Spray forming process for producing molds, dies and related tooling

McHugh, Kevin M; Key, James F

Title: Spray forming process for producing molds, dies and related tooling

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Abstract

A method for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers.

Inventors:

McHugh, Kevin M ^[1]; Key, James F ^[1]

Idaho Falls, ID

Issue Date:: 1998-01-01

Research Org.:: Idaho National Lab. (INL), Idaho Falls, ID (United States)

OSTI Identifier:: 871371

Patent Number(s):: 5718863

Assignee:: Lockheed Idaho Technologies Company (Idaho Falls, ID)

Patent Classifications (CPCs):: B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29K - INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS

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B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29K - INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
B29K2105/126 - {Whiskers, i.e. reinforcement in the form of monocrystals}

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS
B29C41/08 - Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder {
B29C2033/3864 - {Spraying at least one layer to create the mould}

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
B33Y40/00 - Auxiliary operations or equipment, e.g. for material handling

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS
B29C33/3857 - {by making impressions of one or more parts of models, e.g. shaped articles and including possible subsequent assembly of the parts}
B29C41/365 - {Construction of spray-up equipment, e.g. spray-up guns

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29K - INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
B29K2105/12 - of short lengths, e.g. chopped filaments, staple fibres or bristles

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
B33Y30/00 - Apparatus for additive manufacturing

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DOE Contract Number:: AC07-94ID13223

Resource Type:: Patent

Country of Publication:: United States

Language:: English

Subject:: spray; forming; process; producing; molds; dies; related; tooling; method; manufacturing; near-net-shape; toolings; liquid; material; molten; metal; metallic; alloys; polymers; atomized; fine; droplets; temperature; velocity; gas; deposited; pattern; quenching; provides; heat; sink; allowing; undercooled; partially; solidified; formed; in-flight; composites; combining; solid; particles; whiskers; fibers; velocity gas; metallic alloys; metallic alloy; liquid material; solid particles; heat sink; molten metal; spray forming; atomized droplets; solid particle; forming process; related tooling; related toolings; near-net-shape molds; forming manufacturing; producing molds; /264/164/425/

Citation Formats


                    McHugh, Kevin M, and Key, James F. Spray forming process for producing molds, dies and related tooling.  United States: N. p., 1998. 
        Web.

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                    McHugh, Kevin M, & Key, James F. Spray forming process for producing molds, dies and related tooling.  United States.

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                    McHugh, Kevin M, and Key, James F. Thu .  
        "Spray forming process for producing molds, dies and related tooling".  United States.  https://www.osti.gov/servlets/purl/871371.

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@article{osti_871371,

  title        = {Spray forming process for producing molds, dies and related tooling},

  author       = {McHugh, Kevin M and Key, James F},

  abstractNote = {A method for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {1998},

  month        = {1}

}

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