G6211 weld porcedure.pdf

This is a technical specification and welding procedure document for forging hammers, specifically detailing the fabrication, repair, and quality control requirements for rotary forge dies and forging hammers used in industrial applications.

The document establishes comprehensive procedures for welding and repairing forging hammers with a base body of semi-austenitic stainless steel (material per ASTM A-276) and intermediate layers of 4638 FCG (a nickel-cobalt alloy) topped with a wear-resistant tungsten carbide layer. Key specifications include: underlay welding using 4637 FCG with 3/32" diameter at 280 amps and 29 volts, overlay welding using 4637 FCG with 3/32" diameter at 210 amps and 25-27 volts, and strict prohibitions on exceeding 4637 voltage specifications to prevent aluminum and titanium alloy burnout. The repair procedures address hammer face cracks and defects through careful surface preparation, metallurgical brushing, dimensional verification, and controlled welding sequences. Design and welding instructions mandate that forging hammers be preheated to 350°C/662°F before welding, with subsequent stress relief at 1022°F for ten hours followed by slow cooling at 100°F per hour. The document specifies that welding seams maintain 3-4mm thickness, expansion joints are incorporated to prevent cracking, and all roundings on hammer faces must be designed exactly per specified dimensions. Additional requirements include furnace stress relief at 350°C/1022°F, surface removal via milling cutters with tungsten carbide inserts, and comprehensive crack detection procedures to ensure structural integrity and operational reliability.