G6211 weld procedure.pdf

This is a technical specification and procedure document for welding forging hammers using rotary forge dies. The document provides detailed manufacturing procedures and quality control requirements for hammer fabrication and repair.

The specification covers the procedure for welding 1022F rotary forge dies with specific parameters: 4638 FOG electrode for underlay at 3/32" with 280 amps at 29 volts, and 4637 FOG for overlay at 3/32" with 210 amps at 25-27 volts. Key requirements include preheating the hammer to 750°F minimum and allowing 15-30 minute soak time, with expansion joints between fields permitted. The document details repair procedures for forging hammers with semi-austenitc base bodies and intermediate layers of 4638 FOG, specifying minimum surface preparation standards and crack repair protocols. Forging hammer design requirements mandate that all roundings on hammer faces be designed exactly and symmetrically to specified dimensions, with preheating required before casting to avoid crack formation. The welding instruction section requires proper cleaning of the welding area and filling of deep cracks with 4638 FOG, with an intermediate layer of 4638 FOG and final wear protective tungsten overlay. Critical parameters include maintaining welding current intensity at low levels to prevent adhesion issues, using 5mm electrode diameter with 180-190 ampere current intensity, and maintaining appropriate layer metallic brightness. The hammer base is manufactured from 56 NiCr Mo V17 steel (ASTM A29/ASTM A322), and quality control includes furnace stress relief at 350°C/662°F and post-weld layer hammering protocols. The document references multiple figures showing cross-sections, weld patterns, and visual inspection requirements for completed welds.