
extrusion tools ROBOTOOL 58 STELLOY 6
Individual developments and new TETRA/TRI S 312
innovative products are created by STELLOY Ni520
Extensive cracked wear, friction, ROBOTOOL 47 STELLOY 6
our highly experienced welding 1.2367 X38CrMoV5-3 1600 48 - 49
Deburring tools / guides / handling, ejecting,
expansion, edge wear, partial ROBOTOOL 49W HARDFACE DCO
grasping devices
engineers and metallurgists in breakouts ROBOTOOL 58 STELLOY 21
GAMMA 625
cooperation with customers.
STELLOY 6
STELLOY 21
STELLOY 25
GAMMA 182
HARDFACE NICOMO
Parting knives, shear blades, GAMMA 625
ROBOTOOL 34W HARDFACE DCO
1.2714 56NiCrMoV7 1800 52 gravure edges, mandrels, cold forging Grooves, cracks, chipping, TETRA/TRI S 307
ROBOTOOL 46 HARDFACE NICOMO
punches, hole punches transverse cracks, erosions, (partial) TETRA/TRI S 309LMo
GAMMA 625
breakouts, edge wear, general wear TETRA/TRI S 312
STELLOY 25
STELLOY 6
STELLOY Ni520

1.2767 X45NiCrMo16 2050 56 Plastic moulds, shear blades ROBOTOOL 49W

1.7225 42 CrMo4 1100 34 - 35 Various applications ROBOTOOL 47 TETRA/TRI S 307
STELLOY 6
1.2779 X6NiCrTi 26-15 930-1180 30 - 39 Bushes, pressure pads Friction HARDFACE NICOMO TETRA/TRI S 309LMo
STELLOY 21
GSF Kind&Co,Edelstahl KG 845 - 997 266-314HB Die plates Erosion TETRA/TRI S 312
ROBOTOOL 58
GSF Kind&Co,Edelstahl KG 1260 - 1350 399-427HB Hot calibration twister General wear
Cold working tools
1.2067 100 Cr 6 1910 - 2200 54 - 58
1.2080 X210 Cr 12 2200 - 2491 58 - 63
1.2082 X21Cr 13 800-1000 22 - 32
1.2162 21MnCr 5 2050 56
1.2311 40CrMnMo 7 1000-1100 32 - 35
1.2363 X100 CrMoV 5-1 2050 56
1.2379 X155 CrVMo 12-1 2050 56
ROBODUR K 250
1.2436 X210 CrW 12 2200 - 2491 58 - 63 ROBODUR K 350
1.2550 60WCrV 7 1910 - 2200 54 - 58 ROBODUR K 450
ROBODUR K 500
1.2601 X165 CrMoV 12 2200 - 2421 58 - 62 GAMMA 625
Parting knives, shear blades, ROBODUR K 600
Edge wear, grooves, cracks, rounded TETRA/TRI S 307
1.2713 55NiCrMoV 6 1790 - 2200 52 - 58 gravure edges, mandrels, cold forging ROBODUR K 650
cutting edges TETRA/TRI S 309LMo
1.2721 50NiCr 13 1680 - 1790 50 - 52 punches, hole punches HARDFACE W
TETRA/TRI S 312
HARDFACE WLC
1.2764 X19CrNiMo 4 2312 60 HARDFACE L
1.2767 X45NiCrMo 4 1790 - 2050 52 - 56 HARDFACE AR
HARDFACE DCO
1.2769 G45CrNiMo 4-2 1680 - 2200 50 - 58
1.2842 90MnCrV 8 2050 - 2421 56 - 62
1.7140 G47CrMn 6 1910 - 2200 54 - 58
1.7218 G25CrMo 4 1330 - 2050 42 - 56
1.7218 G25CrMo 4 900-1100 28 - 37
1.7225 G42CrMo 4 -2050 42 - 56
Table of contents 1.7225 G42CrMo 4 1100-1300 37 - 43
Maraging steel
Selection of welding consumables ............................................... 2 1.2709 X3NiCoMoTi 18-9-5 1975 - 2050 55 - 56
Die-casting moulds, plastic moulds, cold
Abrasive wear HARDFACE DCO
GAMMA 625
forging tools TETRA/TRI S 307
STELLOY 21
TETRA/TRI S 309LMo
Welding consumables 1.2799 X2NiCoMoTi 12-8-8 1845 - 1975 53 - 55 Tool holder Abrasion, edge wear STELLOY 6
TETRA/TRI S 312

for hot working tools ....................................................................................4-6 High-speed steel

