US3915699A - Method for producing metal dies or molds containing cooling channels by sintering powdered metals - Google Patents

Method for producing metal dies or molds containing cooling channels by sintering powdered metals Download PDF

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Publication number
US3915699A
US3915699A US318195A US31819572A US3915699A US 3915699 A US3915699 A US 3915699A US 318195 A US318195 A US 318195A US 31819572 A US31819572 A US 31819572A US 3915699 A US3915699 A US 3915699A
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United States
Prior art keywords
mold
powder
sintering
die
pattern
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Expired - Lifetime
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US318195A
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English (en)
Inventor
Hanji Umehara
Takashi Kimura
Hiroshi Hamamoto
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Toyota Central R&D Labs Inc
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Toyota Central R&D Labs Inc
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Priority to US318195A priority Critical patent/US3915699A/en
Publication of USB318195I5 publication Critical patent/USB318195I5/en
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Publication of US3915699A publication Critical patent/US3915699A/en
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    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F3/26—Impregnating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/06—Permanent moulds for shaped castings
    • B22C9/061—Materials which make up the mould
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • B22F2005/103—Cavity made by removal of insert
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy

Definitions

  • the method includes the steps of disposing sintering [22] Filed: Dec. 26, 1972 powder, such as iron, copper, tungsten carbide or titanium carbide, in a frame or box, about a attern made [211 App! 318l95 of an infiltrant metal, such as copper, lead, cobalt, [44] Published under the Trial Volunta P t t nickel, iron or alloys thereof, having a lower melting Program on January 28, 1975 as document no. point than that of the sintering powder, the pattern B 318,195. corresponding in configuration to that of the cavity Related US.
  • sintering [22] Filed: Dec. 26, 1972 powder, such as iron, copper, tungsten carbide or titanium carbide, in a frame or box, about a attern made [211 App! 318l95 of an infiltrant metal, such as copper, lead, cobalt, [44] Published under the Trial Volunta P t t nickel, iron or alloys thereof, having a lower melting Program on January 28, 1975 as document no
  • This invention relates to a sintered metal die or mold, such as a casting mold, a pressing die, or a die-cast mold, having formed therein an internal channel for conducting a heat transfer medium therethough, and to a method of producing same.
  • the present invention provides for the manufacture of a metal die mold, having formed therein an internal channel for conducting a heat transfer medium therethough, by means of a sintering process which obviates the disadvantages of the conventional methods briefly outlined above.
  • the channel formed by means of the present process can be of any desire shape and at any desired position in the metal mold or die and does not require any machining operations nor much time and expense.
  • the improved method comprises the steps of disposing sintering powder, such as iron, copper, tungsten carbide or titanium carbide, in a frame or box, about a pattern made of an infiltrant metal, such as copper, lead, cobalt, nickel, iron or alloys thereof, having a lower melting point than that of the sintering powder, the pattern corresponding in configuration with that of the cavity surface of the desired channel for conducting the heat transfer medium and being positioned within the sintering powder in the position desired for the channel, and heating the powder together with the pattern to sintering temperature.
  • the infiltrant metal pattern melts and infiltrates entirely into the sintered metal powder.
  • the resultant product is hardened sintered mold or die having a cavity or channel having a shape and size corresponding to the surface of the pattern at the portion where the pattern was disposed. Furthermore, the infiltrated metal also serves to strengthen and reinforce the die or mold at the parts surrounding the channel, and
  • a primary object of the present invention is to provide a sintered metal die or mold having formed therein an internal channel for conducting a heat transfer medium therethrough, and a method for producing same.
  • Another object of the invention is to provide a method for producing a metal die or mold as described above, without machining.
  • Still another object of the invention is to provide a sintered metal die or mold as described above, having formed therein a curved internal channel for conducting a heat transfer medium therethrough.
  • a further object of the invention is to provide a sintered metal die or mold as described above, wherein the channel for conducting the heat transfer medium is relatively leakproof.
  • a still further object of the invention is to provide a method for producing a metal die or mold as described above, which is easy to follow, inexpensive, provides consistent results, and is commercially practicable.
  • FIG. 1 is a cross-sectional view of a metal casting mold of sintered metal powder material and having formed therein an internal channel for conducting a heat-transfer medium therethrough;
  • FIG. 2 is a horizontal cross-sectional view taken along the line 2-2 of FIG. 1;.
  • FIG. 3 is a perspective view of a pattern used for forming the channel in the metal mold of FIGS. 1 and FIG. 4 is a perspective view of a mother mold for forming the mold surfaces of the metal mold of FIGS. land 2;
  • FIG. 5 is a cross-sectional view of the embodiment for producing the metal mold of FIGS. 1 and 2, showing metal powder having the pattern of FIG. 3 and the mother mold of FIG. 4 disposed therein;
  • FIG. 6 is a cross-sectional view taken along the line 6-6 of FIG. 5;
  • FIG. 7 is a cross-sectional view taken along the line 77 of FIG. 5.
  • the casting mold to be manufactured is of a split type which consists of a lower mold 721 and an upper mold 722 which are made of sintered iron powder material.
  • the lower mold 721 has a lower mold surface 601, a zig-zag shaped internal channel 111 for conducting a heat transfer medium through the lower mold, and guide holes 766.
  • the upper mold 722 has an upper mold surface 602, a down-gate 761, a tapping 762, a zig-zag shaped internal channel 121 for conducting a heat transfer medium through the upper mold similar to the channel 1 1 1, and guides 765.
  • the channels 111 and 121 are provided at their open ends with threaded screw portions 115 and 116 to connect with an inlet pipe and outlet pipe, respectively, for a heat transfer medium, such as cooling water.
  • a heat transfer medium such as cooling water.
  • the pattern 11 for the formation of the channel 111 of the lower mold is shown in FIG. 3.
  • the pattern 11 is made from copper, has a U-shaped zig-Zag form, and is provided at each end with threaded screw portions and 16 for the formation of threaded screw portions 115 and 116 of the channels.
  • the mother mold 6 for the formation of the casting mold surfaces has, as shown in FIG. 4, a cup portion 60 having at its open edge a gate stick 61 for the formation of the down-gate 761 and a tapping bar 62 for forming the tapping 762.
  • FIGS. 1 and 2 The process of forming the casting mold of FIGS. 1 and 2 is illustrated in F IGS'. 5 to 7.
  • a ceramic forming frame 31 having a bottom is coated with alumina powder as a demolding agent on the inner peripheral surface thereof.
  • a layer of iron powder is then charged on the bottom of the forming frame 31.
  • the pattern 11 shown in FIG. 3 is then disposed on the layer of iron powder over which additional iron powder is then charged.
  • Upon these layers is then mounted a ceramic mother mold 6 coated with alumina powder over the entire surface. Additional iron powder is then charged to the level of the upper edge of the mother mold 6, thereby forming the lower layer 71.
