U.S. patent number 3,826,301 [Application Number 05/297,866] was granted by the patent office on 1974-07-30 for method and apparatus for manufacturing precision articles from molten articles.
Invention is credited to Reginald Gwyn Brooks.
United States Patent |
3,826,301 |
Brooks |
July 30, 1974 |
METHOD AND APPARATUS FOR MANUFACTURING PRECISION ARTICLES FROM
MOLTEN ARTICLES
Abstract
A method and apparatus for manufacturing shaped precision
articles from molten metals (including alloys), which articles may
either be effectively non-porous or have a controlled degree of
porosity and may be finished (i.e. no further processing is
required) or may require a small amount of finish machining (e.g.
trimming of flash and/or heat treatment), wherein the method
comprises directing a stream of molten metal or molten metal alloy
at a collecting surface to form a deposit, and working the deposit
by means of a die to form a precision metal or metal alloy
article.
Inventors: |
Brooks; Reginald Gwyn (Swansea,
Glamorgan, WA) |
Family
ID: |
26258181 |
Appl.
No.: |
05/297,866 |
Filed: |
October 16, 1972 |
Foreign Application Priority Data
|
|
|
|
|
Oct 26, 1971 [GB] |
|
|
49646/71 |
Jun 6, 1972 [GB] |
|
|
26307/72 |
|
Current U.S.
Class: |
164/46; 29/527.5;
29/527.6; 164/76.1 |
Current CPC
Class: |
B21J
5/00 (20130101); C23C 24/04 (20130101); C23C
4/185 (20130101); B22F 9/082 (20130101); B21J
5/002 (20130101); C22C 47/16 (20130101); C23C
4/123 (20160101); B22D 18/02 (20130101); B22D
23/003 (20130101); B22F 3/115 (20130101); Y10T
29/49988 (20150115); B22F 2999/00 (20130101); Y02P
10/25 (20151101); B22F 2998/10 (20130101); B22F
2998/00 (20130101); B22F 2003/1046 (20130101); Y10T
29/49982 (20150115); Y10T 29/49989 (20150115); B22F
2998/00 (20130101); B22F 10/10 (20210101); B22F
2998/10 (20130101); B22F 3/115 (20130101); B22F
3/20 (20130101); B22F 2999/00 (20130101); B22F
2203/01 (20130101); B22F 2207/15 (20130101); B22F
2201/02 (20130101); B22F 2999/00 (20130101); B22F
9/082 (20130101); B22F 2201/02 (20130101); B22F
2998/00 (20130101); C22C 47/00 (20130101); B22F
2998/00 (20130101); B22F 10/10 (20210101) |
Current International
Class: |
C23C
4/18 (20060101); C23C 4/12 (20060101); B22D
18/00 (20060101); B22D 23/00 (20060101); B22D
18/02 (20060101); B22F 3/115 (20060101); B22F
9/08 (20060101); B22F 3/00 (20060101); B21J
5/00 (20060101); C22C 47/16 (20060101); C22C
47/00 (20060101); B22d 011/10 () |
Field of
Search: |
;29/527.2,527.4,527.5,527.6 ;164/46,76 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lanham; Charles W.
Assistant Examiner: Reiley, III; D. C.
Attorney, Agent or Firm: Norris & Bateman
Claims
I claim:
1. A method for manufacturing shaped precision articles from molten
metal or molten metal alloy, comprising directing an atomised
stream of molten metal or molten metal alloy onto a collecting
surface to form a solid deposit, then directly working the deposit
on the collecting surface by means of a die to form a precision
metal or metal alloy article of desired shape, and subsequently
removing the precision shaped article from the collecting
surface.
2. A method as claimed in claim 1, wherein the collecting surface
is in the form of a second die.
3. A method as claimed in claim 2, wherein the molten metal or
metal alloy is atomised in an inert atmosphere.
4. A method as claimed in claim 1, wherein the molten metal or
metal alloy is atomised in a reducing atmosphere.
5. A method as claimed in claim 1, wherein the molten metal or
metal alloy is atomised by compressed air.
6. A method as claimed in claim 1, wherein several atomised streams
of different molten metals or alloys are provided, which streams
are simultaneously mixed in flight or are sprayed
consecutively.
