Fabrication of alloy variant structures using direct metal deposition

Direct-metal deposition (DMD), preferably under closed-loop control, is used to fabricate alloy-variant material structures which provide a combination of desirable physical and mechanical properties. Use of the invention facilitates the production of high-strength, high-wear, and impact-resistant s...

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Bibliographische Detailangaben
Hauptverfasser:	SKSZEK TIMOTHY W, LOWNEY MATTHEW T. J, MORGAN DWIGHT
Format:	Patent
Sprache:	eng
Schlagworte:	AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL CASTING CASTING OF METALS CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES CHEMICAL SURFACE TREATMENT CHEMISTRY CLADDING OR PLATING BY SOLDERING OR WELDING 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 CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING DIFFUSION TREATMENT OF METALLIC MATERIAL FOUNDRY MOULDING INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION INGENERAL MACHINE TOOLS METAL-WORKING NOT OTHERWISE PROVIDED FOR 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 SOLDERING OR UNSOLDERING SPRAYING OR ATOMISING IN GENERAL SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THESURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION TRANSPORTING WELDING WORKING BY LASER BEAM WORKING OF PLASTICS WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
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Beschreibung
Zusammenfassung:	Direct-metal deposition (DMD), preferably under closed-loop control, is used to fabricate alloy-variant material structures which provide a combination of desirable physical and mechanical properties. Use of the invention facilitates the production of high-strength, high-wear, and impact-resistant structures which decrease the likelihood of erosion, heat checking and brittle failure in injection molds, die casting, thixomolding and other, more exotic tooling. The invention uses DMD to deposit a first material or alloy in an area exposed to high wear, such as the tooling gate area, with a second material or alloy being used elsewhere in the tool for greater impact resistance. Advantageously, the areas may be of a user-defined thickness to further improve longevity. The resulting composite material structure has mechanical properties (i.e., yield strength, hardness and abrasion resistance) which exceed that of the homogeneous compositions currently used for mold materials, thereby enhancing productivity while improving part quality in these and other applications.