US20050019199A1 - Double-layer metal sheet and method of fabricating the same - Google Patents
Double-layer metal sheet and method of fabricating the same Download PDFInfo
- Publication number
- US20050019199A1 US20050019199A1 US10/875,204 US87520404A US2005019199A1 US 20050019199 A1 US20050019199 A1 US 20050019199A1 US 87520404 A US87520404 A US 87520404A US 2005019199 A1 US2005019199 A1 US 2005019199A1
- Authority
- US
- United States
- Prior art keywords
- powder
- compact
- binder
- green compact
- sintering
- 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.)
- Abandoned
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
Definitions
- This invention relates to a method for bonding two metal powder components having different shrinkage factors using powder metallurgy, more particularly but not exclusively, for fabricating double layer metal parts, sheets or components.
- the intermediate gradient material is a mixture of the two material powders to be bonded to mutually compensate the respective shrinkage factor of each material and thus provides a region or zone to allow a gradual change between the two material powders when the two layers are sintered together. This alleviates deformation or warpage of the two layers during sintering.
- the use of the intermediate gradient zone creates extra process steps of preparing the intermediate mixture and arranging the mixture between the two layers during the fabricating process which may further complicate the process.
- a method of bonding two metal powder components having different shrinkage factors comprising the steps of:
- An advantage of the described embodiment of the invention is that the two metal powder components can be bonded without an intermediate gradient zone.
- the use of an appropriate amount of pressure during the sintering process helps to control the shrinkage of the compact and reduces or prevents warpage thereof.
- the powder binder reduces the shrinkage difference between the two metal powder components such that the shrinkage factor of one metal powder component is substantially matched to that of the other metal powder component.
- the other metal powder component may also be mixed with powder binder before the compacting step (ii).
- the powder binder for one powder component may be the same or different from that used for the other metal powder.
- one of the metal powder is mixed with three to five weight % of powder binder.
- the method further comprises a step of removing the powder binder in a debinding furnace prior to the sintering step.
- the powder binder is removed in a sintering furnace followed by the sintering step.
- the green compact is formed in a suitably shaped die and the method further comprises the steps of arranging one of the powder component mixtures in the die as a base layer, arranging the other powder component mixture on top of the base layer; and compressing the powder component mixtures together to form a desired shape of the compact.
- the pressure applied on the surface of the compact during the sintering step is between 2 g/cm 2 and 10 g/cm 2 .
- the pressure applied on the surface of the compact during the sintering step may be more than 10 g/cm 2 .
- the required pressure is produced by a ceramic plate.
- the ceramic plate may be placed directly on the surface of the compact during the sintering step to exert the required amount of pressure.
- the ceramic plate may be spaced from the compact such that the space between the plate and the compact may be 50 to 100 microns.
- the green compact may be formed by tape casting and the method further comprises the step of mixing the powder component mixtures with a solvent and polymer binder to form respective slurry mixtures prior to the compacting step.
- the method further comprises the steps of layering one slurry mixture on top of the other to form a double layer slurry and heating the double layer slurry to form the compact.
- the compact may also be formed by powder rolling.
- the present invention also relates to a metal part, double layer or multi-layer plate or part produced using the method for different materials.
- FIG. 1 is a flow chart depicting a preferred method for producing a double layer component without an intermediate gradient zone using powder metallurgy
- FIG. 2 shows a die set used in the method of FIG. 1 ;
- FIG. 3 shows a sintered double layer component according to the preferred embodiment
- FIG. 4 shows a microstructure view of the double layer component of FIG. 3 ;
- FIG. 5 shows a microstructure view of another double layer component produced using the method of FIG. 1 ;
- FIGS. 5 a and 5 b show microstructure views of two further double layer components produced using the method of FIG. 1 ;
- FIG. 6 shows a method of applying pressure on a surface of a green compact during sintering
- FIG. 7 shows a tape casting apparatus for forming a double layer green compact.
- FIG. 1 shows a flowchart depicting the fabrication steps.
- an iron (Fe) based powder material hereinafter referred to as powder A is used to form the first metal layer.
- powder A an iron (Fe) based powder material
- Ni nickel
- the described embodiment is also applicable to other types of metal such as titanium (Ti), stainless steel metal powder or other alloys.
- Powders A and B have different shrinkage factors and to reduce the shrinkage difference, a powder binder, such as wax powder binder is used. As shown in FIG. 1 , at step 1 . 1 , powders A and B are separately mixed with respective proportions of the powder binder using an experimental blender.
- typically powder B is mixed or blended with 3 to 5 wt % wax powder binder whereas powder A is mixed with 5 to 15 wt % powder binder.
- layer and binder formulation is optimised at about 5 wt % binder for the base layer (powder B) and about 7 wt % binder for the top layer (powder A). It should be apparent that the above binder and material wt. proportions are only examples and the proportions may be varied according to the types of powder materials used since different material have different shrinkage characteristics and the proportions may be determined by trial and error to obtain satisfactory results.