7. A method as claimed in claim 6, wherein metallic and/or
non-metallic powders, fibres, filaments or whiskers are
incorporated in the sprayed deposit during deposition.
8. A method as claimed in claim 2, wherein the second die is
transferred to a press chamber to enable working to be carried
out.
9. A method as claimed in claim 1, wherein the collecting surface
is in the form of a container provided with an extrusion die, and
working of the deposit is carried out by a ram which extrudes the
deposit through the die to form a precision metal article.
10. A method as claimed in claim 1, wherein the collecting surface
is in the form of a container and working is carried out by a ram
having an extrusion die through which the article is extruded.
11. A method as claimed in claim 1, wherein the collecting surface
moves relative to the atomised stream of molten metal or metal
alloy so that a continuous layer of metal or metal alloy is
deposited on the collecting surface.
12. A method as claimed in claim 1, wherein a masking plate or
plates is mounted in the atomised steam of molten metal or metal
alloy to ensure that metal or metal alloy is only deposited on
desired areas of the collecting surface.
13. A method as claimed in claim 1, wherein any surplus metal or
metal alloy deposited on the collecting surface is removed by a
suitably shaped trimming or cutting tool.
14. A method as claimed in claim 1, wherein a release agent is
applied to the collecting surface to facilitate release of the
sprayed deposit therefrom.
15. A method as claimed in claim 1, wherein the die or dies are
made from nickel-chromium-molybdenum steel,
chromium-molybdenum-vanadium steel, nickel based alloys or metallic
carbides.
16. A method as claimed in clam 1, wherein the deposit is cold
worked.
17. A method as claimed in claim 1, wherein the deposit is cold
worked.
18. An apparatus for manufacturing shaped precision articles from
molten metal or molten metal alloy, comprising a chamber having
means for atomising a stream of molten metal or metal alloy and for
directing the atomised stream onto a collecting surface so as to
form a solid deposit on said surface, a die movable by operating
means for effecting working of said deposit on said surface in
order to form a precision metal or metal alloy article, and means
for removing the precision metal or metal alloy article from the
chamber.
19. An apparatus as claimed in claim 18, wherein the atomising
means is an annular gas atomiser which surrounds a nozzle through
which molten metal or metal alloy is fed from a tundish.
20. An apparatus as claimed in claim 18, wherein the collecting
surface is in the form of a second die which is movable between a
depositing position, and a working position wherein it cooperates
with said first die.
21. An apparatus as claimed in claim 18, wherein an inert gas
atmosphere is maintained in the chamber.
22. An apparatus as claimed in claim 18, wherein the collecting
surface is in the form of a container provided with an extrusion
die, and a piston is provided for extruding the deposit from the
die.
23. An apparatus as claimed in claim 18, wherein the collecting
surface is in the form of a container and working is carried out by
a ram having an extrusion die through which the article is
extruded.
24. An apparatus as claimed in claim 18, wherein means are provided
for moving the collecting surface relative to the atomised spray so
that a continuous layer of metal or metal alloy is deposited on
said surface, press means being provided for forming the worked
article from the layer of metal or metal alloy.
25. An apparatus as claimed in claim 18, wherein an inert gas
atmosphere is maintained in the chamber.
26. An apparatus as claimed in claim 18, wherein a reducing
atmosphere is maintained in the chamber.
27. An apparatus as claimed in claim 18, wherein the molten metal
or metal alloy is atomised by compressed air.
28. An apparatus as claimed in claim 18, wherein the atomising
means is arranged to atomise several streams of different molten
metals or metal alloys, which streams are simultaneously mixed in
flight or are sprayed consecutively.
29. An apparatus as claimed in claim 28, wherein means are provided
for incorporating metallic and/or non-metallic powders, fibres,
filaments or whiskers in the sprayed deposit.
30. An apparatus as claimed in claim 18, wherein the die is made
from a material selected from the group consisting of
chromium-molybdenum steel, chromium-molybdenum-vanadium steel,
nickel based alloys and metallic carbides.
31. An apparatus as claimed in claim 18, wherein a release agent is
applied to the collecting surface to facilitate release of the
sprayed deposit therefrom.
32. An apparatus as claimed in claim 18, wherein any surplus metal
or metal alloy deposited on the collecting surface is removed by a
suitably shaped trimming or cutting tool.
