EP1046725A1 - Dépot de métaux par projection - Google Patents

Dépot de métaux par projection Download PDF

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Publication number
EP1046725A1
EP1046725A1 EP20000303022 EP00303022A EP1046725A1 EP 1046725 A1 EP1046725 A1 EP 1046725A1 EP 20000303022 EP20000303022 EP 20000303022 EP 00303022 A EP00303022 A EP 00303022A EP 1046725 A1 EP1046725 A1 EP 1046725A1
Authority
EP
European Patent Office
Prior art keywords
ceramic pattern
alkali solution
ceramic
spray
metal object
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP20000303022
Other languages
German (de)
English (en)
Inventor
Gregory John Gibbons
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bayerische Motoren Werke AG
Original Assignee
Bayerische Motoren Werke AG
MG Rover Group Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bayerische Motoren Werke AG, MG Rover Group Ltd filed Critical Bayerische Motoren Werke AG
Publication of EP1046725A1 publication Critical patent/EP1046725A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment
    • C23C4/185—Separation of the coating from the substrate

Definitions

  • the present invention relates to the spray deposition of metals, and in particular, but not exclusively, to the use of spray deposition of metals in the manufacture of tooling for use in the production of plastic mouldings and metal castings.
  • a method of removing a spray cast metal object from a ceramic pattern on which the spray cast metal object has been cast comprises dissolving at least a part of the ceramic pattern in an alkali solution.
  • a further advantage is that the ceramic pattern can be removed from complex areas of the metal object and also from areas of the metal object to which access would be relatively difficult when using a mechanical tool.
  • the ceramic pattern is coated with a metal hydroxide powder prior to spray casting of the metal object, and after spray casting of the metal object the ceramic pattern and the metal object are immersed in a bath of water to allow the metal hydroxide powder to dissolve in the water to form the alkali solution.
  • passageways are formed in the ceramic pattern through which the alkali solution may pass. This has as an advantage that the alkali solution contacts a greater surface area of the ceramic pattern and so has a greater opportunity to dissolve the ceramic pattern. This in turn means that the ceramic pattern dissolves relatively quickly allowing the spray cast metal object to be removed from the ceramic pattern in a shorter amount of time than might otherwise be possible.
  • a bath 2 for use in accordance with the method of the present invention.
  • the bath 2 is formed of any suitable material able to resist the effects of a strongly alkali solution.
  • the bath 2 may be made of a steel, for example a stainless steel.
  • the bath 2 is filled with an alkali solution 4 at an elevated temperature.
  • the alkali solution 4 may be prepared by dissolving an alkali metal hydroxide in water.
  • the alkali metal hydroxide may be sodium hydroxide (NaOH) or potassium hydroxide (KOH).
  • the water may be distilled and de-ionised.
  • the molarity of the solution is preferably between 2M and 10M. More preferably, the molarity of the solution is 5M.
  • the water temperature is preferably greater than 60°C. The water temperature is more preferably 80°C.
  • a sprayed metal object in the form of a metal shell 6, produced in accordance with known spray deposition techniques, together with an associated ceramic pattern 8 on which the metal shell has been spray cast, is immersed in the heated alkali solution 4 within the bath 2.
  • the ceramic pattern 8 is conveniently manufactured from a freeze cast silica or a freeze cast alumina.
  • the metal shell 6 is left immersed in the heated alkali solution 4 until the ceramic pattern 8 has dissolved partially or totally, so as to enable the metal shell to be separated from the ceramic pattern. Any part of the ceramic pattern that remains may then be easily removed.
  • the alkali solution 4 may be agitated by any suitable means, for example by rocking, by the use of a chemical pump or by ultrasonic means. It will be understood that a combination of any or all of these means is possible. Agitation of the alkali solution 4 ensures that the solution is able to fully contact and penetrate the ceramic pattern 8 within the bath 2.
  • Such a method is particularly suitable for removing ceramic patterns from a metal shell where together the ceramic pattern 8 and the metal shell 6 represent a comparatively small volume.
  • the following method illustrated with reference to Figures 2 to 5 is useful.
  • a ceramic pattern 12 is produced according to known methods.
  • a layer 14 of alkali metal hydroxide in the form of a powder is then applied to a surface of the pattern 12 onto which a metal object is to be spray cast ( Figure 2).
  • the powder may conveniently adhered to a surface of the ceramic by using a suitable inorganic binder.
  • the binder is water soluble, for example salt-glass.
  • the metal object in the form of a metal shell 16 is then oversprayed onto the coated ceramic pattern 12 (Figure 3).
  • the ceramic pattern and associated metal shell are then soaked in water 18 by immersion in a bath 20 ( Figure 4).
  • the alkali metal hydroxide powder dissolves in the water to produce an alkali solution which dissolves the ceramic pattern 12, in particular in a region adjacent to the metal shell 16.
  • the metal shell 16 may be removed from a remaining portion of the ceramic pattern 12 ( Figure 5).
  • the metal shell 16 may be washed to remove any small particles of ceramic pattern detritus that remain in the spray cast metal object.
  • a ceramic pattern 22 is produced according to known methods.
