Skill to Salvage Forging Dies.

SOLUTIONS with Effective, Practical Advice

High Deposition Rate Processes

Welding Problem? Solve it! with
Help from a Welding Professional
Contact Us.

Note: To view Google Ads, Pls.
Right Click and
Open in a New Window.

Flood-welding includes a set of processes identified by their exceptionally high deposition rate.

It can reach up to 14 kg/h (30 lb/h) and even more in certain cases.

They are used to repair and recondition defective or worn out forging dies.

Reclaiming and returning to service repaired dies, besides the time gain vs. purchasing new sets, provides more economic operation.

High deposition rate is achieved using large size consumable electrodes in one of the possible processes selected for the application.

The most used Flood-welding Processes are:

  • Shielded Metal Arc Welding (SMAW) with covered electrodes up to 19 mm (3/4" or 0.75") diameter,
  • Flux Cored Arc Welding (FCAW) with electrodes up to 4 mm (5/32"), and
  • Submerged Arc Welding (SAW).

Such large size electrodes, as used almost exclusively for Flood-welding, require high currents and develop much heat.

Special fixtures are required for protection, to keep the welder removed from the elevated temperature, by enabling electrode manipulation from a suitable distance.

Forging dies may be built of low alloy steel like AISI Type 4350 or of Tool steel like AISI Type H-13, a type of air hardening heat resistant hot work steel.

Before performing Flood-welding repair all cracked and worn out areas must be removed.

Note: To view Google Ads, Please
Right Click and
Open in a New Window.

Carbon arc gouging is the process usually employed after the dies have been suitably preheated in a furnace.

Attention must be exerted to make sure that sound surface has been reached.

When advisable two different filler metals can be used. The first one, for the deepest parts, should be selected to provide ductility and toughness.

The material for the superficial application could be one of the available heat and wear resistant filler metals.

Preheating of the whole die, usually to be performed in a suitable furnace, is essential to successful Flood-welding repair.

Due to the large mass of molten weld metal present at any given time in the die undergoing repair, the use of ceramic blanketing is necessary to reduce the cooling rate and to keep interpass temperature within the required limits.

After solidification but while the weld is still hot, the Flood-welding slag has to be removed and manual peening is applied.

This is done using a pneumatic hammer with a blunt tool to reduce residual stresses.

Once the required amount of weld metal has been applied, a process that may last many hours, procedures for uniform, low cooling rate after welding must be applied.

The procedure may require reheating in a furnace to 540 °C (~1000 °F) to reduce local thermal gradients, and slow cooling to room temperature for air hardening the tool steel.

Note: - Air hardening tool steels owe their capability to composition, that permits the development of acceptable hardness even after slow cooling in air. The massive dimensions of dies and other tools do not allow rapid cooling.

Finally post weld heat treating for stress relieving and tempering must be selected according to the materials involved and must be applied with care.

Correct heat treating is the essential factor for successful Flood-welding.

Experience will suggest the most suitable electrode selection, depending on the base metal and on the service that the reclaimed die has to sustain.

When professionally performed, Flood-welding reduces costs, improves turnaround time and keeps the forging industry competitive.

Watch the following Video from a Commercial Company
No endorsement or recommendation intended.

What Type of Gas Should I Use When Flood Welding?


* * *

Any questions or comments or feedback? Write them down and send them to us by e-mail. Click on the Contact Us button in the NavBar at top left of every page.

Hardness Testing
made simple Let us remind you that, if you are interested, we offer a no cost subscription to our Practical Welding Letter and a bonus book in pdf format to be made available for download to your computer on the subject of
Click on Subscription.

To reach a Guide to the collection of the most important Articles from Past Issues of Practical Welding Letter, click on
Welding Topics.

Note: To view Google Ads, Please
Right Click and
Open in a New Window.

Back Home
Site Map

Gas Welding Processes
Arc Welding Processes
Flux Cored Arc Welding Tips
Submerged Arc Welding Tips
Shielded Metal Arc Welding Tips
Electroslag Welding
Electrogas Welding
Tack Welds
Laser Drilling
Stress Relieving
Weld Preheating
Heat Treating
Steel Finishing
Vapor Degreasing
Abrasive Blast Cleaning

If you did not yet find what you need, why not typing your question in the following Search Box?

How can you solve
your Welding Problems?

Click on Welding Consultation and
Metallurgical Expertise.

Flood-welding Top

Watch the following:

Click on the following image to watch the SBI! TV Show!



Solo Build It!

Click on this Logo NOW!

Watch - The Video:

Why Don't I Work From Home?

and also

Think outside the Cube.

Copyright (©) 2011, 2012, 2013, 2014, 2015, 2016, 2017
by Elia E. Levi and
All Rights Reserved