Die-casting system with a refractory metal alloy surface

Patent metadata

Field	Value
Publication number	US-2016296997-A1
Application number	US-201514682411-A
Country	US
Kind code	A1
Filing date	Apr 9, 2015
Priority date	Apr 9, 2015
Publication date	Oct 13, 2016
Grant date	—

Abstract

A die-casting mold, includes a die insert including a mold surface with a refractory metal alloy layer and a method of manufacturing a die-casting mold, including machining a mold surface of a die insert such that the mold surface is a near net shape with respect to a workpiece and applying a refractory metal alloy layer onto the die insert.

First claim

1 . A die-casting mold, comprising:
a die insert including a near net shape mold surface with a refractory metal alloy layer, wherein the refractory metal alloy layer is manufactured from a compositionally homogeneous powder mixture that is utilized in a laser cladding operation to produce the refractory metal alloy layer.

2 . The mold as recited in claim 1 , wherein the mold surface is undersized with respect to a workpiece.

3 . The mold as recited in claim 2 , wherein the refractory metal alloy layer is sized to form the workpiece.

4 . The mold as recited in claim 1 , wherein the refractory metal alloy layer includes Anviloy®.

5 . The mold as recited in claim 1 , wherein the refractory metal alloy layer includes Tungsten (W).

6 . The mold as recited in claim 1 , wherein the refractory metal alloy layer is W90Ni4Mo4Fe2.

7 . The mold as recited in claim 1 , wherein the refractory metal alloy layer is manufactured from a compositionally homogeneous powder mixture that is utilized in a laser cladding operation to produce the refractory metal alloy layer.

8 . The mold as recited in claim 7 , wherein the compositionally homogeneous powder mixture includes tungsten (W) powder of less than about 44 microns particle size and other powders of less than about 74 microns particle size.

9 . The mold as recited in claim 8 , wherein the other powders include Nickel (Ni), Molybdenum (Mo,) and Iron (Fe) powder.

10 . The mold as recited in claim 1 , wherein the refractory metal alloy layer is about 0.010″ in thickness.

11 . The mold as recited in claim 1 , further comprising a die housing, the die insert at least partially receivable into the die housing.

12 . A method of manufacturing a die-casting mold, comprising:
machining a mold surface of a die insert such that the mold surface is undersized with respect to a desired near net shape with respect to a workpiece; applying a refractory metal alloy layer onto the die insert to form a near net shape wherein the refractory metal alloy layer is manufactured from a compositionally homogeneous powder mixture that is utilized in a laser cladding operation to produce the refractory metal alloy layer; and performing a post-clad machining operation to finalize the near net shape mold surface with respect to the workpiece.

13 . The method as recited in claim 12 , wherein the die insert is manufactured of steel.

14 - 15 . (canceled)

16 . The method as recited in claim 12 , further comprising ball milling a powder mixture to form the compositionally homogeneous powder mixture.

17 . The method as recited in claim 12 , further comprising ball milling a powder mixture including tungsten (W) powder of less than about 44 microns particle size, and other powders of less than about 74 microns particle size to form the compositionally homogeneous powder mixture.

18 . The method as recited in claim 17 , wherein the other powders include Nickel (Ni), Molybdenum (Mo,) and Iron (Fe) powder.

19 . The method as recited in claim 12 , wherein a powder mixture forming the compositionally homogeneous powder mixture includes tungsten (W) powder of about 325M.

20 . The method as recited in claim 19 , wherein the powder mixture includes other powders of about 200M.

21 . The mold as recited in claim 1 , wherein a hardness is controlled by a fine microstructure in the refractory alloy layer.

22 . The method as recited in claim 12 , further comprising adjusting a rate of solidification via the laser cladding operation to control the hardness by control of a fine microstructure in the refractory alloy layer.

Assignees

• United Technologies Corp

Inventors

• Kwang Lim Yuan
• Andrew Tan Yong Sheng
• Mahmood Muhammad Azzli Bin
• Seng Loh Yan

Classifications

• B22F10/66

  by mechanical means · CPC title

• B22F10/34

  of powder characteristics, e.g. density, oxidation or flowability · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/38

  to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures · CPC title

• C22C1/045

  Alloys based on refractory metals · CPC title