Method of manufacturing molds, dies or forming tools having a cavity formed by thermal spraying

Described are molds, dies and forming tools comprising: a) a heat exchanging body support member; and b) within the support member, a molding cavity portion formed by thermal spraying metallic particles to a desired configuration in the support member. Also described are methods of making a mold, di...

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Bibliographische Detailangaben
Hauptverfasser:	MCDONALD, ROBERT R
Format:	Patent
Sprache:	eng
Schlagworte:	AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL BLASTING CASTING CHEMICAL SURFACE TREATMENT CHEMISTRY COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATIONOR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY IONIMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL COATING MATERIAL WITH METALLIC MATERIAL COATING METALLIC MATERIAL DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OFGENERAL APPLICATION DIFFUSION TREATMENT OF METALLIC MATERIAL FOUNDRY MOULDING HEAT EXCHANGE IN GENERAL HEATING INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION INGENERAL LIGHTING MECHANICAL ENGINEERING METALLURGY PERFORMING OPERATIONS POWDER METALLURGY PROCESSES FOR APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TOSURFACES, IN GENERAL SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDEDFOR SHAPING OR JOINING OF PLASTICS SPRAYING OR ATOMISING IN GENERAL SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THESURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION TRANSPORTING WEAPONS WORKING OF PLASTICS WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
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Beschreibung
Zusammenfassung:	Described are molds, dies and forming tools comprising: a) a heat exchanging body support member; and b) within the support member, a molding cavity portion formed by thermal spraying metallic particles to a desired configuration in the support member. Also described are methods of making a mold, die or forming tool comprising the steps of: a) providing a body support member having a controlled and designed porosity which permits the enhancement of the heat transfer ability of said mold, die or forming tool; b) configuring a surface of the support member to a desired cavity; and c) spraying particles to the configured cavity in the support member, thereby producing a mold, die or forming tool. Preferably, the materials of construction are metallic and are applied by thermal plasma spraying. The particles may also be ceramics, metal matrix composites, ceramic matrix composites, thermoplastic resins, thermoset resins, and composites based thereupon. The controlled porosity of the body of the mold, die and/or forming tool is as important as the use of thermal spray to subsequently form the cavity.