Member and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-11980964-B2
Application number	US-201917053814-A
Country	US
Kind code	B2
Filing date	Jul 2, 2019
Priority date	Jul 6, 2018
Publication date	May 14, 2024
Grant date	May 14, 2024

Abstract

A member includes a first metallic region made of a first material; a second metallic region made of a second material that is a different from the first material; and a mix region made of mixture of the first and second materials between the first and second metallic region. In a cross-sectional view, an interface between the first metallic region and the mix region is represented by a line having a first curved line protruding toward the first metallic region and a second curved line protruding toward the first metallic region, and an angle at a cross point of the first and second curved lines, the angle being made by a tangent line of the first curved line and a tangent line of the second curved line in a region of the first metallic region, is equal to or larger than 70 degrees and smaller than 180 degrees.

First claim

The invention claimed is:

1. A member comprising:
a first metallic region made of a first material;
a second metallic region made of a second material that is a different material from the first material; and
a mix region made of mixture of the first material and the second material, between the first metallic region and the second metallic region,
wherein, in a cross-sectional view,
an interface between the first metallic region and the mix region is represented by a line having a first curved line protruding toward the first metallic region and a second curved line protruding toward the first metallic region, and
an angle at a cross point of the first curved line and the second curved line is equal to or larger than 70 degrees and smaller than 180 degrees, the angle being made by a tangent line of the first curved line and a tangent line of the second curved line in a region of the first metallic region;
wherein a dent portion is formed in the first metallic region,
the second metallic region is formed inside the dent portion, and
the first metallic region is provided with a protrusion extending toward an upper surface of the dent portion, in the middle of a plane extending from a bottom surface of the dent portion to an upper surface of the first metallic region out of the dent portion.

2. The member according to claim 1 ,
wherein the angle is equal to or larger than 90 degrees and smaller than 180 degrees.

3. The member according to claim 1 ,
wherein the angle is equal to or larger than 90 degrees and smaller than 180 degrees, and
the second material is a material made of cermet.

4. The member according to claim 1 ,
wherein, inside the second metallic region, a content ratio of the second material in a region farther than the mix region from the first metallic region is larger than a content ratio of the second material in the mix region.

5. The member according to claim 1 ,
wherein the member is a mold member configuring a part of a mold.

6. A member comprising:
a first metallic region made of a first material; and
a second metallic region made of a second material that is a different material from the first material,
wherein, in a cross-sectional view,
an interface between the first metallic region and the second metallic region is represented by a line having a first curved line protruding toward the first metallic region and a second curved line protruding toward the first metallic region, and
an angle at a cross point of the first curved line and the second curved line is equal to or larger than 70 degrees and smaller than 180 degrees, the angle being made by a tangent line of the first curved line and a tangent line of the second curved line in a region of the first metallic region;
wherein a dent portion is formed in the first metallic region,
the second metallic region is formed inside the dent portion, and
the first metallic region is provided with a protrusion extending toward an upper surface of the dent portion, in the middle of a plane extending from a bottom surface of the dent portion to an upper surface of the first metallic region out of the dent portion.

7. The member according to claim 6 ,
wherein the angle is equal to or larger than 90 degrees and smaller than 180 degrees.

8. The member according to claim 6 ,
wherein the angle is equal to or larger than 90 degrees and smaller than 180 degrees, and
the second material is a material made of cermet.

9. The member according to claim 6 ,
wherein the member is a mold member configuring a part of a mold.

10. A method of manufacturing a member comprising the steps of:
(a) preparing a base member made of a first material;
(b) forming a plurality of stepwise stairs each having an upper surface, a side surface and a corner by machining the base member; and
(c) buildup-welding a shaped article on the base member by using an additive manufacturing method that supplies a powder material that is a second material that is different from the first material into a spot diameter of laser light while emitting the laser light,
wherein the laser light is emitted to the base member so as to be emitted to at least one of the corners.

11. The method of manufacturing the member according to claim 10 ,
wherein the powder material is a material made of cermet.

12. The method of manufacturing the member according to claim 10 ,
wherein the step (c) includes the steps of:
(c1) forming a first weld object on a first surface of the base member by supplying the powder material into the spot diameter of the laser light while emitting the laser light to the base member; and
(c2) forming a second weld object on a surface of the first weld object and a second surface of the base member, the second surface being adjacent to the first surface, by supplying the powder material into the spot diameter of the laser light while emitting the laser light to the first weld object.

13. The method of manufacturing the member according to claim 10 ,
wherein the step (c) includes the steps of:
(c3) forming a part of the shaped article while displacing a laser head emitting the laser light along a first track; and
(c4) forming another part of the shaped article while displacing the laser head along a second track,

when a length of the side surface, the length being parallel to an emission direction of the laser light, is defined as “L 1 ” while a length of the upper surface, the length being in perpendicular to the emission direction of the laser light, is defined as “L 2 ”, the spot diameter of the laser light is larger than L 2 , and
the second track includes a track made by displacing a part of the first track by (i) L 1 in a direction that is parallel to the side surface as well as perpendicular to an elongation direction of the corner and (ii) L 2 in a direction that is parallel to the upper surface as well as perpendicular to the elongation direction of the corner.

14. The method of manufacturing the member according to claim 10 ,
wherein, when a length of the side surface is defined as L 1 while a length of the upper surface is defined as L 2 , a “L 1 /L 2 ” value of each stair is equal to or smaller than 4.

15. The method of manufacturing the member according to claim 10 ,
wherein an angle of the corner of each of the plurality of stairs is equal to or larger than 90 degrees and equal to or smaller than 120 degrees.

16. The method of manufacturing the member according to claim 10 ,
wherein the member is a mold member configuring a part of a mold.

Assignees

• Proterial Ltd

Inventors

• Kunitomo Kenichiro
• Koseki Shuho
• Shiratori Hiroshi
• Kawanaka Hirotsugu

Classifications

• B23K26/0093 Primary

  combined with mechanical machining or metal-working covered by other subclasses than B23K · CPC title

• B23K11/0013

  welding for purposes other than joining, e.g. build-up welding · CPC title

• B23K26/144 Primary

  the fluid stream containing particles, e.g. powder · CPC title

• B23K26/342

  Build-up welding · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title