Methods of Manufacturing Corrosion Resistant Bimetal Parts and Bimetal Parts Formed Therefrom

Patent metadata

Field	Value
Publication number	US-2016339540-A1
Application number	US-201615159573-A
Country	US
Kind code	A1
Filing date	May 19, 2016
Priority date	May 19, 2015
Publication date	Nov 24, 2016
Grant date	—

Abstract

The methods including applying a corrosion resistant alloy to a metal substrate to create a bimetal blank. The bimetal blank can undergo a variety of shaping and machining operations to form the net shape and internal structures of the part. Further, the part can undergo a finishing operation (e.g. polishing) to create the desired cosmetic appearance on the exterior surfaces and remove any surface imperfections resulting from the shaping and machining operations.

First claim

What is claimed is:

1 . A method of forming a metal part, comprising:
providing a metal substrate; applying a corrosion resistant alloy to at least a portion of a surface of a metal substrate to create a bimetal blank; shaping the bimetal blank to create a bimetal preform; and machining the bimetal preform to form internal structures and an exterior geometry of the bimetal part.

2 . The method of forming a metal part according to claim 1 further comprising finishing the bimetal part to polish exterior surfaces of the bimetal part.

3 . The method of forming a metal part according to claim 1 wherein the step of applying the corrosion resistant alloy includes coating the metal substrate with the corrosion resistant alloy.

4 . The method of forming a metal part according to claim 1 wherein the step of applying the corrosion resistant alloy includes cladding the metal substrate with the corrosion resistant alloy.

5 . The method of forming a metal part according to claim 1 wherein the metal substrate is a nonmagnetic metal.

6 . The method of forming a metal part according to claim 1 wherein the metal substrate is a stainless steel.

7 . The method of forming a metal part according to claim 1 wherein the corrosion resistant alloy is a cobalt chrome alloy.

8 . The method of forming a metal part according to claim 7 wherein the cobalt chrome alloy comprises at least 20% chrome by weight.

9 . The method of forming a metal part according to claim 1 wherein the corrosion resistant alloy is a metallic-glass forming alloy.

10 . The method of forming a metal part according to claim 1 wherein the corrosion resistant alloy has a hardness of at least 300 HV.

11 . A method of forming a bimetal part, comprising:
forming a shaped metal preform; applying a corrosion resistant alloy to at least a portion of a surface of the metal preform to create a bimetal preform; and shaping the bimetal preform to create the bimetal part.

12 . The method of forming a metal part according to claim 11 wherein the step of forming the shaped metal preform includes forging, metal injection molding, or combinations thereof.

13 . The method of forming a metal part according to claim 11 wherein the step of applying the corrosion resistant alloy includes coating the metal substrate with the corrosion resistant alloy.

14 . The method of forming a metal part according to claim 11 wherein the step of applying the corrosion resistant alloy includes cladding the metal substrate with the corrosion resistant alloy.

15 . The method of forming a metal part according to claim 11 wherein the metal substrate is a nonmagnetic metal.

16 . The method of forming a metal part according to claim 10 wherein the metal substrate is a stainless steel.

17 . The method of forming a metal part according to claim 10 wherein the corrosion resistant alloy is a cobalt chrome alloy.

18 . The method of forming a metal part according to claim 17 wherein the cobalt chrome alloy comprises at least 20% chrome by weight.

19 . The method of forming a metal part according to claim 10 wherein the corrosion resistant alloy has a hardness of at least 300 HV.

20 . A housing for an electronic device comprising:
a metal substrate; and a corrosion resistant alloy coating on at least a portion of an exterior surface of the metal substrate; the coating comprising at least 20% chrome by weight percent and having a hardness of at least 300 HV.

Assignees

• Apple Inc

Inventors

• Kuehmann Charles J
• Werner Christopher M
• Ely Colin M
• Wright James A

Classifications

• B32B15/013 Primary

  one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium · CPC title

• C23C2/04

  characterised by the coating material · CPC title

• B23K2103/08

  Non-ferrous metals or alloys · CPC title

• B23K2103/05

  Stainless steel · CPC title

• H01B1/02

  mainly consisting of metals or alloys · CPC title