- the die set 20 comprises a base die 21 having a cavity 21 a , an upper die 22 a and an ejector/lower die 22 b .
- the ejector 22 b is first arranged in the cavity 21 a of the base die 21 prior to the step of consolidating the powder mixtures in the die set 20 .
- the powder mixture including powder A which is the base layer, is spread evenly on the ejector 22 b to form the desired thickness, which in this particular case is approximately 700 to 950 microns.
- the process is repeated for the powder mixture containing powder B as the coating or top layer with a lesser layer thickness of about 50 ⁇ m.
- both layers are compressed to shape or compacted together using the upper die 22 to form a compact commonly known as a green body 23 of a desired shape such as that shown in FIG. 2 .
- the green body 23 has dimensions as depicted in FIG. 2 .
- the compression force applied on the upper die 22 is about 25 tons.
- the green body 23 is unsintered but possess sufficient green strength to be ejected (using the ejector 22 b ) as an integrated part from the base die 21 ready for the next process step.
- the green body 23 is formed at room temperature. Alternatively and preferably, the green body 23 may be formed at a temperature between 40° C. and 90° C.
- the compacting can be performed before the powder mixture containing powder B is layered onto powder A. This means that after the powder mixture containing powder A is arranged on the base die 21 , the upper die 22 is used to compress powder A first and when the mixed powder of powder B is subsequently arranged on top of powder A, the upper die 22 is used again to compact the composition.
- the green body is thermally debinded to remove the binder materials at a temperature of up to 900° C. with a heating rate between 1° C. to 3° C. per minute.
- the holding time at the maximum temperature is about 0.5 to 2.5 hours.
- the purpose of the debinding is to remove the binders completely prior to sintering, so that when the parts are sintered in a separate furnace, there will be no contamination to the furnace and the parts from the residual binders.
- the green body 23 is subject to a sintering process and it is at this step the two layers are permanently bonded together to form a double layer plate.
- Sintering requires heating the green body 23 in a furnace, typically a batch or continuous furnace, at below the melting point of the lower melting temperature of either powder A or B. Atomic diffusion takes place and the boundary between powders A and B “grow” to create a permanent and strong bond.
- the green body is subjected to a sintering temperature of 1200° C. with a heating rate of 2° C. to 5° C. per minute. When the maximum temperature is reached, this is held for 0.5 to 2 hours.
- the sintering is performed in a controlled environment which is typically vacuum or of inert atmosphere.
- a pressure of about 2 to 10 g/cm 2 is applied uniformly to a surface of the green body 23 during the sintering process.
- This pressure is achieved by placing a flat ceramic plate having a predetermined weight so as to produce the required amount of pressure on the surface of the green body 23 .
- the plate has a weight of 100 to 200 grams to produce a direct pressure of approximately 4.5 to 9.0 g/cm 2 .
- the amount of pressure to be applied varies since different types of metal components have different characteristics.
- the pressure is maintained throughout the entire sintering process which will alleviate warping of the green body 23 .
- FIG. 3 shows a sintered double layer plate 24 produced in accordance with the method proposed in FIG. 1 .
- FIG. 4 is a microstructure view of the double layer plate 24 of FIG. 3 which illustrates a chemical bonding boundary between the base layer (powder A including Fe) and the top layer (powder B including Ni) which have been bonded together directly without using an intermediate gradient zone.
- FIG. 5 is a microstructure view of another double layer plate formed from Fe powder and 17-4 PH powder.
- FIGS. 5 a and 5 b show microstructure views of further double layer plates formed from M2 (commercial tool steel) and Fe, and M2 and Ni respectively.
- a ceramic plate 50 is supported at four corners by four members 51 formed from green bodies of powder A or B, as illustrated in FIG. 6 , so that the plate 50 is spaced from the green body or compact 23 by about 50 to 100 microns during sintering.
- the ceramic plate 50 is arranged to apply a pressure of more than 10 g/cm 2 on the top surface of the compact 23 when the green body 23 warps during sintering so that the pressure controls the distortion of the green body 23 .
- the embodiment describes forming the green compact 23 using die pressing (using a die set 20 ), alternative one step shaping techniques may be used such as tape casting or powder rolling which is preferred for mass producing double layer plates or parts.
- FIG. 7 shows a tape casting apparatus for forming a double layer green compact according to another embodiment of the present invention.
- the tape casting apparatus 40 comprises two pairs of “doctor blades” 42 , 44 , reservoirs A and B, and a carrier tape 46 which moves from right to left as shown by the arrow X.
- metal powders A and B are separately mixed with polymer binders to reduce the shrinkage difference between the two metal powders.
- each metal powder is further mixed with solvent and a small amount of corrosion inhibitor to minimise corrosion of the double layer component when fabricated to form a slurry.