  • the ceramic pattern 22 is provided with a network of drilled passageways 24.
  • the passageways may be drilled either before or after spray casting of the metal object.
  • the passageways 24 are formed prior to spray casting ( Figure 6).
  • plugs 26 of a suitable material to seal at least some ends of the passageways ( Figure 6A).
  • drilling the passageways after spray casting of a metal object has as an advantage that it removes the need to use such plugs.
  • a suitable alkali solution 30, such as that described previously, is allowed to pass through the passageways. This may conveniently be achieved by immersing the ceramic pattern 22 and the associated spray cast metal shell 28 in a bath 32 of the alkali solution 30 ( Figure 8).
  • the passageways 24 allow a large amount of the alkali solution to penetrate the ceramic pattern 22 quickly. Accordingly, the spray cast metal shell 28 may be removed from any remains of the ceramic pattern 22 relatively quickly ( Figure 9).
  • the alkali solution 30 may be introduced under pressure into the passageways 24. This enables the alkali solution 30 to pass through the ceramic pattern 22 quickly and also induces the alkali solution 30 to permeate into the ceramic pattern 22. In this way, the alkali solution 30 will reach an interface between the metal shell and the ceramic pattern to dissolve the ceramic pattern 22 at the interface enabling the metal shell 28 to be separated from the ceramic pattern 22 without the need to wait for all of the ceramic pattern 22 to be dissolved.
  • a ceramic pattern 33 is produced according to known methods.
  • the ceramic pattern 33 incorporates a plurality of integrally formed non-communicating passageways 35.
  • the passageways are formed with the aid of an array of pins 34 (Figure 10).
  • the pins 34 can be configured to any suitable array.
  • an outer face of the ceramic is spaced from the ends of the pins. The array is removed following forming of the ceramic pattern and prior to casting of a metal shell 36 ( Figure 11).
  • a suitable alkali solution 37 such as that described previously, is allowed to pass through the passageways 35. This may conveniently be achieved by immersing the ceramic pattern 33 and the associated spray cast metal shell 36 in a bath 38 of the alkali solution 37 ( Figure 12).
  • the passageways 35 allow a large amount of the alkali solution to penetrate the ceramic pattern 33 quickly. Accordingly, the spray cast metal shell 36 may be removed from any remains of the ceramic pattern relatively quickly ( Figure 13).
  • a ceramic pattern 42 is produced according to known methods with passageways formed integrally with the ceramic pattern.
  • the passageways may be formed as part of a lost core method, or alternatively may be formed by tubular members 44 cast into the ceramic pattern ( Figure 14).
  • the tubular members 44 include walls that allow the alkali solution to pass therethrough. This may be achieved by any suitable means, for example by providing holes in the walls of the tubular members or by constructing the walls of the tubular members of a material sufficiently porous to allow the passage of an alkali solution 46 therethrough.
  • the suitable alkali solution 46 such as that described previously, is allowed to pass through the passageways. This may conveniently be achieved by immersing the ceramic pattern and the associated spray cast metal shell in a bath of a suitable alkali solution. Alternatively, the alkali solution 46 may be poured through the passageways 44 ( Figure 16).
  • the passageways 44 allow a large amount of the alkali solution to penetrate the ceramic pattern 42 relatively quickly.
  • the alkali solution 46 will reach an interface between the metal shell and the ceramic pattern to dissolve the ceramic pattern 42 at the interface enabling the metal shell 48 to be separated from the ceramic pattern 42 without the need to wait for all of the ceramic pattern 42 to be dissolved. Accordingly, the spray cast metal shell 48 may be removed from the remains of the ceramic pattern relatively quickly ( Figure 17).
  • the alkali solution 46 may be introduced under pressure into the passageways. This enables the alkali solution 46 to pass through the ceramic pattern 42 more quickly and also induces the alkali solution 46 to permeate into the ceramic pattern. In this way, the alkali solution 46 will more quickly reach the interface between the metal shell and the ceramic pattern 42 to dissolve the ceramic pattern at the interface enabling the metal shell 48 to be separated from the ceramic pattern without the need to wait for all of the ceramic pattern 42 to be dissolved.
  • a further embodiment is illustrated diagrammatically in Figure 18.
  • a ceramic pattern 52 and an associated spray cast metal object in the form of a metal shell 54 are produced in accordance with known methods.
  • a suitable alkali solution 56 of the kind described previously is then directed under pressure in the form of a spray 58 at the ceramic pattern 52.
  • This enables the alkali solution 56 to permeate the ceramic pattern 52 to dissolve the ceramic pattern 52 while the mechanical action of the spray 58 agitates the ceramic pattern and removes those portions of the ceramic pattern 52 dissolved or loosened from the ceramic pattern.
  • the spray 58 is applied until the spray cast metal shell 54 can be removed from all of the ceramic pattern 52 with which it is in contact.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
EP20000303022 1999-04-23 2000-04-10 Dépot de métaux par projection Withdrawn EP1046725A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9909268A GB2349393A (en) 1999-04-23 1999-04-23 Removal of ceramic pattern from spray cast metal objects
GB9909268 1999-04-23