1.3243 S-6-5-2-6 2312 - 2549 60 - 64
GAMMA 625
1.3343 S-6-5-2 2421 - 2616 62 - 65
Welding consumables Cutting edges Edge wear, rounded cutting edges HARDFACE AR
TETRA/TRI S 307
1.3346 S-2-9-1 2312 - 2549 60 - 64 TETRA/TRI S 309LMo
for cold working tools ........................................................................................ 6 1.3348 S-2-9-2 2312 - 2491 60 - 63
TETRA/TRI S 312

Cast steel
Welding consumables 0.6025 GJL 250 180-240 HB
for buffering ..................................................................................................................... 7 0.6025 alloyed SGG 25 220-240 HB Gearbox housings, turbine housings, guide
0.6030 GJL 300 200-260 HB rails
Special tool steels ................................................................................................. 7 0.6030 alloyed VSGG 30 240-270 HB
Breakouts, cracks, abrasive wear,
0.7040 EN-GJS-400-15 140-185 HB HARDFACE W CAST NIFE
rework in the production ROBODUR K 600
0.7050 EN-GJS-500-7 170-220 HB HARDFACE DCO CAST NICI
Crankshafts, rollers, gears, impact stressed
0.7060 EN-GJS-600-3 220-250 HB
parts in the vehicle construction
0.7070 EN-GJS-700-2 235-285 HB
0.7080 EN-GJS-800-2 270-335 HB
2 3 div. Ingot moulds Ingot moulds Erosion, cracks
 ROBOTOOL Cored wires for toolmaking
Advantages of WELDING ALLOYS
cored wires and stick electrodes for Hot working tools
the toolmaking industry: Iron-based
C (%) Mn (%) Si (%) P (%) S (%) Cr (%) Ni (%) Mo (%) V (%) Ti (%) W (%) Fe (%) Co (%) Hardness (HRC) Tensile strength (MPa)
ROBOTOOL 46-G 0.25 1.10 0.60 0.03 0.03 5.30 0.20 5.30 - 0.35 - Bal. - 42-46 1320-1485
> ROBOTOOL is the only range of seamless, laser-welded cored
ROBOTOOL 47-G 0.20 1.10 0.60 0.03 0.03 6.50 0.20 4.00 - 0.30 - Bal. - 40-44 1255-1385
wires in the world.
ROBOTOOL 58-G 0.37 1.40 0.60 0.03 0.03 7.00 2.50 - 0.30 - Bal. - 53-58 1845-2180
> Cost savings by avoiding the need to buy new construction tools. ROBOTOOL (S) 34W 0.18 0.90 0.60 0.02 0.02 5.40 0.80 2.50 0.90 0.20 2.50 Bal. - 33-40 1030-1255
> Repairability of worn tools. ROBOTOOL (S) 45 W 0.24 0.90 0.60 0.03 0.03 5.40 0.04 2.30 0.80 0.20 2.10 Bal. - 44-47 1385-1520
ROBOTOOL (S) 49W 0.30 0.90 0.60 0.03 0.03 5.80 0.50 2.80 0.90 0.20 2.30 Bal. - 48-52 1555-1775
> Improvement of wear resistance and lifetime of the tools.
ROBOTOOL (S) 54W 0.40 0.90 0.60 0.02 0.02 5.90 0.40 3.00 1.00 0.20 3.10 Bal. - 52-55 1775-1955
> Optimisation of tools through a specific selection of the base
material and welding consumables. HARDFACE (S) 37-G 0.15 0.60 - - - 10.20 1.60 2.70 - 0.20 - Bal. - 35-41 1095-1290
> Correction of manufacturing defects during the toolmaking. HARDFACE (S) 41-G 0.20 1.00 1.00 0.03 0.03 7.00 1.80 2.40 - - - Bal. - 48-50 1555-1685
HARDFACE (S) 43-G 0.17 0.70 0.70 0.02 0.03 11.00 1.70 3.10 - - - Bal. - 41-46 1290-1485
HARDFACE (S) 46-G 0.22 1.00 0.80 0.03 0.03 10.00 1.90 2.40 - - - Bal. - 50-54 1665-1880
HARDFACE VMOLC-G 0.08 1.00 0.60 - - 10.00 1.80 2.50 - - - Bal. - 34-36 1060-1125
HARDFACE WM-G 0.30 0.30 0.40 - - 2.40 - - 0.60 - 4.00 Bal. - 47 1520
Welding-guidlines for the toolmaking industry HARDFACE WMOLC-G 0.30 0.80 0.60 - - 6.50 - 2.20 0.60 - 2.00 Bal. - 52 1775
HARDFACE DCO-G 0.15 0.40 0.70 - - 14.00 - 2.50 - - - Bal. 12.50 47 1520
1. Selection of the correct welding consumable regarding
the base material and stress of the tool. Nickel-based
C (%) Mn (%) Si (%) Cr (%) Mo (%) Ni (%) W (%) Fe (%) Co (%) Hardness (HB) Tensile strength (MPa)
2. Before welding, the work piece should be thoroughly
STELLOY C-G 0.05 0.60 0.50 16.00 16.00 Bal. 4.50 5.00 - 200 HB WH 350 675-1155
cleaned to avoid pore formation and smoke emitting.
STELLOY C-O 0.05 1.00 0.60 15.50 16.00 Bal. 4.50 3.00 2.30 220 HB WH 350 740-1155
3. Complete preheating to avoid crack formation. STELLOY Ni 520-G 0.06 0.02 0.02 13.00 6.00 Bal. 0.80 2.20 11.50 190 640
STELLOY Ni 520Co-G 0.05 0.20 0.60 17.50 6.00 Bal. 3.00 >2 18.00 210 705
4. Hammering during the cooling phase to improve the
stress condition. Cobalt-based
C (%) Mn (%) Si (%) Cr (%) Mo (%) Ni (%) W (%) Fe (%) Co (%) Hardness (HRC) Tensile strength (MPa)
5. Postheating and a slow cool-down to reduce stresses.
STELLOY 1-G 2.30 1.00 1.00 29.00 - - 12.00 4.00 Bal. 53 1845
STELLOY 6-G* 1.05 1.00 1.00 29.00 - - 4.50 4.00 Bal. 42 1320
STELLOY 12-G* 1.60 1.50 1.00 29.00 - - 8.00 3.00 Bal. 46 1485
STELLOY 21-G* 0.25 1.00 1.00 28.5 5.50 3.00 - 4.00 Bal. 33 1060
STELLOY 25-G 0.15 1.50 1.00 20.00 - 10.00 14.00 4.00 Bal. 210 HB 705