33. An apparatus as claimed in claim 18, wherein a masking plate or
plates is mounted in the atomised stream of molten metal or metal
alloy to ensure that metal or metal alloy is only deposited on
desired areas of the collecting surface.
34. An apparatus as claimed in claim 18, wherein the deposit is hot
worked.
35. An apparatus as claimed in claim 18, wherein the deposit is
cold worked.
Description
This invention relates to the manufacture from molten metals
(including alloys), of shaped precision articles which may either
be effectively non-porous or have a controlled degree of porosity.
The articles produced according to this invention may be finished
(i.e., no further processing is required) or they may require a
small amount of finish machining (e.g., the trimming of flash
and/or heat treatment).
Shaped metal articles are usually produced at present by one of
three main methods. One known method involves the casting of molten
metal into a desired shape; this can be achieved by several
different techniques, e.g., sand-casting, die-casting, centrifugal
casting, shell-moulting or investment casting. Articles produced by
these methods, however, may possess poor mechanical properties
mainly as a result of relatively large grain sizes, structural
weaknesses and defects arising from the casting process, e.g.,
shrinkage, segregation (particularly in highly-alloyed metals) and
splashings onto the side of the mould.
A second known method involves the casting of molten metal as an
ingot, followed by either a hot-working process (e.g., hot-rolling,
forging, pressing or extruding) and/or a cold-working process
(e.g., cold-rolling, pressing, drawing, coining or spinning). In
either case semi-finished products (i.e., plates, billets and bars)
often have to be manufactured before subsequent processing to
produce finished articles. Such processing may involve re-heating
of the semi-finished product at various stages, each time followed
by a forming operation which can involve high loads, resulting in
considerable wearing of the forming dies. In addition, machining is
often needed to obtain the required dimensions of the finished
product (e.g., a gear wheel).
By this second method articles of complex shape can be manufactured
which can possess mechanical properties generally superior to those
articles produced by the first known method already described.
Defects in the original ingot, however, can result in a final
product of poor quality.
In a third known method, metal powders (produced, for example, by
gas or water atomisation of molten metal, mechanical pulverisation
or chemical reduction of ore) often have to be mechanically
handled, graded and heat treated, prior to forming operations. In
many instances a brittle "compact" has to be made, usually by
cold-pressing powdered metal in a die before sintering and other
forming operations can be carried out to produce an article of
finished shape. By powder metallurgical techniques it is possible
to produce finished articles of complex shape which do not require
any machining.
Advantages of this third method of manufacturing articles over the
other two known methods described previously include the
elimination of problems arising from liquid/solid shrinkage and
segregation and the capability of producing articles from a mixture
of metals which are not mutually soluble in the liquid state.
Non-metallic substances, which would be insoluble in the liquid
alloy, can also be added to powder-metallurgical products such that
they will be evenly distributed throughout the structure. In
addition, products with a controlled degree of porosity can be
produced by this third method.
One of the main disadvantages in the manufacture of articles by
powder metallurgical methods is the high cost of powdered metal
which can be used in such methods. In addition, the subsequent
forming and sintering operations necessary to produce articles are
expensive.
It is an aim of the present invention to provide a simplified and
more economic method for manufacturing shaped precision articles
which possesses most of the advantages of the third mentioned
method described previously and/or by which articles can be
obtained having mechanical properties similar to those produced by
the known methods described above.
With these aims in view this invention provides a method for
manufacturing shaped precision articles from molten metal or molten
metal alloy, comprising directing an atomised stream of molten
metal or molten metal alloy at a collecting surface to form a
deposit, and working the deposit by means of a die to form a
precision metal or metal alloy article.
The invention also provides an apparatus for manufacturing shaped
precision articles from molten metal or molten metal alloy,
comprising a chamber having means for atomising a stream of molten
metal or metal alloy and for directing the atomised stream onto a
collecting surface so as to form a deposit on said surface, a die
movable by operating means for effecting working of the deposit to
form a precision metal or metal alloy article, and means for
removing the precision metal or metal alloy article from the
chamber.
The collecting surface can be in the form of a deposition second
die which can be of any suitable shape or contour; for instance, it
can contain an impression of a gear wheel, or a connecting rod for
an automobile. The collecting surface may also simply be a plain
surface.
