Welding System - Kemwelder IV

Rapid and reliable repairs in tool making and mould building

This welder is designed for mould and dye repair and this can help save you time and money by keeping mould repair in-house instead of sending out for service. It's very easy to use and nearly anyone can begin welding within a very short period of time. It's also mobile, so you can transport this around your company and weld any mould size, large or small and it utilises very little heat so you don't have to worry about heat distortion that you get from traditional TIG welders.

The welder works by gently touching the spot of the welding point with the electrode tip. After 2 seconds, the control unit triggers welding, at the same time, an electromagnet draws the electrode back. You then precisely position the electrode for subsequent points which can then be triggered every second. For safety, the shutter of the microscope closes with each weld.

welding system for toolmakers

  • Pre-set welding parameters for variety of materials (e.g. Steel & Aluminium) of up to Ø 0.8 mm and even up to 1.0 mm under certain conditions.
  • Electronically controlled hand piece - The welding process starts only if all requirements are complied
  • Ability to program bespoke welding operations
  • Shielding gas process
  • Package includes microscope (10x magnification). Supplied with a green, translucent protection shield.
  • Welding kit is small and portable
  • Product Code: 339102

New features

  • The amperage (TIG) has been increased by 15% to 720 A. This means you can now weld wires of up to Ø 1 mm
  • Auto cooling system
  • Improvements to handpeice
  • New software monitors the welding process:
    • Avoidance of welding errors due to interruption of the welding process in case of excessive pressure on the electrode
    • Increased service life of the electrode tip
    • Avoidance of tungsten inclusions on surfaces or on workpieces and materials that still need further processing
  • Enhanced process reliability and more consistent quality

adjustable microscope

The microscope has many features that make welding easy. The 10 x magnification microscope has a built in integrated LED light uniformly which illuminates the entire welding area. The visual field is of adequate size with a diameter of 20 mm. When using the handpiece and welding filler, you can very accurately determine the spot where you wish to weld using the thin, pointed electrode. Using the hydraulic swivel arm, you can quickly position the microscope to exactly where needed.

The integrated LCD vision protection filter closes the beam path during the welding time that gives eye protection during the welding process. The whole process takes place in milliseconds.

The kemwelder has pre-set welding parameters for mould repair applications and this is going to make it much easier to select the correct setting for your welding application. You’ll have settings for three different metals; steel, aluminium and copper and four different welding wire diameters up to 0.8mm and then five different surface applications for flat, edge, corner, rib and three corner. So, at the touch of your fingertips, you have access to sixty different mould repair applications.

Contents Include:

  • Control unit with touch screen
  • Hand piece with cable 2 m
  • 1 each collet Ø 0.6, Ø 0.8 and Ø 1.0 mm
  • Fixing hand piece
  • 1 each fine welding ceramic nozzle Ø 3 and 4 mm
  • Earth cable 1,50 m with magnet
  • Stereo microscope 10 x magnification with electronic shutter LED lighting, hydraulic swivel arm, switchable magnet (1,200 N)
  • Flowmeter
  • Brass brush
  • 10 each special electrodes Ø 0.6 mm and Ø 0.8 mm with 1 diamond grinding disk
  • 10 special electrodes Ø 1.0 mm x 200 mm
  • 1 Electrode Grinder / Sharpener
  • Foot switch
  • 5 m gas hose
  • Green transparent protection shield.

When welding with the Kemwelder, you must use argon gas to get the best results, the argon gas is going to eliminate oxidation and it is also going to give you clean welds. You will need a bottle of Argon 4.6, and the correct fillers for your material.

Technical Data:

Supply voltage ~230 V 50 ~60 Hz, +/-10%
Fuse T 3,15 A
Power input 400 VA
Load voltage 30 - 43 V
No-load voltage 43 V
Duty cycle 80%
max. Charge time 0.8 s
Shielding gas ARGON 4.6
Gas pressure 2 bar
Protection gas I
Inslation class B
Safety class IP 21S
Dimensions LxWxH 320x155x320 mm
Weight 8.2 kg

welding system

Welding rods for the Kemwelder

Only the right welding rods will ensure good results. You will get good results if the composition of the welding rod corresponds to your material. The rods are 333 mm long with a minimum weight of 100 grams. Coils available on request. Please contact us if you do not find the right rod for your application. Wires with a diameter of 0.8 mm welds the Kemwelder without any problems, and with good conditions even up to 1 mm.

Welding fillers (length 333 mm, Ø 0.4 mm)
Hardness For Al C Ci Cr Cu Fe Mg Mn Mo Ni Si Ti Zn Zr Code
Soft 1.2311, 1.2312, 1.2162, 1.2738

Modifications and repairs to moulds made of 1.2311, 1.2312, 1.2162 and 1.2738. The welding can be eroded, structured, chrome-plated, etched, nitrated, annealed and hardened.

