Key Responsibilities and Required Skills for Tool Welder

🎯 Role Definition

The Tool Welder is a specialized artisan who applies advanced TIG, Micro-TIG, and sometimes laser welding techniques to repair and maintain critical production tooling. This role requires a deep understanding of tool steel metallurgy, blueprint interpretation, and precision finishing. You will work closely with the toolroom and engineering teams to diagnose failures, develop repair strategies, and execute welds that meet exacting dimensional and surface finish specifications, directly impacting our operational efficiency and product quality.

📈 Career Progression

Typical Career Path

Entry Point From:

Apprentice Welder / Welder Trainee
Production TIG Welder
Machinist or Toolmaker with welding experience

Advancement To:

Lead Tool Welder / Toolroom Team Lead
Toolroom Supervisor or Manager
Welding Specialist or Welding Engineer

Lateral Moves:

Tool and Die Maker
Quality Control Inspector (Welding)

Core Responsibilities

Primary Functions

Perform high-precision Gas Tungsten Arc Welding (TIG) and Micro-TIG welding on a variety of tool steels (P-20, H-13, S-7, D-2) to repair injection molds, stamping dies, and other production tooling.
Analyze and interpret complex blueprints, engineering drawings, 3D models, and work orders to determine welding requirements, locations, and specifications.
Expertly repair damaged, cracked, or worn parting lines, shut-offs, core/cavity surfaces, and engineering change areas on high-value tooling.
Select the appropriate filler metals, tungsten electrodes, and shielding gases based on the base material composition and the specific repair application.
Utilize pre-heating and post-heating techniques, including the use of torches and ovens, to manage thermal stress, prevent cracking, and achieve desired metallurgical properties.
Perform meticulous post-weld finishing operations, including grinding, stoning, blending, and polishing, to restore repaired areas to original contour and surface finish requirements.
Conduct thorough quality inspections of completed weld repairs using visual examination, dye penetrant testing, and precision measurement instruments like micrometers and calipers.
Diagnose tooling failures and collaborate directly with toolmakers, machinists, and engineers to develop the most effective and durable repair strategies.
Set up, operate, and maintain TIG welding machines, laser welders, and associated equipment, performing routine troubleshooting to ensure optimal performance.
Document all repair activities, including procedures followed, filler materials used, and inspection results, to maintain accurate maintenance logs and ensure traceability.
Operate overhead cranes, forklifts, and other material handling equipment to safely maneuver heavy and expensive tooling within the facility.
Assess damaged tooling to determine the scope of repair, providing accurate estimates for time and materials required to complete the job.
Perform intricate laser welding for delicate and precise repairs on small components, inserts, and texturing that are not suitable for conventional TIG welding.
Work independently with minimal supervision, demonstrating a high level of craftsmanship, initiative, and accountability for quality outcomes.
Apply a strong understanding of metallurgy to predict how different tool steels will react to the heat and stress of the welding process.
Perform benching and spotting on repaired dies and molds to verify proper fit, function, and sealing before they are returned to production.

Secondary Functions

Adhere strictly to all company safety policies, OSHA regulations, and best practices for shop safety, including the proper use of personal protective equipment (PPE).
Contribute to continuous improvement initiatives by suggesting and helping implement more efficient and effective tool repair techniques and processes.
Maintain a clean, organized, and safe work area in accordance with 5S principles.
Assist in managing the inventory of welding consumables, filler rods, and other necessary supplies, and report when reordering is needed.

Required Skills & Competencies

Hard Skills (Technical)

Expert-level TIG Welding (GTAW): Demonstrated mastery of TIG welding, especially on various tool steels.
Micro-Welding/Micro-TIG: Proven ability to perform extremely fine, detailed welds, often under a microscope.
Blueprint & Schematic Reading: Ability to read and interpret complex technical drawings, including an understanding of Geometric Dimensioning and Tolerancing (GD&T).
Tool Steel Metallurgy: Strong knowledge of the properties and weldability of common tool steels (H-13, S-7, P-20, stainless steels).
Post-Weld Finishing: Skilled in grinding, stoning, hand-working, and polishing to achieve specified surface finishes (e.g., SPI standards).
Metrology & Inspection: Proficient in using precision measuring tools such as calipers, micrometers, depth gauges, and indicators.
-Laser Welding: Experience with Nd:YAG or Fiber laser welding systems for tool and mold repair is highly desirable.
Equipment Operation: Safe operation of overhead cranes and forklifts for handling heavy tooling.
Heat Treatment: Foundational knowledge of pre-heating, post-heating, and stress-relieving procedures for welded components.
Die/Mold Spotting: Experience in spotting and fitting mold components to ensure proper shut-off and function.

Soft Skills

Exceptional Attention to Detail: A meticulous and precise approach is critical for high-quality tool repair.
Problem-Solving: Strong analytical skills to diagnose tooling issues and determine the best repair method.
Patience and a Steady Hand: Ability to perform delicate, time-consuming tasks with precision and control.
Independent Work Ethic: Self-motivated and able to manage time and tasks effectively with minimal supervision.
Verbal Communication: Ability to clearly communicate technical information with engineers, machinists, and supervisors.
Adaptability: Flexible and able to pivot between different types of repairs and materials as production needs change.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED.

Preferred Education:

Welding Certification from an accredited institution (e.g., American Welding Society - AWS).
Completion of a formal apprenticeship in Tool & Die or Welding.
Associate's Degree in Welding Technology or a related field.

Relevant Fields of Study:

Welding Technology
Manufacturing Engineering Technology
Metallurgy

Experience Requirements

Typical Experience Range:

3-7 years of professional experience in TIG welding, with at least 2 years focused specifically on tool, die, or mold repair.

Preferred:

5+ years of dedicated experience in a fast-paced toolroom environment performing intricate repairs on plastic injection molds and/or metal stamping dies.
Demonstrable portfolio of past repair work.