Microstructure

Close-contoured welding of a forging die ROBOTOOL 45W-G in welded condition, ROBOTOOL 46-G in welded condition, ROBOTOOL 47-G after heat treatment, ROBOTOOL 34W-G in welded condition, ROBOTOOL 34W-G after heat
magnification: x500, etched with Nital magnification: x500, etched with Nital magnification: x500, etched with Nital magnification: x200, etched with Nital treatment, magnification: x200,
MS = 271°C MS = 202°C MS = 231°C MS = 271°C etched with Nital
MS = 271°C
* TIG cold wire version also available.
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 ROBOTOOL welding consumables for toolmaking
Stick electrodes
C (%) Mn (%) Si (%) Cr (%) Mo (%) W (%) Fe (%) V (%) Hardness (HRC) Tensile strength (MPa)
HARDFACE AR-G 1.10 0.40 0.25 5.00 7.60 2.20 Bal. 1.10 60 > 2200
HARDFACE 250-E 0.25 1.00 0.50 1.00 - - Bal. - 250 HB 835
HARDFACE 400-E 0.30 1.00 0.50 1.50 - - Bal. - ~400 HB 1350
HARDFACE L-E 0.50 0.60 2.00 9.50 - - Bal. - ~58 2200
HARDFACE AR-E 0.80 0.50 0.50 5.00 10.00 1.50 Bal. 1.50 ~65 2200

Solid wires and TIG rods

Aluminium cover to reduce the Partial repair of a aluminium-injection-mold Build-up welding of an engraving (1.2713)
heat emissions with ROBOTOOL 58-G C (%) Mn (%) Si (%) Cr (%) Mo (%) V (%) W (%) Al (%) Ti (%) Hardness (HRC) Tensile strength (MPa)
AX 250 0.30 1.10 0.45 1.00 - - - 0.10 0.20 225-275 HB 770