- the slurry can be formulated using commercial standard formulation such as 75-80.32% of metal powders A or B; 0.4% of Menhaden fish oil, brown Z-3; 7.23% of Xylenes; 95% of Ethyl alcohol; 7.23% denatured; 2.41% of Butylbenzyl phthalate, S-160; and 2.41% of Poly(vinyl butyral) grade B-98.
- a powder binder is also mixed in the composition to minimise the mismatch of the shrinkage difference due to the different materials.
- the first slurry 48 comprising powder A which is the base layer
- the second slurry 49 comprising powder B being the top layer
- the first pair of doctor blades 42 “shears” or spreads the moving slurry 48 evenly to form the base layer.
- the second slurry 49 comprising powder B is spread on top of the base layer with the help of the second pair of doctor blades 44 to form a double layer slurry.
- the double layer slurry is then dried typically by infrared lamps mounted along the moving carrier tape after the second pair of doctor blades 44 . After drying, this forms a green compact having sufficient green strength for further handling before the sintering process.
- the green compact is first cut into the desired shape and then debinded and sintered to form the double layer plate.
- the sintering process is similar to what has been described in the first embodiment, i.e. pressure is applied on a surface of the green compact, to prevent warping or distortion.
- the present invention is able to overcome the different properties between the two metal powders for example, melting temperature difference and shrinkage difference, to produce a double layer plate which does not exhibit the effects of distortion or warping.
- the described embodiment should not be construed as limitative.
- the preferred embodiment describes mixing the two metal powders separately with different amounts of powder binders, but this may not be absolutely necessary since it may be possible to mix one of the two metal powders with binder powder to change the shrinkage characteristics of one and still reduce the shrinkage difference between the two metal powders.
- powder B is required to be coated also on the other side of the base layer (powder A)
- a layer of the powder mixture containing powder B is first arranged on the base die 21 prior to depositing the powder mixture containing powder A. After the powder mixture containing powder A is applied on top of the powder B layer, a further coating layer of powder B is applied on top of powder A to form another coating.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Powder Metallurgy (AREA)
Abstract
Description
- This invention relates to a method for bonding two metal powder components having different shrinkage factors using powder metallurgy, more particularly but not exclusively, for fabricating double layer metal parts, sheets or components.
- It is widely known that formation or fabrication of a double layer metal component using powder processing requires an intermediate gradient material composition disposed between the two layers of metal powder. The intermediate gradient material is a mixture of the two material powders to be bonded to mutually compensate the respective shrinkage factor of each material and thus provides a region or zone to allow a gradual change between the two material powders when the two layers are sintered together. This alleviates deformation or warpage of the two layers during sintering.
- However, the use of the intermediate gradient zone creates extra process steps of preparing the intermediate mixture and arranging the mixture between the two layers during the fabricating process which may further complicate the process.
- It is an object of the present invention to provide a bonding method which alleviates at least one of the disadvantages of the prior art and/or provides the public with a useful choice.
- In a first aspect of the invention, there is provided a method of bonding two metal powder components having different shrinkage factors, the method comprising the steps of:
-
- i. mixing one of the powder components with a powder binder to reduce the shrinkage difference between the powder components,
- ii. forming a green compact from the powder component mixtures,
- iii. sintering the compact to form a permanent bond between the two powder components, and
- iv. applying pressure on a surface of the compact during the sintering step (iii).
- An advantage of the described embodiment of the invention is that the two metal powder components can be bonded without an intermediate gradient zone. The use of an appropriate amount of pressure during the sintering process helps to control the shrinkage of the compact and reduces or prevents warpage thereof.
- Preferably, the powder binder reduces the shrinkage difference between the two metal powder components such that the shrinkage factor of one metal powder component is substantially matched to that of the other metal powder component.
- The other metal powder component may also be mixed with powder binder before the compacting step (ii). The powder binder for one powder component may be the same or different from that used for the other metal powder.
- Preferably, one of the metal powder is mixed with three to five weight % of powder binder.
- Preferably, the method further comprises a step of removing the powder binder in a debinding furnace prior to the sintering step. Alternatively, the powder binder is removed in a sintering furnace followed by the sintering step.
- In one embodiment, the green compact is formed in a suitably shaped die and the method further comprises the steps of arranging one of the powder component mixtures in the die as a base layer, arranging the other powder component mixture on top of the base layer; and compressing the powder component mixtures together to form a desired shape of the compact.
- Preferably, the pressure applied on the surface of the compact during the sintering step is between 2 g/cm2 and 10 g/cm2. Alternatively, the pressure applied on the surface of the compact during the sintering step may be more than 10 g/cm2. Preferably, the required pressure is produced by a ceramic plate. As an example, the ceramic plate may be placed directly on the surface of the compact during the sintering step to exert the required amount of pressure. As a further example, the ceramic plate may be spaced from the compact such that the space between the plate and the compact may be 50 to 100 microns.
