Mold and production method therefor

Patent metadata

Field	Value
Publication number	US-11820048-B2
Application number	US-201716464301-A
Country	US
Kind code	B2
Filing date	Nov 27, 2017
Priority date	Nov 28, 2016
Publication date	Nov 21, 2023
Grant date	Nov 21, 2023

Abstract

The purpose of the present invention is to provide a mold having both good adhesion resistance and smoothness, and a production method therefor. Provided is a mold made of a composite material comprising hard phases and metal phases characterized in that the mold has a reinforced layer made of hard phases for a working surface and the working surface satisfies the arithmetic average roughness Ra≤0.1 μm and skewness Rsk≤−0.01. Also provided is a production method for a mold made of a composite material comprising hard phases and metal phases characterized in having: a shaping step for working the surface of the mold made of said composite material and adjusting to Ra≤0.1 μm; and after the shaping step, a surface layer-modifying step for etching the surface of the mold adjusted to Ra≤0.1 μm and removing the metal phases near the surface.

First claim

The invention claimed is:

1. A mold made of a composite material comprising a hard phase and a metal phase, wherein:
the mold has a reinforced layer composed of a hard phase for a working surface and voids in the reinforced layer, wherein the hard phase is formed by removing a metal phase from the working surface to faun the voids in the reinforced layer and so that the reinforced layer is free of the metal phase, and
the working surface satisfies an arithmetic average roughness of Ra≤0.1 μm and skewness Rsk≤−0.01.

2. The mold according to claim 1 , wherein the working surface of the mold satisfies skewness Rsk≤−1.0.

3. The mold according to claim 2 , wherein the hard phase is WC, and the metal phase is Co.

4. The mold according to claim 1 , wherein the hard phase is WC, and the metal phase is Co.

5. A mold made of a composite material comprising a hard phase and a metal phase, wherein:
the mold has a reinforced layer composed of a hard phase for a working surface and voids in the reinforced layer, wherein the hard phase is formed by removing a metal phase from the working surface to form the voids in the reinforced layer and so that the reinforced layer is free of the metal phase,
a hard film is provided on a top surface of the reinforced layer,
the hard film is one or more kinds selected from at least one kind of carbide, nitride, carbonitride, oxide, and boride of Groups 4, 5, and 6 transition metals, Si, and Al, and diamond-like carbon, and
wherein a surface of the hard film satisfies an arithmetic average roughness of Ra≤0.1 μm and skewness Rsk≤−1.0.

6. A production method for a mold made of a composite material comprising a hard phase and a metal phase, the method comprising:
a shaping step for working a surface of the mold made of the composite material and adjusting to Ra≤0.1 μm; and
a surface layer-modifying step after the shaping step for etching the surface of the mold adjusted to Ra≤0.1 μm and removing the metal phase near the surface to form a reinforced layer composed of the hard phase for a working surface and voids in the reinforced layer, wherein the reinforced layer is free of the metal phase, and the working surface satisfies an arithmetic average roughness of Ra≤0.1 μm and skewness Rsk≤−0.01.

7. The production method for a mold according to claim 6 ,
wherein the surface layer-modifying step is wet etching using an acidic solution.

8. The production method for a mold according to claim 6 , comprising:
a coating step of forming a hard film of one or more kinds selected from at least one kind of carbide, nitride, carbonitride, oxide, and boride, of Groups 4, 5, and 6 transition metals, Si, and Al, and diamond-like carbon on the surface of the mold after the surface layer-modifying step.

9. The production method for a mold according to claim 7 , comprising:
a coating step of forming a hard film of one or more kinds selected from at least one kind of carbide, nitride, carbonitride, oxide, and boride, of Groups 4, 5, and 6 transition metals, Si, and Al, and diamond-like carbon on the surface of the mold after the surface layer-modifying step.

Assignees

• Proterial Ltd

Inventors

• Shinno Daiki
• Koseki Shuho

Classifications

• B29C33/3842 Primary

  Manufacturing moulds, e.g. shaping the mould surface by machining · CPC title

• B22D17/2209 Primary

  Selection of die materials (for permanent moulds B22C9/061) · CPC title

• C23F17/00

  Multi-step processes for surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by subclass C21D or C22F or class C25 (coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups C23C2/00 - C23C26/00, or by combinations of methods providedfor in subclasses C23C and C25D, C23C28/00) · CPC title

• B22D17/22 Primary

  Dies (manufacture, see the appropriate class, e.g. B23P15/24); Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies · CPC title

• C23F1/28

  for etching iron group metals · CPC title