capilla-capiTool

capilla-capiTool

 

Areas of application for capiTool service:

Tools, molds, dies, extrusion, forging, pressing, drawing tools and much more.

Mouthpieces, molds, dies and tools are used in various industries, including casting, forging, pressing and extruding and much more.

Every wear pattern of wear phenomenon is unique in its form. There are often parallels, but it can also be said that wear is not the same as wear. Rather, we are talking about a series of many factors that cause these phenomena. Often, this is also referred to as a stress collective. Theoretically, the phenomena can be divided into four different types of wear. These include:

  • adgesion
  • abrasion
  • tribochemical reaktion
  • Surface disruption

However, all kinds have the surface removal of the workpiece in common. In the above mentioned extreme wear on components and tools often occurs in these areas due to high temperatures, temperature differences, many temperature cycles, compression, high pressure or many pressure peaks, oxidation, hydrogen embrittlement, abrasion, cavitation, plastic deformation, extreme adhesion (seizure) and much more.

Reasons for component failure are complex. This mostly predictable and progrssive wear of material fatigue inevitably leads to production stops for possible tool changes, maintenance and repairs.

This type of downtime is unavoidable, but the intervals can be extended significantly by selecting suitable materials, combinations and technology thus significantly increasing production figures.

capilla has had a special service for the above-mentioned areas for many years.

capiTool service is a service in which our application consults offer our partners – also on-site – support in analyzing damage patterns and reginerating or RetroFit components.

Core competence here lies in the selection of suitable materials and the selection of a suitable wear protection system for tools, molds and dies, but also in the determination of parameters, etc.

Prior to actual capiTool, a careful inspection and measurement of the indicidual worn components is required. This includes, among other things, the exact inspection of the material composition of the base body or the coating using a factory certificate, alternatively spectral analysis and the inspection of dimensions such as holes, fits and contours using 3D scan comparison.  

After the suitability of the components for capiTool has been determined, the components are usually cleaned and presented to the subsequent customer processes such as electrode, MIG/MAG, laser or TIG welding systems, welded by hand or measured fully automatically, path programming is initiated via software and the component is automatically coated according to the agreed procedure. 

Decisive advantages of capiTool service in general are:

  • in general capiTool usually costs 25-60 % of the cost of purchasing a new part
  • repairs can be planned, can be moved to and processed in revision periods and are particularly characterized by a very high level of reproducibility thanks tto a high degree of automation. This also results in shorter processing times and these are usually accompanied by shorter delivery times compared to purchasing new parts
  • welding filler materials, alloy systems, alloy windows and any carbide components can be adapted to the task as required
  • the selected wear and corrosion protection is always selected or composed individually according to the task

Decisive advantages of an automated capiTool service are:

  • automated and process-controlled laser and TIG hot wire armoring is characterized by ist significantly lower dilution with the base material and a significantly lower material requirement for the same task
  • dilution is usually less than 5% and therefore significantly less than classic arc coatings (20-35%). This means that in the laser and TOG hot wire process , the required properties such as emergency running properties, hardness, freedom from pores, etc. are often achieved in the first layer
  • wear protection as if from a single cast. Layer thicknesses of 0,15-6,00mm and layer widths of 0,20-10,00mm close to the final contour or 20-30mm and more in different surface qualities are easily possible. Coating materials and properties can be combined
  • thanks to the different technologies, sensors and optics available, a very high contour accuracy with a very high level of precision can already be achieved, so that components can be coated close to the final contour without any problems. This is also clearly evident in shortened downstream processes such as turning and milling and much more

Components such as molds, dies, extrusion, forging, pressing and drawing tools

Areas of these components that are exposed to varying degrees of stress during the process can be protected or enhanced with the laser in specific places where wear such as abrasion, cavitation, adhesion, surface disruption and corrosionactually occur or are most severe.

For special, complicated contours, in urgent cases and/or when necessary original parts cannot be obtained, 3D printing of complex geometries or significant areas is possible at short notice.

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