Hot working tools AX 350 0.70 1.90 0.45 1.00 - - - 0.10 0.20 325-375 HB 1095
AX 450 W 0.30 0.40 0.25 2.50 - 0.60 4.50 - - 41-46 1290
Stick electrodes
AX 500 1.10 1.90 0.45 1.80 - - - 0.10 0.15 47-52 1520
C (%) Mn (%) Si (%) Cr (%) Mo (%) Ni (%) W (%) Fe (%) Co (%) Hardness (HRC) Tensile strength (MPa)
AX 600 0.45 0.40 3.00 9.20 - - - - - 57-62 2145
HARDFACE 40-E 0.15 0.70 0.50 6.50 3.50 - - Bal. - ~40 1255
HARDFACE 48-E 0.30 0.60 0.50 5.50 4.10 - - Bal. - ~48 1555 AX 600 Mo 1.00 0.30 0.30 4.00 8.30 1.90 1.80 - - 57-62 2145
HARDFACE 58-E 0.40 1.00 0.50 7.00 2.50 - - Bal. - ~58 2200 AX 650 0.35 0.40 1.10 5.50 1.20 0.25 1..30 - - 55-60 1955
HARDFACE DCO-E 0.15 0.60 0.60 14.00 2.30 - - Bal. 13.00 47 1520
STELLOY 6-E 1.10 - 1.00 28.00 - - 4.50 3.00 Bal. 44 1385 Repair and Buffering
STELLOY 21-E 0.30 0.50 0.80 28.00 5.00 2.50 - 2.00 Bal. 33 HRC WH 47 1030-1520 Cored wires
STELLOY 25-E 0.10 1.00 0.80 20.00 5.00 10.00 15.00 2.00 Bal. 220 HB 740
C (%) Mn (%) Si (%) Cr (%) Mo (%) Ni (%) S (%) P (%) Nb (%) Fe (%) Tensile strength (MPa)
Solid wires and TIG rods TRI S 307-O 0.03 6.50 0.80 19.00 - 8.20 0.008 0.02 - Bal. 630
C (%) Mn (%) Si (%) Cr (%) Mo (%) Ti (%) V (%) Hardness (HRC) Tensile strength (MPa) TRI S 312-O 0.03 1.30 0.80 29.00 0.40 9.50 0.008 0.02 - Bal. 860
AX-WZ 143 0.35 1.10 0.40 7.00 2.20 0.30 - 52-57 1775 TRI S 309LMo-O 0.03 1.80 0.80 24.00 2.80 13.00 0.008 0.02 - Bal. 760
AX-WZ 267 0.25 0.60 0.30 5.00 3.60 0.60 - 42-47 1320 GAMMA 625-G 0.02 0.40 0.30 21.00 9.00 Bal. - - 3.40 0.40 780
AX-WA 3-SG 0.10 0.60 0.30 6.20 3.20 - - 37-42 1155 GAMMA 182-G 0.01 6.00 0.30 17.00 - Bal. - - 1.70 6.00 610
AX-WA 4-SG 0.38 0.40 1.00 5.00 1.10 - 0.45 52-57 1775 TETRA S 307-G 0.10 6.00 0.90 19.00 - 9.50 0.008 0.02 - Bal. 610
TETRA S 312-G 0.10 1.30 0.80 29.00 0.40 8.60 0.008 0.02 - Bal. 860
Cold working tools TETRA S 309LMo-G 0.03 1.40 0.80 23.50 2.80 12.50 0.008 0.02 - Bal. 760
Cored wires
Stick electrodes
C Mn Si Cr Mo Ni W V Al Ti Co Hardness Tensile strength
(%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (HRC) (MPa) C (%) Mn (%) Si (%) Cr (%) Mo (%) Ni (%) Nb (%) Fe (%) Tensile strength (MPa)
ROBODUR K 250-G 0.10 1.50 0.70 1.50 0.20 - - - - - - 225-275 HB ~770 TETRA 312-E 0.10 0.60 1.00 29.00 0.50 9.50 - Bal. 800
ROBODUR K 350-G 0.15 1.50 0.70 2.00 0.20 - - - - - - 325-375 HB ~1095 TETRA 307-E 0.10 4.50 1.20 18.00 - 8.00 - Bal. 620
ROBODUR K 450-G 0.40 1.50 0.70 2.50 0.50 - - - - - - 41-46 ~1290 TETRA 309LMo-E <0.03 0.70 0.80 22.50 2.30 12.50 - Bal. 700
ROBODUR K 600-G 0.50 1.20 0.70 6.00 0.70 - - - - - - 57-62 ~2145 TETRA SUPRA S-E 0.05 0.50 1.00 >20.00 - >8.00 - Bal. 830
ROBODUR K 650-G 0.50 1.30 1.30 5.60 1.30 - 1.30 0.30 - - - 55-60 ~1955
GAMMA 625-E <0.04 0.60 0.40 22.00 9.00 Bal. 3.40 3.00 760
ROBODUR K LMONI-G 0.35 0.50 0.40 8.00 2.40 2.10 0.30 0.30 - - - 55 ~1955
GAMMA 182-E <0.04 6.00 0.40 16.50 0.20 Bal. 2.00 6.00 630
HARDFACE L-O/G 0.50 1.50 2.50 8.50 - - - - - - - 650 HB > 2200
HARDFACE T-O/G 0.15 1.50 0.80 1.50 - - - - - - - 360 HB 1190
HARDFACE P-O/G 0.20 2.00 0.80 3.00 - - - - - - - 400 HB 1350
HARDFACE AR-G 1.10 0.40 0.25 5.00 7.60 - 2.20 1.10 - - - 60 > 2200
HARDFACE NICOMO-G 0.03 0.10 0.10 - 4.00 18.00 2.20 1.10 0.20 1.60 12.00 >52 after PWHT 1100 - 1800 ISO 9001 Certified
Forging die, hardfaced with Hardfacing of a forging die Die-cast tool for aluminium, hardfaced
STELLOY Ni 520-G with HARDFACE 48-E with ROBOTOOL 46-G

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