  • ceramic mother molds 65 having a cup-like configuration in crosssection and coated with alumina powder over their entire surface, are then buried in the iron powder at positions in four radial directions of the mother mold 6 such that their upper ends are respectively located on the same level as the upper edge of the cup 60.
  • On the lower layer 71 is then coated a layer 8 of alumina powder for the formation of a parting surface.
  • the obtained surface is charged with additional iron powder, upon which is mounted within the mother mold 6 a copper pattern 21, similar to the pattern 11, having a zig-zag shape with its middle portion bent downward as shown in FIG. 3. Additional iron powder is then charged upon all these layers, thereby forming the upper layer 72.
  • a load of about 0.8 ton per square centimeter is then applied upon the upper layer 72 to compress the iron powder.
  • the compressed iron powder compact within the forming frame 31 is then placed in a sintering furnace and sintered at 1 120C. for 60 minutes in an atmosphere of nitrogen.
  • the copper patterns 11 and 21 melt during the sintering operation.
  • the molten copper infiltrates into the spaces in the sintered iron powder by a capillary action, thereby leaving cavities in the sintered material in the form of internal channels 111 and 121 corresponding in dimensions and shape to the patterns 11 and 21, respectively, at the portions where these patterns had been located.
  • the infiltration of the molten copper into the sintered iron powder strengthens the binding of the iron powder around the channels 111 and 121 and also fully closes any small holes around the channels in the material so as to prevent leakage of any heat transfer medium from the channels into the mold when the mold is in use.
  • the sintered product is then cooled and removed from the outer frame 31.
  • the alumina powder parting agent prevents the upper charged layer 72 and the lower charged layer 71 from becoming sintered to each other, to the mother molds 6 and 65, or to the outer frame 31 during the sintering operation. Therefore the mother molds 6 and 65 may be readily removed, thereby resulting in the sintered metal casting mold shown in FIGS. 1 and 2, comprising a lower mold 721 having formed therein an internal channel 111, and an upper mold 722 having formed therein an internal channel 121.
  • the upper mold 722 is laid upon the lower mold 721, their meeting surfaces are snugly fitted to each other, thereby preventing any leaking of molten metal when they are used in manifacturing molded products.
  • the mother molds 6 and 65 are made out of ceramic material, having a softening point much higher than the sintering temperature. Therefore no collapsing or deformation of the mother molds occur during the sintering operation, and these molds may be reused many times.
  • the mother molds 6 and 65 may be made of copper similar to the patterns 11 and 21.
  • the mother molds 6 and 65 would melt during the sintering ation and infiltrate into the spaces of the sintered iron powder, thereby strengthening and reinforcing the sintered product, and forming the mold surfaces 601 and 602, the down-gate 761, the tapping 762, the guides 765 and the guide holes 766 in a manner similar to the formation of the channels 111 and 121 as described above.
  • the iron powder is compressed prior to being sintered. This increases the density and strength of the final mold and also helps to prevent collapse of the iron powder surfaces at the portions in contact with the copper patterns 11 and 21 when the patterns melt and form cavities during the sintering operation.
  • a two-stage sintering process can advantageously be employed which includes a presintering for about 2 hours at 900C followed by the normal sintering operation for about 60 minutes at 1 C as above described.
  • the presintering operation the copper of the pattern will not melt but the iron powder will be sintered and there will be obtained a substantially skeleton-like material.
  • the infiltration of the copper and the normal sintering of the iron powder will occur. Consequently the infiltration is carried out smoothly and a more sturdy sintered material can be obtained.
  • a molding frame which can endure compression and sintering is used as a molding frame, as in the above-described embodiment, it is possible to sinter the metal powder within the forming frame.
  • the metal powder before or while it is sintered is not subjected to collapsing.
  • a molding frame may not always be required during the sintering operation.
  • a forming die can be used as a molding frame in which the metal powder, patterns for forming the channels, and mother molds for forming the mold surfaces, are disposed in an arrangement and compressed by the forming die. The resulting compact with the patterns and mother molds will be very sturdy and can be taken out of the die and sintered without a molding frame.
  • the metal powder used as the sintering material may be iron, copper, tungsten carbide, titanium carbide or the like.
  • the infiltrant metal used to form the pattern must have a melting point lower than the sintering temperature of the sintering material.
  • the sintering conditions will, of course, vary with the particular materials used for the sintering material and for the pattern.
  • the infiltrant metal used for forming the pattern should be either copper, a copper-manganese alloy or a copper-cobalt alloy, for example, a 95% copper 5% manganese alloy, a 97% copper-3% cobalt alloy, or the like.
  • Typical sintering conditions for these materials would be 60 minutes at 1 120C in an atmosphere of nitrogen.
  • the infiltrant metal used for forming the pattern should be lead, a lead-tin alloy or lead-cadmium alloy, for example, a 50% lead-50% tin alloy, an 82% lead- 18% cadmium alloy or the like, with typical sintering conditions being 60 minutes at 500C in an atmosphere of hydrogen. If a metal powder whose main ingredient is tungsten carbide is used as the sintering material, then the infiltrant metal used for forming the pattern should be cobalt, nickel, an iron alloy or the like, with typical sintering conditions being 60 minutes at l550C in an atmosphere of hydrogen.
  • the infiltrant metal used for forming the pattern should be nickel, a nickel molybdenum alloy for example, a 95% nickel-5% molybdenum alloy, a cobalt alloy or the like, with typical sintering conditions being 60 minutes at l550C in an atmosphere of hydrogen.
  • the patterns used in the present invention will have the same dimensions and shape as the channels desired to be formed in the die or mold. Furthermore, the channels may be located at any desired position within the die or mold merely by varying the position of the pattern within the sintering powder when the pattern and powder are charged into the frame.
  • the molding surfaces of the metal die or mold are formed together with the formation of the sintered product with the channels. It is also possible, however, to first form the sintered material having the channels formed therein, and thereafter form the molding surfaces by cutting the sintered material.
  • the method of the present invention can be applied not only to the manufacture of casting molds as shown in the above-described embodiment, but also to the manufacture of press-dies, die-casting molds, molds for plastic, glass or rubber molding, and to any other metal molds in the broad sense.
  • titanium carbide in a frame forming a mother mold conforming in size and configuration to a desired mold cavity, forming a pattern of long and slender shape having a desired surface configuration corresponding to that of said internal channel for conducting a heat transfer medium and which complements the surface of the desired mold cavity, said pattern being made of metal infiltratable into the pores of said sintering powder and having a lower melting point than that of said sintering powder, at least partially embedding said mother mold in said layer of sintering powder, adding a second layer of said sintering powder to completely embed the mother mold and separated from the first layer by a demolding agent, completely embedding said pattern in complementary spaced relation in one of said layers of sintering powder so that both ends of said pattern contact with the inside of a wall of said frame, heating said sintering powder, mother mold and pattern to a sintering temperature to sinter said powder and to infiltrate said infiltratable metal of said pattern into said powder, and cooling so as to obtain a