Publications (1)

Publication Number Publication Date
EP1046725A1 true EP1046725A1 (fr) 2000-10-25

Family

ID=10852061

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20000303022 Withdrawn EP1046725A1 (fr) 1999-04-23 2000-04-10 Dépot de métaux par projection

Country Status (2)

Country Link
EP (1) EP1046725A1 (fr)
GB (1) GB2349393A (fr)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1177637A (fr) * 1957-06-29 1959-04-28 Procédé pour la réalisation directe, en une seule opération, de parois poreuses métalliques ou en résines synthétiques
FR1500888A (fr) * 1966-07-01 1967-11-10 Comp Generale Electricite Procédé de fabrication d'objets comportant une partie réfractaire et au moins une partie métallique
DE1273296B (de) * 1959-08-18 1968-07-18 Kurt G Kersten Verfahren zum Herstellen von Metallgegenstaenden hoher Praezision, insbesondere Elektroden fuer die Funkenerosion, durch Metallspritzen
FR2291736A1 (fr) * 1974-11-21 1976-06-18 Europ Composants Electron Article de prothese et son procede de fabrication
JPS60110864A (ja) * 1983-11-22 1985-06-17 Mitsubishi Heavy Ind Ltd スラスタ製造方法
JPS60114560A (ja) * 1983-11-22 1985-06-21 Mitsubishi Heavy Ind Ltd スラスタ製造法
US5189781A (en) * 1990-08-03 1993-03-02 Carnegie Mellon University Rapid tool manufacturing

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2084895A (en) * 1980-10-04 1982-04-21 Rolls Royce Dissolving refractory materials in particular cores from castings
SU950800A1 (ru) * 1980-12-22 1982-08-15 Предприятие П/Я М-5481 Способ очистки отливок от остатков керамики
GB2126931B (en) * 1982-09-04 1986-04-23 Rolls Royce Dissolving ceramic materials
GB2126569B (en) * 1982-09-04 1986-01-15 Rolls Royce Non-silica based ceramic cores for castings
JPS59174558A (ja) * 1983-03-24 1984-10-03 タテホ化学工業株式会社 セラミック網目成形体の製造方法
JPS6116807A (ja) * 1984-07-04 1986-01-24 三洋電機株式会社 セラミツク薄板の製造方法

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1177637A (fr) * 1957-06-29 1959-04-28 Procédé pour la réalisation directe, en une seule opération, de parois poreuses métalliques ou en résines synthétiques
DE1273296B (de) * 1959-08-18 1968-07-18 Kurt G Kersten Verfahren zum Herstellen von Metallgegenstaenden hoher Praezision, insbesondere Elektroden fuer die Funkenerosion, durch Metallspritzen
FR1500888A (fr) * 1966-07-01 1967-11-10 Comp Generale Electricite Procédé de fabrication d'objets comportant une partie réfractaire et au moins une partie métallique
FR2291736A1 (fr) * 1974-11-21 1976-06-18 Europ Composants Electron Article de prothese et son procede de fabrication
JPS60110864A (ja) * 1983-11-22 1985-06-17 Mitsubishi Heavy Ind Ltd スラスタ製造方法
JPS60114560A (ja) * 1983-11-22 1985-06-21 Mitsubishi Heavy Ind Ltd スラスタ製造法
US5189781A (en) * 1990-08-03 1993-03-02 Carnegie Mellon University Rapid tool manufacturing

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 009, no. 260 (C - 309) 17 October 1985 (1985-10-17) *
PATENT ABSTRACTS OF JAPAN vol. 009, no. 267 (C - 310) 24 October 1985 (1985-10-24) *

Also Published As

Publication number Publication date
GB9909268D0 (en) 1999-06-16
GB2349393A (en) 2000-11-01

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