Rapid solidification processing system for producing molds, dies and related tooling
AssigneeBechtel BWTX Idaho, LLC
InventorKevin M. McHugh
Life of this patent
Estimating the term…
Abstract
A system for the 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 in-flight 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 powders, whiskers or fibers.
Claims21
A system for the spray forming manufacture of near net shape molds, dies and related toolings, comprising:
- a nozzle having a flow channel, said flow channel having an inlet end, an outlet end and a longitudinal axis;
- a liquid reservoir in fluid communication with said nozzle flow channel, said reservoir adapted to contain a liquid material capable of forming a mold, said liquid being pressurized in a pressurized reservoir and injected from said reservoir through a conduit ending in said nozzle flow channel between said inlet and outlet ends and proximate to said nozzle longitudinal axis;
- means for flowing a high temperature atomizing gas through the nozzle flow channel from the inlet end to the outlet end at a pressure range of 20 psia to 30 psia to atomize the liquid injected into the flow channel into a plume of atomized droplets;
- a chamber adapted to contain a quench gas having a controlled temperature and composition for increasing in-flight convection cooling of the atomized droplets thereby enhancing formation of undercooled and partially solidified droplets;
- means for directing and depositing the undercooled and partially solidified droplets onto a pattern to form the mold.
A system for the spray forming manufacture of near net shape molds, dies and related toolings, comprising:
- a plurality of nozzles, each nozzle having a flow channel, each of said flow channels having an inlet end, an outlet end and a longitudinal axis;
- a liquid reservoir in fluid communication with each of said nozzle flow channels, said reservoir adapted to contain a liquid material capable of forming a mold, said liquid being pressurized in a pressurized reservoir and injected from said reservoir through a conduit ending in said nozzle flow channel between said inlet and outlet ends and proximate to said nozzle longitudinal axis;
- a high temperature atomizing gas flowing through each of the nozzle flow channels from the inlet end to the outlet end at a pressure range of 20 psia to 30 psia to atomize the liquid injected into the flow channels into a plume of atomized droplets directed to a chamber adapted to contain a quench gas having a controlled temperature and composition for increasing in-flight convection cooling of the atomized droplets thereby enhancing formation of undercooled and partially solidified droplets;
- means for directing and depositing the undercooled and partially solidified droplets onto a pattern to form the mold.
A system for the spray forming manufacture of near net shape molds, dies and related toolings, comprising:
- a nozzle having a flow channel, said flow channel having an inlet end, an outlet end, and a longitudinal axis;
- a plurality of reservoirs in separate fluid communication with said nozzle flow channel, at least one of said reservoirs adapted to contain under pressure a liquid material capable of forming a mold and injected from said reservoir through a conduit ending in said nozzle flow channel between said inlet and outlet ends and proximate to said nozzle longitudinal axis;
- means for flowing a high temperature atomizing gas through the nozzle flow channel from the inlet end to the outlet end at a pressure range of 20 psia to 30 psia to atomize the liquid injected into the flow channel into a plume of atomized droplets directed to a chamber adapted to contain a quench gas having a controlled temperature and composition for increasing in-flight convection cooling of the atomized droplets thereby enhancing formation of undercooled and partially solidified droplets;
- means for directing and depositing the undercooled and partially solidified droplets onto a pattern to form the mold.
Dependencies are inferred from the claim text.