The stream of molten metal or metal alloy may be atomised into a
spray of hot, metal particles by the impingement of high velocity
gas jets. By these means a spray of fine, molten metal particles
can be produced from which heat is extracted in flight by the
relatively cold gas jets so that the metal particles can be either
solid, partly-solid/partly-liquid or liquid at the moment of
impacting the deposition die. On impacting the die surface the
particles deform, coalesce and build up to form a coherent, hot
mass of deposited metal which has a finely divided grain
structure.
After deposition heat can be added, if necessary, to the sprayed
deposit of metal particles before the forming operation is carried
out, but the preferred method is to shape and simultaneously work
(i.e., forge or press) the metal deposit without the addition of
heat after the deposition operation. This forming operation is
normally carried out as soon as the required mass of metal has been
deposited onto the die so that the deposit is hot-worked but, when
necessary, the sprayed deposit can be cold formed after it has been
cooled, e.g., to form a highly porous article.
Generally, if the metal is sprayed onto a deposition die, the die
acts as the lower die of a die set; the upper die block, which is
also suitably contoured, then shapes the top portion of the sprayed
deposit when the dies are loaded against each other. Any surplus
metal can be forced out of the die cavity into suitably designed
`flash` gutters. In this way shaped, hot-worked precision metal
articles can be manufactured. Alternatively the hot, sprayed
deposit in the deposition die may be removed from the die, for
instance by an ejection mechanism, and transferred rapidly into
another suitably shaped die block which may be the lower die of a
die set. The subsequent forming of the hot metal can then be
rapidly completed by loading the shaped top die against the bottom
die and a hot-worked, shaped precision metal article is
produced.
For the production of extruded articles, metal particles can be
sprayed into a container, into the base of which an appropriately
shaped orifice die is located. When the required mass of metal has
been sprayed into the container the hot deposit of metal particles
can then be forced through the die by the application of pressure
(by means of, for instance, an hydraulically driven ram) to produce
an extruded product of the same cross-section as that of the
orifice die. Alternatively, extruded articles can be produced by
indirect extrusion, the shaped orifice die being located in the ram
instead of in the base of the container.
By the method of the invention shaped precision metal articles can
be rapidly produced from molten metal and metal alloys and,
therefore, the invention is particularly well suited to
mass-production methods.
After spraying the deposit of metal particles is not solid, the
degree of porosity being a function of several factors, notably the
temperature, mass and velocity of the metal particles on
deposition. Values of these factors, in turn, can depend on one or
more of the process parameters; namely, the geometry of the
atomising system, the temperature of the molten metal prior to
atomisation; the distance which the particles have to travel before
being deposited (hereinafter termed the "spray distance"); the mass
ratio of atomising gas to metal being atomised; the relative
velocity between the gas jets and the molten metal stream; the
temperature and pressure of the atomising gas; and the temperature
of the deposition die. In addition, the degree of porosity of the
sprayed deposit can be reduced simply by densification or
compaction; this can be achieved, for instance, by applying
pressure to the deposit by means of an hydraulically operated ram
or top die. Therefore, metal articles may be fabricated in a wide
range of porosity by the method of the invention. For instance,
articles can be produced with a porosity of approximately 50
percent or they can be produced with a porosity effectively equal
to zero, or they can have a porosity of any value between these two
values. The actual value of the porosity depends primarily on the
temperature, size and velocity of the particles on deposition and
on the nature and loading of the subsequent forming operation (if
this is required).
Articles can be produced in accordance with the invention in most
ferrous or non-ferrous metals or alloys which can be melted and
atomised; e.g., carbon steels, alloy steels, aluminium, aluminium
alloys, brasses, and phosphor bronzes. In addition, articles can be
fabricated from a mixture of metals which are not mutually soluble
in the liquid state as is the case with some of the existing powder
metallurgical methods.
In utilising the method of the invention, the mixing of the
different metals can be achieved by spray depositing dissimilar
metals either simultaneously, so that mixing of the particles
occurs whilst they are in flight, or one after the other so that a
sprayed deposit is produced with a structure which consists
basically of layers of dissimilar metals. If desired, metallic
and/or non-metallic powders, fibres, filaments or whiskers can be
incorporated in the sprayed deposit during the deposition
operation.
