Overlay Repair Application Case Studies

Plastic forming mold — parting line burr elimination

On-site overlay repair of the parting line in a plastic forming mold eliminates burr formation, and reduces downtime and production cost by controlling overlay thickness without distortion or shrinkage from low heat input.

Automotive aluminum engine block — casting defect filling

Filling overlay for minor casting defects using aluminum alloy electrodes, without distortion, shrinkage, or porosity, thanks to low heat input.

Aluminum automotive tire mold — wear & wound repair

Overlay repair of wear and wounds on aluminum automotive tire molds avoids the problems of other welding methods, such as distortion, shrinkage, and melting of surrounding areas.

Automotive plastic forming mold — finishing overlay

Overlay on finished automotive part plastic forming molds settles problems typical of argon welding — under-cuts, hardening, and pin-holes — while reducing finishing time.

Thin overlay on wide R part

Overlay applied on a wide-radius part of the mold: 0.05mm thick, 5.0mm wide, 80mm long — demonstrating the process's control over overlay thickness on shallow, wide-radius geometry.

Overlay into the deep spot

Overlay applied into a deep spot on the mold: 25mm gate width, 20mm overlay depth, 3R shape — demonstrating overlay build-up into a narrow, deep feature without distortion.

Press squeezing die — chrome plating repair

Overlay repair and coating for wear and scuffing of chrome plating on a press squeezing die. Achieves fine overlay repairs without distortion, cracks, pin-holes, or shrinkage — re-chrome plating is unnecessary thanks to the tungsten carbide coating.

Casting aluminum wheel — minor defect repair

Minor casting defects found on casting aluminum wheels after finishing can be filled by overlay repair. Low heat input reduces production defects and eliminates distortion, residual stress, or under-cuts — repaired products have also passed hydraulic leak tests.