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US318195A 1969-11-08 1972-12-26 Method for producing metal dies or molds containing cooling channels by sintering powdered metals Expired - Lifetime US3915699A (en)

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US318195A US3915699A (en) 1969-11-08 1972-12-26 Method for producing metal dies or molds containing cooling channels by sintering powdered metals

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JP44089965A JPS5013205B1 (tr) 1969-11-08 1969-11-08
US8433570A 1970-10-27 1970-10-27
US318195A US3915699A (en) 1969-11-08 1972-12-26 Method for producing metal dies or molds containing cooling channels by sintering powdered metals

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US3915699A true US3915699A (en) 1975-10-28

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US11318529B2 (en) 2018-12-20 2022-05-03 Honda Foundry Co., Ltd. Casting device

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CN104741884B (zh) * 2015-01-30 2017-03-08 东莞劲胜精密组件股份有限公司 一种内部具有随形水路的模具及其制作方法
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US11318529B2 (en) 2018-12-20 2022-05-03 Honda Foundry Co., Ltd. Casting device

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Publication number Publication date
DE2054972B2 (de) 1976-08-19
FR2067051B1 (tr) 1973-11-23
DE2054972A1 (de) 1971-05-27
USB318195I5 (tr) 1975-01-28
FR2067051A1 (tr) 1971-08-13
GB1308344A (en) 1973-02-21
JPS5013205B1 (tr) 1975-05-17

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