In a preferred method of the invention, the molten metal (or alloy)
stream is atomised by the impingement on it of one or more gas jets
and generally the greater the velocity and flow rate of the gas
jets the finer are the particles produced. Alternatively, any means
of breaking up the molten metal stream can be used in conjunction
with gas jets which serve to comminute further the molten metal
particles and to extract heat from them; for instance, a rotating
disc atomiser in conjunction with peripheral gas jets can be used.
Any suitable gas may be used to atomise the stream of molten metal,
but it is often desirable to use nitrogen or argon or some other
inert or reducing gas, so that oxidation of the metal particles is
minimised. If oxidation of the particles is not undesirable,
compressed air can be used as an atomising medium. To preserve a
controlled atmosphere during the deposition process (if required)
and for safety reasons the deposition die is disposed within a
spray chamber which can be fitted with suitable filters which allow
the expanding gas to exhaust but which prevents loss of metallic
powders. Any particles which do not adhere to the deposition die
(i.e., over-sprayed particles) can be collected from the bottom of
this chamber and subsequently re-melted for further spraying and
deposition processes. Thus, any oversprayed particles of metal can
be re-used in this process (or could be used as a powdered metal
product) and as no expensive operations have been performed on this
metal (it has only been atomised) the financial loss incurred by
overspraying is minimal. The chamber can be constructed simply of
welded mild steel panels which may have water-cooled jackets fitted
where necessary to remove surplus heat and so maintain the surfaces
of the spray chamber at temperatures low enough for safe working
during operation. If desired, an inert or reducing atmosphere can
be maintained up to, for example, the forging press and also during
any subsequent forging (or other forming) operation.
The collecting surface onto which the hot metal particles are
deposited can be of a suitable shape and if the surface also acts
as the lower die of a die set in, for instance, a forging operation
it must be capable of withstanding the stresses involved. In
addition it must be resistant to wear that may occur during the
deposition of hot metal particles and the subsequent forming
operation. Typically, dies are made from nickel-chromium-molybdenum
steel for the production of forged steel articles or
chromium-molybdenum-vanadium steel for the forging of non-ferrous
alloys or for steel forgings where lower temperatures are
encountered. Alternatively, nickel based alloys or metallic
carbides can be used to make the dies.
One or more sprays of hot, metal particles may be employed in order
to obtain the required rate of deposition and/or the required area
of deposition. In those cases which involve several sprays, they
may be employed to act either simultaneously, or consecutively to
produce the required shape and mass of the sprayed deposit. These
objectives may also be achieved by relative movements between the
deposition die and the spray (or sprays) of hot, metal particles.
These movements can occur in any suitable plane (e.g., laterally or
axially) and can be of any suitable form (e.g., rotary or
oscillatory).
To prevent deposition occurring on selected areas of the deposition
die a suitably shaped masking plate may be used; sprayed metal
particles being deposited onto this in preference to the deposition
die block. When required the masking plate or plates can be removed
before the metal deposited into the die cavity is forged or
pressed. For example, such masking plates can be used at the edges
of the deposition die so that metal is deposited only in the shaped
section of the die, i.e., metal which normally would overspray the
shaped die is deposited onto the masking plates. The masking plate
or plates can be arranged to move away from deposition die at a
rate similar to that at which the thickness of the deposit builds
up. Over-spraying of the deposition die can also be reduced by
modifying the shape of the spray by suitable changes in the
arrangement and geometry of the atomising gas-jets. Alternatively,
or additionally, any surplus metal that has been deposited on the
die block can be removed by other mechanical means, for example, by
means of a suitably shaped trimming tool or cutter. This is
normally carried out before the subsequent forming operation.
With prior methods which employ the spray depositing of metal
particles to form certain semi-finished products, e.g., metallic
strip electrodes for condensers, or metal shapes of long length and
relatively thin section (e.g., strip material) it is essential that
the thickness of the sprayed deposit is uniform or substantially
uniform across the width of the deposit, particularly when a
rolling operation is employed, as non-uniformities in the thickness
of the deposit can result in cracking of the strip during the
rolling operation. This is not the case in the present invention as
greater variations in the thickness of the deposit can be
tolerated. Surplus material flows out between the shaped dies
during the forging, pressing or like forming operation and can then
be removed, for example, by the shearing action of the two suitably
designed dies as they are loaded against each other. In addition,
the deposition surface of the die cavity does not usually require
special treatment to ensure optimum adhesion prior to deposition,
as the surface finish of the formed component conforms to the
surface finish of the dies. In certain instances, however, the
application of a suitable releasing agent to the surfaces of the
dies aids the ejection of the formed component from the dies.