- In another embodiment, the green compact may be formed by tape casting and the method further comprises the step of mixing the powder component mixtures with a solvent and polymer binder to form respective slurry mixtures prior to the compacting step. Preferably, the method further comprises the steps of layering one slurry mixture on top of the other to form a double layer slurry and heating the double layer slurry to form the compact.
- The compact may also be formed by powder rolling.
- The present invention also relates to a metal part, double layer or multi-layer plate or part produced using the method for different materials.
- An embodiment of the invention will now be described, by way of example, with reference to the accompanying drawings in which,
-
FIG. 1 is a flow chart depicting a preferred method for producing a double layer component without an intermediate gradient zone using powder metallurgy; -
FIG. 2 shows a die set used in the method ofFIG. 1 ; -
FIG. 3 shows a sintered double layer component according to the preferred embodiment; -
FIG. 4 shows a microstructure view of the double layer component ofFIG. 3 ; -
FIG. 5 shows a microstructure view of another double layer component produced using the method ofFIG. 1 ; -
FIGS. 5 a and 5 b show microstructure views of two further double layer components produced using the method ofFIG. 1 ; -
FIG. 6 shows a method of applying pressure on a surface of a green compact during sintering; and -
FIG. 7 shows a tape casting apparatus for forming a double layer green compact. - A preferred embodiment of the invention will be described using an example of fabricating a double layer metal plate using powder metallurgy and
FIG. 1 shows a flowchart depicting the fabrication steps. - In this embodiment, an iron (Fe) based powder material, hereinafter referred to as powder A is used to form the first metal layer. For the second metal layer, nickel (Ni) powder is used. It should be apparent that the described embodiment is also applicable to other types of metal such as titanium (Ti), stainless steel metal powder or other alloys.
- Powders A and B have different shrinkage factors and to reduce the shrinkage difference, a powder binder, such as wax powder binder is used. As shown in
FIG. 1 , at step 1.1, powders A and B are separately mixed with respective proportions of the powder binder using an experimental blender. - In this embodiment, to achieve the desired results, typically powder B is mixed or blended with 3 to 5 wt % wax powder binder whereas powder A is mixed with 5 to 15 wt % powder binder. To further reduce the effects of warping or distortion during sintering, it is preferred that layer and binder formulation is optimised at about 5 wt % binder for the base layer (powder B) and about 7 wt % binder for the top layer (powder A). It should be apparent that the above binder and material wt. proportions are only examples and the proportions may be varied according to the types of powder materials used since different material have different shrinkage characteristics and the proportions may be determined by trial and error to obtain satisfactory results.
- When both powders A and B are properly mixed, the powder mixtures are further processed or consolidated in a suitably shaped die to obtain a self-supporting compact or green body, and in this embodiment a
die set 20 shown inFIG. 2 is used to form the required shape of the double layer plate. The dieset 20 comprises a base die 21 having acavity 21 a, anupper die 22 a and an ejector/lower die 22 b. Theejector 22 b is first arranged in thecavity 21 a of the base die 21 prior to the step of consolidating the powder mixtures in thedie set 20. - At step 1.2, the powder mixture including powder A, which is the base layer, is spread evenly on the
ejector 22 b to form the desired thickness, which in this particular case is approximately 700 to 950 microns. At step 1.3, the process is repeated for the powder mixture containing powder B as the coating or top layer with a lesser layer thickness of about 50 μm. - Next, at step 1.4, both layers are compressed to shape or compacted together using the upper die 22 to form a compact commonly known as a
green body 23 of a desired shape such as that shown inFIG. 2 . In this particular case, thegreen body 23 has dimensions as depicted inFIG. 2 . The compression force applied on the upper die 22 is about 25 tons. Thegreen body 23 is unsintered but possess sufficient green strength to be ejected (using theejector 22 b) as an integrated part from the base die 21 ready for the next process step. Typically, thegreen body 23 is formed at room temperature. Alternatively and preferably, thegreen body 23 may be formed at a temperature between 40° C. and 90° C. - It would be appreciated that the compacting can be performed before the powder mixture containing powder B is layered onto powder A. This means that after the powder mixture containing powder A is arranged on the base die 21, the upper die 22 is used to compress powder A first and when the mixed powder of powder B is subsequently arranged on top of powder A, the upper die 22 is used again to compact the composition.
- Next at step 1.5 and prior to the sintering step 1.6, preferably the green body is thermally debinded to remove the binder materials at a temperature of up to 900° C. with a heating rate between 1° C. to 3° C. per minute. The holding time at the maximum temperature is about 0.5 to 2.5 hours. The purpose of the debinding is to remove the binders completely prior to sintering, so that when the parts are sintered in a separate furnace, there will be no contamination to the furnace and the parts from the residual binders.
