Spray forming process for producing molds, dies and related tooling
AssigneeLockheed Idaho Technologies Company
InventorsKevin M. McHugh, James F. Key
Life of this patent
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Abstract
A method for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers.
Claims21
A process for the spray forming manufacture of near net shape molds, dies, and related toolings, the steps comprising:
- (a) providing a pattern of a mold to be formed;
- (b) providing a liquid capable of forming a mold, said liquid being pressurized in a pressurized reservoir;
- (c) providing a nozzle having a flow channel, said flow channel having a longitudinal axis and inlet and outlet ends;
- (d) feeding the pressurized liquid into the flow channel through a conduit ending proximate to the longitudinal axis of the flow channel;
- (e) passing through the nozzle flow channel from the inlet end to the outlet end, a high temperature, high velocity atomizing gas to atomize the liquid fed into the flow channel into a plume of atomized droplets;
- (f) directing the plume of atomized droplets toward the pattern;
- (g) controlling the in-flight cooling of the atomized droplets by use of a quench cell through which a quench gas is provided, said quench gas being entrained in the plume of atomized droplets to quench the atomized droplets to a temperature below the liquidus temperature of the liquid being atomized, to create undercooled and partially solidified droplets;
- (h) depositing the undercooled and partially solidified droplets onto the pattern to form a mold of the pattern;
- (i) removing the mold from the pattern.
Dependencies are inferred from the claim text.