Under certain circumstances, it is desirable that the porosity of
the coherent mass of deposited metal particles is minimal. To
achieve this requirement the temperature, size, velocity and degree
of solidification of the metal particles have to be such that on
impacting the die surface they readily flatten, coalesce and
build-up to form a coherent deposit which has a fine grain
structure (this is essential to reduce segregation problems
particularly in highly alloyed materials).
It has been mentioned previously that the condition of the deposit
can depend to a large extent on the temperature, size and velocity
of the hot particles on impacting the deposition die and as these
factors can be altered by variations in the process parameters; for
example, the temperature of the deposit can be increased simply by
increases in the temperature of the deposition die, the molten
metal prior to atomising and the flow-rate of the molten metal;
alternatively reductions in the spray height, the flow-rate and the
velocity of the atomising gas also result in an increase in the
temperature of the mass of particles in the deposition die. This
facility to vary the conditions of the sprayed deposit by simple
variations in one, or several, of the many operational parameters
is highly desirable and is indicative of the flexibility in
operation of the invention.
EXAMPLE
Operational conditions for the production of a typical forged or
pressed non-porous aluminium (or aluminium alloy) precision
component in accordance with the invention are given below:
The metal to be atomised is heated to between 100.degree. and
200.degree.C above its melting point and then poured through a
nozzle (between 3 and 7 mm bore), at the exit of which the stream
of molten metal is atomised by means of high velocity jets of
nitrogen gas. The atomising gas is fed to an annular atomising
system which is located at the periphery of the molten stream.
Generally gas is supplied to the atomiser at pressures greater than
approximately 30 lb/in.sup.2 gauge; the actual value depending on
the design of the atomiser, the required temperature of deposition,
the diameter of the molten metal stream, etc. A typical gas
pressure for atomising a 3 mm diameter stream of molten aluminium
is 60 lbs/in.sup.2 gauge, the atomiser comprising 12 outlet holes
each 1 mm in diameter, on a pitch circle diameter of 15 mm. The
temperature of the atomising gas can be varied over a considerable
range, but is usually at room temperature (i.e., about 20.degree.C)
and the gas consumption is generally greater than 700 ft.sup.3
/ft.sup.3 of metal sprayed. By these means a spray of hot metal
particles of median size between 100 and 200 microns can be
obtained.
The resultant spray of hot metal particles is directed into a
deposition die, which is placed at such a distance from the
atomising system so that most of the particles, on impacting the
die are at the solidus temperature of the metal or are just solid.
Typical values of the distance between the atomising system and the
surface of the deposition die (i.e., the spray distance), for the
production of an aluminium (or aluminium alloy) component, are in
the range of 20 cm to 45 cm.
On impacting the die the particles flatten and build up to form a
coherent mass at a temperature suitable for the subsequent
hot-forming operation which can be performed without the addition
of heat. The approximate hot-working temperature for aluminium
and/or its alloys is typically 450.degree.C. The die can be held at
a desired temperature; e.g., between 100.degree. and 200.degree.C,
to prevent drastic cooling of the initially deposited layers of
particles.
The pressure required for hot-working depends primarily on the
alloy used and its temperature. In the case of a forged or pressed
aluminium or aluminium alloy component the pressure applied to the
deposited metal, between the deposition and top dies, can be up to
13 tons/in.sup.2 of face area of the component. Generally the
sprayed deposit should be transferred and hot formed in an inert
gas atmosphere (e.g., in a nitrogen atmosphere). After completion
of the hot-forming operation the shaped component can be ejected
from the dies.
It has been mentioned above that shaped precision metal products
containing a controlled degree of porosity can also be manufactured
by the process of this invention. In this way aluminium (or
aluminium alloy) parts, having a porosity of approximately 50
percent, can be produced for use as impact energy absorbers as, for
example, during collisions involving automobiles. In this instance,
it is desirable that the rigid cabin which contains the driver and
passengers is protected in front and at the rear by respective
crumpling zones formed from deformable parts having a high energy
absorption capacity. Spray-formed, porous parts of this nature may
also be used as energy absorbing liners in the protective covers of
highspeed grinding wheels.