- At step 1.6, the
green body 23 is subject to a sintering process and it is at this step the two layers are permanently bonded together to form a double layer plate. Sintering requires heating thegreen body 23 in a furnace, typically a batch or continuous furnace, at below the melting point of the lower melting temperature of either powder A or B. Atomic diffusion takes place and the boundary between powders A and B “grow” to create a permanent and strong bond. For this case, the green body is subjected to a sintering temperature of 1200° C. with a heating rate of 2° C. to 5° C. per minute. When the maximum temperature is reached, this is held for 0.5 to 2 hours. Preferably, the sintering is performed in a controlled environment which is typically vacuum or of inert atmosphere. - To reduce the effects of or prevent warping and distortion of the green body 23 a pressure of about 2 to 10 g/cm2 is applied uniformly to a surface of the
green body 23 during the sintering process. This pressure is achieved by placing a flat ceramic plate having a predetermined weight so as to produce the required amount of pressure on the surface of thegreen body 23. In this embodiment, the plate has a weight of 100 to 200 grams to produce a direct pressure of approximately 4.5 to 9.0 g/cm2. It will be apparent that the amount of pressure to be applied varies since different types of metal components have different characteristics. Preferably, the pressure is maintained throughout the entire sintering process which will alleviate warping of thegreen body 23. -
FIG. 3 shows a sintereddouble layer plate 24 produced in accordance with the method proposed inFIG. 1 .FIG. 4 is a microstructure view of thedouble layer plate 24 ofFIG. 3 which illustrates a chemical bonding boundary between the base layer (powder A including Fe) and the top layer (powder B including Ni) which have been bonded together directly without using an intermediate gradient zone.FIG. 5 is a microstructure view of another double layer plate formed from Fe powder and 17-4 PH powder.FIGS. 5 a and 5 b show microstructure views of further double layer plates formed from M2 (commercial tool steel) and Fe, and M2 and Ni respectively. Please note that the microstructure drawings illustrated herein portray photographs taken on the respective microstructures in order to permit satisfactory reproduction which would not be possible if the actual photographs are used. However, due to the difficulty of illustrating such stipple rendered images, the effect of the drawings may not be as good as the actual photographs. - The application of a suitable amount of pressure on the
green body 23 during sintering is unconventional since in a traditional sintering process of the green body without an intermediate gradient zone, thegreen body 23 will distort during sintering. However, the inventors realised that applying an appropriate amount of pressure actually helps to reduce or prevent warpage of thegreen body 23 when the two powders A and B are sintered together without an intermediate gradient zone. - In another variation, a
ceramic plate 50 is supported at four corners by fourmembers 51 formed from green bodies of powder A or B, as illustrated inFIG. 6 , so that theplate 50 is spaced from the green body or compact 23 by about 50 to 100 microns during sintering. In this case, theceramic plate 50 is arranged to apply a pressure of more than 10 g/cm2 on the top surface of the compact 23 when thegreen body 23 warps during sintering so that the pressure controls the distortion of thegreen body 23. - Although the embodiment describes forming the green compact 23 using die pressing (using a die set 20), alternative one step shaping techniques may be used such as tape casting or powder rolling which is preferred for mass producing double layer plates or parts.
-
FIG. 7 shows a tape casting apparatus for forming a double layer green compact according to another embodiment of the present invention. Thetape casting apparatus 40 comprises two pairs of “doctor blades” 42,44, reservoirs A and B, and a carrier tape 46 which moves from right to left as shown by the arrow X. Similar to the first embodiment, metal powders A and B are separately mixed with polymer binders to reduce the shrinkage difference between the two metal powders. In addition, each metal powder is further mixed with solvent and a small amount of corrosion inhibitor to minimise corrosion of the double layer component when fabricated to form a slurry. The slurry can be formulated using commercial standard formulation such as 75-80.32% of metal powders A or B; 0.4% of Menhaden fish oil, brown Z-3; 7.23% of Xylenes; 95% of Ethyl alcohol; 7.23% denatured; 2.41% of Butylbenzyl phthalate, S-160; and 2.41% of Poly(vinyl butyral) grade B-98. - Similar to the first embodiment, a powder binder is also mixed in the composition to minimise the mismatch of the shrinkage difference due to the different materials. The
first slurry 48 comprising powder A, which is the base layer, is received in the reservoir A and thesecond slurry 49 comprising powder B, being the top layer, is received in the reservoir B. As thefirst slurry 48 is dispensed from the reservoir A due to the relative carrier tape motion, the first pair ofdoctor blades 42 “shears” or spreads the movingslurry 48 evenly to form the base layer. As the base layer reaches the second reservoir B, thesecond slurry 49 comprising powder B is spread on top of the base layer with the help of the second pair ofdoctor blades 44 to form a double layer slurry. The double layer slurry is then dried typically by infrared lamps mounted along the moving carrier tape after the second pair ofdoctor blades 44. After drying, this forms a green compact having sufficient green strength for further handling before the sintering process. - Typically, the green compact is first cut into the desired shape and then debinded and sintered to form the double layer plate. The sintering process is similar to what has been described in the first embodiment, i.e. pressure is applied on a surface of the green compact, to prevent warping or distortion.