0.10 # 1.10 0.50 0.60 339108
42 - 46 HRc 1.2082, 1.2083, 1.2343, 1.2367-1.2606, 1.2767

The filler for highly stressed hot working tools which are simultaneously exposed to high mechanical, thermal and abrasive stresses. E.g. forges for hammers and presses, saddles, aluminium die-casting moulds, plastic moulds, hot shearing blades. Processing with tungsten carbide tools. The welding metal is annealable, nitratable, chrome-platable, CVD coatable, polishable and machinable.

0.25 5.00 # 0.70 4.00 0.50 0.60 339109
53 - 58 HRc 1.2082, 1.2083, 1.2343, 1.2344, 1.2367-1.2606, 1.2767

For highly wear-resistant weldings on tools, exposed to heavy friction and pressure at high temperatures. Forging tools, roller spindles, hot deburring sections. Processing by grinding or tungsten carbide tools.

0.35 7.00 # 1.20 2.00 0.30 0.30 339110
53 - 58 HRc 1.2082, 1.2083, 1.2311, 1.2312, 1.2343. 1.2344, 1.2367-2606, 1.2767, 1.2842

For high-wear-firm welds at tools, which are exposed to strong abrasion and pressure at increased temperatures, e.g. Slidegate valve surfaces, guide ways, sealing rims. Good abrasion behavior with glass-fiber reinforced plastics.

0.35 7.00 # 1.20 2.00 0.30 0.30 339120
54 - 60 HRc 1.2379, 1.2436, 1.2601

Universal for build-up welding on components exposed to heavy impact and moderate abrasion stresses. Also cutting tools and contours in the automobile industry. The welding metal is tough and fracture-proof and edge-retentive. Grindable.

0.50 9.50 0.50 3.00 339121
54 - 60 HRc 2.4060, 2.4061, 2.4066, 2.4068

Used for build-up and connection weldings commercially available pure nickel grades, including LC nickel, nickel alloys and nickel-plated steels. Materials of this kind are primarily used in pressure vessel and apparatus construction, in the chemical industry, in the food industry and in the energy industry where good corrosion and temperature properties are required.

0.10 # 3.50 55.00 + 339122
54 - 60 HRc GG (grey cast iron) and GGG (globular grey cast iron) materials, miscellaneous types of cast iron

Used for build-up and connection weldings of ferritic and austenitic cast irons with spheroidal graphite in addition to mixed compounts with non-alloyed and high-alloy steel, copper and nickel alloys. Build-up weldings on grey cast iron types are possible.

0.10 # 3.50 55.00 + 339123
54 - 60 HRc connections of various different materials. 1.2316

For build-up and joint welding on steels which are difficult to weld. For bufferings and connections on cold and hot working tools.

0.10 30.00 # 1.60 0.40 339124
220 HB Cu-Al multi-alloy bronzes, platings on cast and steel materials

For build-up, crack and joint welding on Ampco bronzes, e.g. cooling inserts in plastic moulds, fittings, drawing tools or aluminium- bronze-steel mixed joints.

7.50 # 2.50 13.00 2.50 339125
140 HB Cu-Al multi-alloy bronzes, platings on cast and steel materials, in addition to mixed joins of different materials

For connection and plate weldings on CuAl bronzes. Mixed joins of CuAl bronze with steel in addition to various different materials with one another, build-ups on tool steel or cast alloys. Platings on steel and cast iron materials. Good sliding properties, seawater-resistant and cavitation-resistant.

8.00 # 2.00 2.20 2.20 339126
140 HB aluminium # <0.4 <0.2 5.00 339127
140 HB aluminium # 0.20 12.00 339128
140 HB ALMg2,7Mn, AKLMg4,5Mn, ALMg5, ALMgSi0,7, ALMgSi1, ALMgSiCu, ALZn4,5Mg1, G-ALMg3, G-ALMg5 # 0.05 - 0.25 0.05 0.40 4.5 - 5.2 0.7 - 1.1 0.25 0.15 0.25 0.1 - 0.2 339129

Welding fumes extractor and filter

The advantages of working in an environment free of welding fumes and dust are significant. During welding operations, especially prolonged ones, the reliable extraction of welding fumes is crucial. Similarly, fine dust generated during grinding and other related activities should also be extracted to prevent inhalation of these substances. We have been diligently searching for a highly capable, efficient, and portable extraction solution, and we are pleased to introduce the Extractor III. This innovative device offers an impressively quiet and effective means of extracting fumes and dust, all at a remarkably affordable price. The Extractor III incorporates a brushless suction motor, which sets it apart from conventional extraction systems. This motor operates silently and boasts a remarkably long lifespan, contributing to the device's exceptional performance and reliability.

welding fumes extraction and filter

Technical Data:

Maximum flow rate: 235 m³/h
Electrical power: 1Ph., 220V, 50Hz
Dimensions (WxDxH): 420 x 400 x 245 mm
Noise level: <50dBA in the workspace
Weight: approximately 15 kg
Filter stage 1: Prefilter for coarse dust
Filter stage 2: Fine filter EU5 for 98% >3μm
Filter stage 3: Activated carbon and fine filter 99.97% <0.3 μm

extraction and filter for welding

kemet ISO 9001

BSI number Q05919

Over 85 years of service to industry

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