US3631745A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of fabricating metal dies
Assignee: Lockheed Martin Corp
•
Filing: 1970-05-22
•
Granted: 1972-01-04
•
Expires: 1990-05-22
Abstract
Abstract A method of fabricating by thermal spraying a die or mold in regard to the manufacture of a high-strength material product, titanium being an example of the material of such product. A wooden or plaster pattern is made or cast into the form of the die or mold, and thereafter an inorganic matrix or substrate of a predetermined thickness is cast thereover. The matrix is oven or air cured, after which it is separated from the pattern and the die material is thermally sprayed over same after the matrix has been preheated to the temperature of the sprayed material. The preheat temperature is maintained during the thermal spraying process. The combination is then placed in a preheated oven, for slow cooling. Due to different contracting rates of the materials of the matrix and die, a clean metallic die surface results. After such cooling, the combination is separated and any excess spray is removed. A reinforcing mixture is then introduced into the cavity formed in the die. Upon cooling and hardening of such mixture, the die or mold is provided with great structural integrity in its shell and provides for a tough, high-temperature characteristic. A modified embodiment of and illustrative examples of dies or molds formed from this process are included in the disclosure.
Inventors
- 👤 George J Walkey
- 👤 Frank N Adgate
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 19:35
CPC Classifications
B; B21; B21D; B21D37/00; B21D37/20
Claims Analysis
Total Claims: 19
Claim 1
Independent Claim
21 words
A method for manufacturing a die as defined in claim 1 wherein the inorganic material is a metal or metal alloy.
Claim 2
Dependent Claim
18 words
A method for manufactuRing a die as defined in claim 1 wherein the inorganic material is a ceramic.
Claim 3
Dependent Claim
26 words
A method for manufacturing a die as defined in claim 1 including: heating the reinforcing material so as to cause it to adhere to the die.
Claim 4
Dependent Claim
64 words
A method for manufacturing a die as defined in claim 1 including: depositing a reinforcing material upon the die opposite the die surface; depositing a binder material upon the die opposite the die surface, the binder material being intermixed with the reinforcing material; and heating and then cooling the binder material so as to cause it to adhere the reinforcing material to the die.
Claim 5
Independent Claim
94 words
A method for manufacturing a die comprising: preparing a pattern of predetermined shape; depositing a parting material upon the pattern so as to form a parting coating; depositing a matrix upon the parting coating; curing the matrix; removing the matrix from the parting coating and pattern; heating the matrix; depositing a layer of inorganic material upon the cured and heated matrix so as to form a die surface therebetween; cooling the matrix and the inorganic material at a controlled rate; and removing the inorganic material from the matrix so as to form a die.
Claim 6
Dependent Claim
28 words
A method for manufacturing a die as defined in claim 6 wherein the matrix is heated to approximately 50 percent of the yield strength of the inorganic material.
Claim 7
Dependent Claim
48 words
A method for manufacturing a die as defined in claim 6 including: depositing a mixture of binder and reinforcing material upon the die opposite the die surface; and heating and cooling the mixture so as to cause the binder material to adhere the reinforcing material to the die.
Claim 8
Independent Claim
97 words
A method of manufacturing a die comprising: preparing a desirably shaped pattern; depositing a parting coating upon the pattern; depositing an inorganic matrix upon the coated pattern; curing the matrix; removing the matrix from the pattern; heating the matrix; depositing a metallic layer upon the heated and cured matrix so as to form a die; cooling the matrix and the die; removing the matrix from the cooled die; depositing a reinforcing material upon the die opposite the forming surface of the die; and curing the reinforcing material so as to cause it to adhere to the die.
Claim 9
Dependent Claim
47 words
A method of manufacturing a die as defined in claim 9 including: depositing a binder upon the die opposite the die surface, the binder being intermixed with the reinforcing material; and curing the binder so as to cause it to adhere the reinforcing material to the die.
Claim 10
Dependent Claim
45 words
A method of manufacturing a die as defined in claim 9 wherein the matrix and the die are cooled in a preheated oven at a temperature approximately equal to the temperature to which the matrix was heated prior to having the metallic layer deposited thereon.
Claim 11
Independent Claim
122 words
A method of manufacturing a die comprising: preparing a desirably shaped pattern; depositing a parting coating upon the pattern; depositing an inorganic matrix upon the coated pattern; curing the matrix; removing the matrix from the coated pattern; heating the matrix; depositing a metallic layer upon the heated matrix at a temperature substantially equal to the temperature of the heated matrix so as to form a die shell having a die surface; cooling the heated matrix and the die shell; removing the cooled matrix from the die shell; depositing a mixture of reinforcing material and binder upon the die shell opposite the die surface; and curing said mixture so as to cause the binder to adhere the reinforcing material to the die shell.
Claim 12
Dependent Claim
25 words
A method of manufacturing a die as defined in claim 12 wherein said matrix and said metallic layer have substantially equal thermal coefficients of expansion.
Claim 13
Dependent Claim
22 words
A method of manufacturing a die as defined in claim 12 wherein said matrix is organic but becomes inorganic upon being heated.
Claim 14
Dependent Claim
30 words
A methOd of manufacturing a die as defined in claim 12 wherein the matrix is heated to approximately 50 percent of the yield strength of the metallic layer subsequently thereon.
Claim 15
Dependent Claim
28 words
A method of manufacturing a die as defined in claim 12 wherein the mixture comprises approximately 5 percent by volume binder and 95 percent by volume reinforcing material.
Claim 16
Dependent Claim
25 words
A method of manufacturing a die as defined in claim 17 wherein the binder is sodium silicate and wherein the reinforcing material is metal shot.
Claim 17
Independent Claim
93 words
A method of manufacturing a die comprising: preparing a pattern of predetermine shape; depositing a parting coating upon the pattern; depositing a matrix upon the coated pattern; curing the matrix; removing the matrix from the coated pattern; depositing a first die material upon the matrix so as to form a die shell having a die surface; removing the die shell from the matrix; depositing a binder material upon the die shell opposite the die surface; and depositing a second die material upon the binder material in reinforcing relationship with the first die material.
Claim 18
Dependent Claim
29 words
A method of manufacturing a die as defined in claim 18 including depositing a binder material upon the second die material in reinforcing relationship with the first die material.
Claim 19
Dependent Claim
31 words
A method of manufacturing a die as defined in claim 19 wherein the first and the second die materials are metal or metal alloys and the binder material is epoxy resin.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1975-01-03 | 1975-07-05 | 1976-01-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1979-01-03 | 1979-07-05 | 1980-01-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1983-01-03 | 1983-07-05 | 1984-01-04 | $7700.00 | Window Closed / Lapsed |