- It will be apparent that other one-step shaping technique is similarly applicable, such as powder rolling.
- Using the described embodiments, the present invention is able to overcome the different properties between the two metal powders for example, melting temperature difference and shrinkage difference, to produce a double layer plate which does not exhibit the effects of distortion or warping.
- The described embodiment should not be construed as limitative. For example, the preferred embodiment describes mixing the two metal powders separately with different amounts of powder binders, but this may not be absolutely necessary since it may be possible to mix one of the two metal powders with binder powder to change the shrinkage characteristics of one and still reduce the shrinkage difference between the two metal powders.
- In addition, if powder B is required to be coated also on the other side of the base layer (powder A), then a layer of the powder mixture containing powder B is first arranged on the base die 21 prior to depositing the powder mixture containing powder A. After the powder mixture containing powder A is applied on top of the powder B layer, a further coating layer of powder B is applied on top of powder A to form another coating.
- Having now fully described the invention, it should be apparent to one of ordinary skill in the art that many modifications can be made hereto without departing from the scope as claimed.
- The present disclosure relates to subject matter contained in Singapore Application No. SG 200303991-4, filed on Jul. 3, 2003, the contents of which are herein expressly incorporated by reference in its entirety.
Claims (23)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SG200303991A SG120941A1 (en) | 2003-07-03 | 2003-07-03 | Double-layer metal sheet and method of fabricatingthe same |
SGSG200303991-4 | 2003-07-03 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050019199A1 true US20050019199A1 (en) | 2005-01-27 |
Family
ID=34075299
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/875,204 Abandoned US20050019199A1 (en) | 2003-07-03 | 2004-06-25 | Double-layer metal sheet and method of fabricating the same |
Country Status (2)
Country | Link |
---|---|
US (1) | US20050019199A1 (en) |
SG (1) | SG120941A1 (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100236688A1 (en) * | 2009-03-20 | 2010-09-23 | Scalzo Orlando | Process for joining powder injection molded parts |
US20130010914A1 (en) * | 2011-07-08 | 2013-01-10 | Battelle Energy Alliance, Llc | Composite materials, bodies and nuclear fuels including metal oxide and silicon carbide and methods of forming same |
EP3067131A3 (en) * | 2015-03-12 | 2016-10-05 | Pratt & Whitney Canada Corp. | Method of forming a component from a green part |
US9517507B2 (en) | 2014-07-17 | 2016-12-13 | Pratt & Whitney Canada Corp. | Method of shaping green part and manufacturing method using same |
US9903275B2 (en) | 2014-02-27 | 2018-02-27 | Pratt & Whitney Canada Corp. | Aircraft components with porous portion and methods of making |
US9970318B2 (en) | 2014-06-25 | 2018-05-15 | Pratt & Whitney Canada Corp. | Shroud segment and method of manufacturing |
CN109986081A (en) * | 2017-12-30 | 2019-07-09 | 青岛海尔智慧厨房电器有限公司 | A kind of porous heater, heater production method and the burner for being equipped with the heater |
DE102019110106A1 (en) * | 2019-04-17 | 2020-10-22 | Rogers Germany Gmbh | Method for producing a composite ceramic and composite ceramic produced using such a method |
Citations (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3293072A (en) * | 1961-06-29 | 1966-12-20 | Vitta Corp | Ceramic-metallizing tape |
US4060413A (en) * | 1975-12-24 | 1977-11-29 | Westinghouse Canada Limited | Method of forming a composite structure |
US4743512A (en) * | 1987-06-30 | 1988-05-10 | Carpenter Technology Corporation | Method of manufacturing flat forms from metal powder and product formed therefrom |
US4920640A (en) * | 1988-01-27 | 1990-05-01 | W. R. Grace & Co.-Conn. | Hot pressing dense ceramic sheets for electronic substrates and for multilayer electronic substrates |
US5132080A (en) * | 1944-11-28 | 1992-07-21 | Inco Limited | Production of articles from powdered metals |
US5405571A (en) * | 1992-06-16 | 1995-04-11 | Aluminum Company Of America | Tape casting fiber reinforced composite structures |
US5423899A (en) * | 1993-07-16 | 1995-06-13 | Newcomer Products, Inc. | Dispersion alloyed hard metal composites and method for producing same |
US5455000A (en) * | 1994-07-01 | 1995-10-03 | Massachusetts Institute Of Technology | Method for preparation of a functionally gradient material |
