One of Three European Specialists in GFM Tool Hardfacing
At Starweld Engineering, we provide specialist hardfacing repair services that significantly extend the life of high-value industrial tools and components. As one of just three companies in Europe capable of performing weld repairs to GFM tools and press tools, we sit at the leading edge of the hardfacing industry — and we can take on work that very few other engineering companies in the UK or mainland Europe are equipped to handle.
See examples of our completed work on our GFM and press tool hardfacing case studies, or read on for an overview of our capabilities.
GFM Tool and Press Tool Hardfacing Repairs
GFM tools and press tools work under extreme stress — high pressures, repeated impact, abrasive contact and harsh thermal cycling. Over time, even the best-engineered tooling wears, cracks, or loses geometry. A full replacement is often a five- or six-figure cost with a long lead time. Our hardfacing service restores worn tools to optimal condition, extending their useful service life and saving our clients significant costs versus replacement.
We work in mild steel, stainless steel and specialist alloys, applying advanced hardfacing techniques to rebuild worn surfaces, improve wear resistance, and restore precise dimensional tolerances.
TIG Hardfacing with Free-Issue Material (Udimet 520 & More)
Alongside hardfacing with our own welding wires, we routinely work with customer-supplied free-issue materials — most commonly Udimet 520, a nickel-based superalloy used in high-temperature applications. This lets you specify and supply the exact material your application demands, while we apply our expert welding techniques.
Our coded TIG welders are highly experienced with free-issue materials and exotic alloys, producing high-quality, precise welds that meet specification every time. Material traceability and welding records are supplied with every job.
What is Hardfacing?
Hardfacing is a metalworking process where a harder, tougher material is welded onto a base metal to improve its wear resistance. It can be used on new components during manufacture, or as part of a maintenance program to rebuild surfaces lost to abrasion, impact or thermal damage.
For tools subject to repeated heavy use, hardfacing typically provides:
- Significantly extended service life — often two to five times the original lifespan
- Lower total cost of ownership compared with replacement
- Shorter lead times than commissioning a new tool
- Improved wear resistance using harder filler alloys than the base metal
- Restored dimensional accuracy in critical wear zones
Industries We Serve
Our hardfacing services support clients across:
- Manufacturing & Fabrication
- Tooling and Pressing
- Construction and Heavy Equipment
- Automotive Industry
- Aerospace
- Energy & Power Generation
- Heavy Machinery and Plant
- Defence and Nuclear (free-issue and traceable work)
Whatever the sector, our hardfacing services keep your equipment in peak condition under the most demanding conditions. If your tools or components have a wear problem, we’d like to hear about it.
Our Collaboration with Böhler Welding
We work closely with voestalpine Böhler Welding, one of the world’s leading manufacturers of welding consumables, to develop and apply high-performance hardfacing wires that outperform off-the-shelf alternatives. The result of this collaboration is a hardfacing solution that lasts longer and delivers greater wear resistance than conventional hardfacing wires currently available on the market.
For our clients, that means tools that stay in service longer, fewer maintenance cycles, and a stronger return on every hardfacing job.
Why Choose Starweld for Hardfacing Repairs?
European-Level Specialism
One of only three companies in Europe undertaking GFM tool and press tool hardfacing repairs. The expertise that goes into this work doesn’t exist in most fabrication shops.
Quick Turnaround
Downtime is expensive. Whether you’re working to tight production schedules or need urgent repairs, our team is geared up to get your tooling back into service as fast as possible, without compromising on quality.
Proven Longevity
Our hardfacing solutions are designed to withstand extreme wear. The welding wire we use, developed with Böhler, has been proven to outlast standard hardfacing options — making it a more cost-effective solution over time, not just at the point of repair.
Free-Issue Material Capability
If you need to specify your own material (Udimet 520, other nickel-based superalloys, or specialist grades), we’ll work with what you supply — fully traceable, fully documented.
Complementary Engineering Services
Hardfacing is often part of a wider tool restoration. We also offer precision engineering, steel fabrication and welding, and cast iron repair — meaning we can handle the full job under one roof, from initial inspection through to finish machining.
Contact Our Hardfacing Experts
If you have a worn GFM tool, press tool, or other industrial component that needs hardfacing — or you’re not sure whether your component is a good candidate for repair — get in touch and we’ll take a look. We can advise on whether hardfacing is the right approach, what material would suit best, and what kind of service life you can expect from the repair.
Call 0114 272 0283 or email sales@starweld.co.uk. Workshop visits welcome — see our Sheffield workshop address.