Products having a relatively high value of porosity (50 percent)
may be produced by a spray of coarse, metal particles which, at the
moment of deposition are moving slowly and have solidified or are
mostly solid. On impacting the deposition die these particles do
not deform readily and a shaped, coherent deposit with large
interparticulate voids is formed.
The degree of porosity of spray-formed precision articles can be
controlled easily by variations in the process parameters, as
discussed above, so that shaped, metal articles can be manufactured
over a wide range of porosities. In this way, porous bearings,
filters and the like can be manufactured simply by spraying the
metal particles at the appropriate conditions into a suitably
shaped die. If necessary the sprayed deposit can be pressed to
obtain the required value of porosity and/or a suitable shape.
The invention will be described further, by way of example, with
reference to the accompanying diagrammatic drawings, in which:-
FIG. 1 is a section through an apparatus for making shaped
precision articles in accordance with the invention;
FIG. 2 is a sectional view of the article produced by the apparatus
shown in FIG. 1;
FIG. 3 shows a section through an apparatus in which the sprayed
deposit is removed from the collecting surface before being
worked;
FIG. 4 shows two stages in producing an extruded article in
accordance with the invention; and
FIG. 5 shows the stages involved in die-stamping a strip of sprayed
metal.
FIG. 1 shows an apparatus for making shaped precision articles
according to the invention, such apparatus comprising a tundish 10
filled with molten metal or molten metal alloy 11. The tundish is
formed into a nozzle 12 at its lower end which is surrounded by an
annular gas atomiser 13 having outer and inner gas galleries 14, 15
respectively. Gas is supplied through delivery pipes 16 to issue
through angled jets 17 connecting with the inner gallery 15. Gas
from the jets 17 serves to break up the stream of molten metal
issuing from the nozzle into a spray 18 which is directed at a
collecting surface in the form of a deposition die 19, where the
sprayed particles form a hot, coherent deposit 20. The waste
atomising gas leaves the atomising chamber 21 through dust filters
22.
The die 19 is mounted on a die block 23 which is itself suitably
supported on a die block support 24. Inert gas cover is maintained
in a press chamber 25 connected to the atomising chamber 21, and an
operating arm 26 is attached to the die block 23 for transferring
the deposit 20 in the die 19 into the press chamber 25. The chamber
25 is provided with a fixed lower die holder 27 and a top die 28
mounted on a top die block 29 which is movable, for example,
mechanically, hydraulically or pneumatically. Seals 30 prevent the
ingress of air into the chamber 25.
When the deposition die 19 is in position on the lower die holder
27, the top die block is operated to close the top die 28 onto the
die 19, thus hot-forming a shaped precision article 31, as
illustrated in FIG. 2, which can be removed for the cycle to be
repeated.
FIG. 3 shows a similar apparatus to that illustrated in FIG. 1.
However, in this instance, the hot metal particles are sprayed onto
a flat collecting surface 32 to form an unshaped deposit 33 which
is ejected from the surface 32 to be hot-worked between shaped top
and bottom dies 34, 35 respectively under the action of a press
(not shown) thereby producing a shaped precision article 36.
In FIG. 4, an apparatus is illustrated which is suitable for
forming an extruded precision article according to the invention.
In this case, the metal spray 18 is directed into a cylindrical
container 37 provided with an extrusion die 37', to form a hot,
coherent deposit 38. The extrusion die 37 is then transferred to a
position wherein a piston 39 of an extrusion press (not shown) can
co-operate with the container 37 to extrude a precision metal
article 40 (see FIG. 4B).
Referring finally to FIG. 5, the spray of metal 18 is directed onto
a moving collecting surface 41 to form a hot, coherent layer 42
which is transferred to a die-stamping press comprising a top die
43 which co-operates with a bottom die 44 to stamp out a hot-worked
product 45 (see FIG. 5B and FIG. 5C). The waste deposit 46 is
returned to the tundish 10 to be recycled.
The invention is not limited to the precise details of the
foregoing examples and variations may be made thereto within the
scope of the appended claims. For example, the deposit may be cold
worked by the die when, for instance it is desired to form a highly
porous article.
In the FIG. 5 embodiment, instead of a die-stamping press, a
forging press may be used to produce articles from a continuous
layer of sprayed deposit.
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