US5592686A (en) * | 1995-07-25 | 1997-01-07 | Third; Christine E. | Porous metal structures and processes for their production |
US6033788A (en) * | 1996-11-15 | 2000-03-07 | Case Western Reserve University | Process for joining powder metallurgy objects in the green (or brown) state |
US6089309A (en) * | 1997-04-15 | 2000-07-18 | South China University Of Technology | Method for manufacturing gradient material by continuous and semi-continuous casting |
US6103187A (en) * | 1997-11-25 | 2000-08-15 | Korea Electrotechnology Research | Process for the production of multilayered bulk materials |
US6248290B1 (en) * | 1997-03-21 | 2001-06-19 | Honda Giken Kogyo Kabushiki Kaisha | Functionally gradient material and method for producing the same |
US20010025407A1 (en) * | 2000-03-23 | 2001-10-04 | Gerd Hartmann | Process for the production of a double-layer metal sheet and a more particularly stove enamelled shaped constructional member shaped therefrom, and also a deep-drawable double-layer metal sheet |
US20020020945A1 (en) * | 2000-08-18 | 2002-02-21 | Uichung Cho | Forming three dimensional objects through bulk heating of layers with differential material properties |
US20020085941A1 (en) * | 2000-12-29 | 2002-07-04 | Deevi Seetharama C. | Processing of aluminides by sintering of intermetallic powders |
US6660225B2 (en) * | 2000-12-11 | 2003-12-09 | Advanced Materials Technologies Pte, Ltd. | Method to form multi-material components |
US20040071781A1 (en) * | 2002-10-11 | 2004-04-15 | Ferro Corporation | Composite particles and method for preparing |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2001059103A (en) * | 1999-08-19 | 2001-03-06 | Injex Corp | Production of metallic sintered body |
-
2003
- 2003-07-03 SG SG200303991A patent/SG120941A1/en unknown
-
2004
- 2004-06-25 US US10/875,204 patent/US20050019199A1/en not_active Abandoned
Patent Citations (20)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5132080A (en) * | 1944-11-28 | 1992-07-21 | Inco Limited | Production of articles from powdered metals |
US3293072A (en) * | 1961-06-29 | 1966-12-20 | Vitta Corp | Ceramic-metallizing tape |
US4060413A (en) * | 1975-12-24 | 1977-11-29 | Westinghouse Canada Limited | Method of forming a composite structure |
US4743512A (en) * | 1987-06-30 | 1988-05-10 | Carpenter Technology Corporation | Method of manufacturing flat forms from metal powder and product formed therefrom |
US4920640A (en) * | 1988-01-27 | 1990-05-01 | W. R. Grace & Co.-Conn. | Hot pressing dense ceramic sheets for electronic substrates and for multilayer electronic substrates |
US5405571A (en) * | 1992-06-16 | 1995-04-11 | Aluminum Company Of America | Tape casting fiber reinforced composite structures |
US5423899A (en) * | 1993-07-16 | 1995-06-13 | Newcomer Products, Inc. | Dispersion alloyed hard metal composites and method for producing same |
US5455000A (en) * | 1994-07-01 | 1995-10-03 | Massachusetts Institute Of Technology | Method for preparation of a functionally gradient material |
US5592686A (en) * | 1995-07-25 | 1997-01-07 | Third; Christine E. | Porous metal structures and processes for their production |
US6033788A (en) * | 1996-11-15 | 2000-03-07 | Case Western Reserve University | Process for joining powder metallurgy objects in the green (or brown) state |
US6248290B1 (en) * | 1997-03-21 | 2001-06-19 | Honda Giken Kogyo Kabushiki Kaisha | Functionally gradient material and method for producing the same |
US6089309A (en) * | 1997-04-15 | 2000-07-18 | South China University Of Technology | Method for manufacturing gradient material by continuous and semi-continuous casting |
US6103187A (en) * | 1997-11-25 | 2000-08-15 | Korea Electrotechnology Research | Process for the production of multilayered bulk materials |
US20010025407A1 (en) * | 2000-03-23 | 2001-10-04 | Gerd Hartmann | Process for the production of a double-layer metal sheet and a more particularly stove enamelled shaped constructional member shaped therefrom, and also a deep-drawable double-layer metal sheet |
US20020020945A1 (en) * | 2000-08-18 | 2002-02-21 | Uichung Cho | Forming three dimensional objects through bulk heating of layers with differential material properties |
US6660225B2 (en) * | 2000-12-11 | 2003-12-09 | Advanced Materials Technologies Pte, Ltd. | Method to form multi-material components |
US20040071581A1 (en) * | 2000-12-11 | 2004-04-15 | Advanced Materials Technology Pte. Ltd. | Method to form multi-material components |
US20040086414A1 (en) * | 2000-12-11 | 2004-05-06 | Advanced Materials Technology Pte. Ltd. | Method to form multi-material components |
US20020085941A1 (en) * | 2000-12-29 | 2002-07-04 | Deevi Seetharama C. | Processing of aluminides by sintering of intermetallic powders |
US20040071781A1 (en) * | 2002-10-11 | 2004-04-15 | Ferro Corporation | Composite particles and method for preparing |
Cited By (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100236688A1 (en) * | 2009-03-20 | 2010-09-23 | Scalzo Orlando | Process for joining powder injection molded parts |
US10226818B2 (en) | 2009-03-20 | 2019-03-12 | Pratt & Whitney Canada Corp. | Process for joining powder injection molded parts |
US11383299B2 (en) | 2009-03-20 | 2022-07-12 | Pratt & Whitney Canada Corp. | Process for joining powder injection molded parts |
US20130010914A1 (en) * | 2011-07-08 | 2013-01-10 | Battelle Energy Alliance, Llc | Composite materials, bodies and nuclear fuels including metal oxide and silicon carbide and methods of forming same |
US9903275B2 (en) | 2014-02-27 | 2018-02-27 | Pratt & Whitney Canada Corp. | Aircraft components with porous portion and methods of making |
US9970318B2 (en) | 2014-06-25 | 2018-05-15 | Pratt & Whitney Canada Corp. | Shroud segment and method of manufacturing |
US9517507B2 (en) | 2014-07-17 | 2016-12-13 | Pratt & Whitney Canada Corp. | Method of shaping green part and manufacturing method using same |
EP3067131A3 (en) * | 2015-03-12 | 2016-10-05 | Pratt & Whitney Canada Corp. | Method of forming a component from a green part |
US11097343B2 (en) | 2015-03-12 | 2021-08-24 | Pratt & Whitney Canada Corp. | Method of forming a component from a green part |
US11883882B2 (en) | 2015-03-12 | 2024-01-30 | Pratt & Whitney Canada Corp. | Method of forming a component from a green part |
CN109986081A (en) * | 2017-12-30 | 2019-07-09 | 青岛海尔智慧厨房电器有限公司 | A kind of porous heater, heater production method and the burner for being equipped with the heater |
DE102019110106A1 (en) * | 2019-04-17 | 2020-10-22 | Rogers Germany Gmbh | Method for producing a composite ceramic and composite ceramic produced using such a method |
Also Published As
Publication number | Publication date |
---|---|
SG120941A1 (en) | 2006-04-26 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US5846664A (en) | Porous metal structures and processes for their production | |
CN101473054B (en) | Process for producing shaped refractory metal bodies | |
CN104588651A (en) | Flexible multi-hole metal foil and manufacturing method thereof | |
JP2010515829A (en) | Ceramic composite molded body and / or powder metallurgy composite molded body and method for producing the same | |
WO1997005083A1 (en) | Method for manufacturing intermetallic/ceramic/metal composites | |
US20050019199A1 (en) | Double-layer metal sheet and method of fabricating the same | |
US4744944A (en) | Process for producing tungsten heavy alloy billets | |
CN104588662A (en) | Flexible multi-hole metal foil and manufacturing method thereof | |
EP1694875B1 (en) | Processes for sintering aluminum and aluminum alloy components | |
CN103397244A (en) | Preparation method of sintered Fe-Al-based porous alloy material with high-temperature oxidization resistance | |
JP2849710B2 (en) | Powder forming method of titanium alloy | |
US7517492B2 (en) | Processes for sintering aluminum and aluminum alloy components | |
CN114932235A (en) | Near-net-shape forming preparation method of controllable metal-based framework for powder metallurgy | |
JPH01194914A (en) | Metallic filter and manufacture thereof | |
CN104759630A (en) | Preparation method of porous metal foil | |
JPH07238302A (en) | Sintered titanium filter and production thereof | |
CN114535342B (en) | Preparation method of foldable nickel film | |
JP3053949B2 (en) | Manufacturing method of aluminum nitride multilayer substrate | |
JPH046163A (en) | Production of carrier consisting of aluminium nitride | |
JP2942212B2 (en) | Manufacturing method of ceramics | |
JPH0768114A (en) | Metallic sintered filter and production thereof | |
JPS6346716A (en) | Manufacture of laminated sintered unit | |
WO2024024290A1 (en) | Method for producing titanium porous body, and titanium porous body | |
JPH1150171A (en) | Production of titanium-aluminum matrix composite | |
JPH01129904A (en) | Production high-density sintered body |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: AGENCY FOR SCIENCE, TECHNOLOGY AND REAEARCH, SINGA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:LI, QINGFA;HO, MENG KWONG;ZHANG, SU XIA;REEL/FRAME:015843/0627 Effective date: 20040901 |
|
AS | Assignment |
Owner name: AGENCY FOR SCIENCE, TECHNOLOGY AND RESEARCH, SINGA Free format text: RE-RECORDED TO CORRECT ASSIGNEE'S NAME ON AN ASSIGNMENT DOCUMENT PREVIOUSLY RECORDED AT REEL 015843 FRAME 0627;ASSIGNORS:LI, QINGFA;HO, MENG KWONG;ZHANG, SU XIA;REEL/FRAME:016682/0464 Effective date: 20040901 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |