WO2009090622A1 - A method of extending the lifespan of a metal cavity mould - Google Patents

A method of extending the lifespan of a metal cavity mould Download PDF

Info

Publication number
WO2009090622A1
WO2009090622A1 PCT/IB2009/050178 IB2009050178W WO2009090622A1 WO 2009090622 A1 WO2009090622 A1 WO 2009090622A1 IB 2009050178 W IB2009050178 W IB 2009050178W WO 2009090622 A1 WO2009090622 A1 WO 2009090622A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
metal
moulding
layer
cavity
Prior art date
Application number
PCT/IB2009/050178
Other languages
French (fr)
Inventor
Hilton Mark Layman
Original Assignee
Mould Technico Cc
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
Priority to ZA2008/00552 priority Critical
Priority to ZA200800552 priority
Application filed by Mould Technico Cc filed Critical Mould Technico Cc
Publication of WO2009090622A1 publication Critical patent/WO2009090622A1/en

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03BMANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B9/00Blowing glass; Production of hollow glass articles
    • C03B9/30Details of blowing glass; Use of materials for the moulds
    • C03B9/48Use of materials for the moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/057Manufacturing or calibrating the moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20Accessories: Details
    • B22D17/22Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D7/00Casting ingots, e.g. from ferrous metals
    • B22D7/06Ingot moulds or their manufacture
    • B22D7/066Manufacturing, repairing or reinforcing ingot moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20Bonding
    • B23K26/32Bonding taking account of the properties of the material involved
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34Laser welding for purposes other than joining
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34Laser welding for purposes other than joining
    • B23K26/342Build-up welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/04Welding for other purposes than joining, e.g. built-up welding
    • B23K9/044Built-up welding on three-dimensional surfaces
    • B23K9/046Built-up welding on three-dimensional surfaces on surfaces of revolution
    • B23K9/048Built-up welding on three-dimensional surfaces on surfaces of revolution on cylindrical surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00Restoring or reconditioning objects
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/50Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
    • B23K35/0244Powders, particles or spheres; Preforms made therefrom
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0261Rods, electrodes, wires
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053Fe as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053Fe as the principal constituent
    • B23K35/308Fe as the principal constituent with Cr as next major constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053Fe as the principal constituent
    • B23K35/308Fe as the principal constituent with Cr as next major constituent
    • B23K35/3086Fe as the principal constituent with Cr as next major constituent containing Ni or Mn

Abstract

A method of extending the lifespan of a metal cavity glass bottle mould, includes the steps of machining the entire moulding surface of the mould to remove a surface layer of metal, cladding the machined moulding surface by depositing a layer of filler metal onto the surface in a laser cladding process and machining an exposed surface of the cladding layer so as to remove excess filler metal and return the moulding cavity to its design dimensions. The method includes a method of repairing a metal cavity mould by removing surface defects in the moulding surface of a damaged mould by machining the moulding surface and thereafter cladding the moulding surface. The method extends to the cladding of the moulding surface of an undamaged metal cavity mould.

Description

A METHOD OF EXTENDING THE LIFESPAN OF A METAL CAVITY MOULD
FIELD OF INVENTION
This invention relates to a method of extending the lifespan of a metal cavity mould. It relates also to a metal cavity mould wherein the lifespan of the mould has been extended in accordance with the method.
BACKGROUND TO INVENTION
Metal cavity moulds for use in moulding glass articles such as bottles or the like, have a limited lifespan. A typical cast iron cavity mould for moulding glass bottles in a continuous moulding process, typically operates at a working temperature of approximately 450 °C and produces approximately 750 000 bottles during its lifetime. When a crack forms in such a metal cavity mould, it is discarded and replaced. In many instances, the production line is brought to a halt to allow for the cracked mould to be removed and replaced, after which production resumes, resulting in a loss of production. If the moulding surfaces do not become cracked, the moulding surfaces of such moulds eventually become worn after a period of use to such an extent that the mould is no longer able to produce glass bottles which meet the required dimensional specification and thus need to be replaced. Any reference herein to the "working temperature" of a metal cavity mould must be interpreted to mean the temperature at which the mould is normally used during a moulding operation.
Any reference herein to "design dimensions" of the mould cavity of a metal cavity mould must be interpreted to mean the dimensions of the mould cavity specified for moulding articles having specific dimensions.
It is an object of the present invention to provide for the repair of damaged metal cavity moulds thereby extending the lifespan of such damaged moulds and also to extend the lifespan of undamaged metal cavity moulds.
SUMMARY OF INVENTION
A method of extending the lifespan of a metal cavity mould, the method including:
machining the entire moulding surface of the mould to remove a surface layer of metal;
depositing a layer of molten filler metal onto the machined moulding surface, wherein the layer of molten filler metal has a thickness which is greater than the thickness of the surface layer of molten filler metal removed during machining; and
machining an exposed surface of the deposited layer of filler metal so as to remove excess filler metal, thereby to return the moulding cavity of the mould to its design dimensions.
The method may be applied to the repair of a metal cavity mould, wherein the mould has at least one relatively shallow surface defect in the mould surface, the method including the steps of:
machining the entire moulding surface of the mould to remove a surface layer of metal to a depth sufficient to remove the depression in the moulding surface; depositing a layer of molten filler metal onto the machined moulding surface, wherein the layer of molten filler metal has a thickness which is greater than the thickness of the surface layer of metal removed during machining; and
machining an exposed surface of the deposited layer of filler metal so as to remove excess filler metal, thereby to return the moulding cavity of the mould to its design dimensions.
In another embodiment of the invention, the method may be applied to the repair of a metal cavity mould wherein the mould has at least one relatively deep crack in the moulding surface, the method including the steps of:
machining the entire moulding surface of the mould to remove the surface layer of metal to a depth which reduces the depth of the crack but does not remove the crack entirely;
enlarging the crack by removing metal surrounding the crack;
heating the mould to a temperature at or above the working temperature of the mould;
while the mould is at said temperature at or above the working temperature of the mould, filling in the enlarged crack by depositing molten filler metal into the enlarged crack and allowing time for the mould to slow cool;
annealing the mould by heating the mould to a temperature above the working temperature of the mould and allowing the mould to slow cool;
depositing a layer of molten filler metal onto the machined moulding surface of the mould, to a thickness which is greater than the thickness of the surface layer of metal removed during machining; and machining an exposed surface of a deposited layer of filler metal to remove excess filler metal, thereby to return the mould cavity of the mould to its design dimensions.
The metal cavity mould may be specifically adapted for use in moulding glass articles. More particularly, the metal cavity mould may be specifically adapted for use in moulding glass bottles.
The metal cavity mould may be of cast iron and the filler metal which is deposited onto the machined moulding surface, may be of a metal having a relatively greater hardness than that of the cast iron of the metal cavity mould.
The filler metal which is deposited onto the machined moulding surface, may be of a metal having a relatively lower thermal conductivity than that of the cast iron of the metal cavity mould.
The layer of molten filler metal may be deposited onto the machined moulding surface by one of a laser cladding, laser cusing and an arc welding process.
The invention extends to a metal cavity mould, wherein the lifespan of the metal cavity mould has been extended in accordance with the method described and defined hereinabove.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the invention are described hereinabove by way of a non-limiting example of the invention, with reference to and as illustrated in the accompanying diagrammatic drawings. In the drawings:
Figure 1 shows a schematic perspective view of a metal cavity mould with a base plate connected thereto;
Figure 2 shows a schematic exploded top plan view of the metal cavity mould and base plate of Figure 1 ; Figure 3 shows a sectional side view of the metal cavity mould of Figure 1 , sectioned along section line Ill-Ill of Figure 1 ;
Figure 4 shows a sectional side view of the metal cavity mould of Figure 1 , sectioned along section line Ill-Ill of Figure 1 , illustrating the mould having a surface defect in the form of a relatively deep crack in the moulding surface thereof;
Figures 5A to 5F show an enlarged sectional side view of detail R of Figure 4, illustrating, in sequence, the manner in which the crack in the moulding surface of the mould is repaired in accordance with the method of the invention;
Figure 6 shows a sectional side view of the mould of Figure 4 in its repaired state;
Figure 7 shows a sectional side view of the mould of Figure 1 , sectioned along section line Ill-Ill of Figure 1 , having a surface defect in the form of a shallow depression in the moulding surface thereof;
Figures 8A to D show enlarged sectional side views of detail S of Figure 7, illustrating, in sequence, the manner in which the depression in the moulding surface of the mould, is repaired; and
Figure 9 shows a sectional side view of the mould of Figure 7 in its repaired state.
DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to Figures 1 to 3 of the drawings, a metal cavity mould for use in moulding glass bottles, is designated generally by the reference numeral 10. The metal cavity mould 10 is of SG600 cast iron and has a mould surface 12 defining one half of a mould cavity 14 in which the sides and neck of a glass bottle is moulded. A base plate 16 also of SG600 cast iron is located relative to the metal cavity mould for forming the base of a glass bottle. Under typical operating conditions, the mould 10 is used for moulding glass bottles in a continuous moulding process at a working temperature of approximately 450 °C. Moulds of this type have a typical lifespan of approximately 750 000 bottles. At the end of its lifespan, the mould begins to show signs of wear and tear. The moulding surface 12 is often pitted and cracks may appear in the moulding surface due to metal fatigue and/or overheating. Depressions may also form due to loss of material as a result of wear. The general practice is to discard moulds which have cracks in the moulding surface and which become worn to an extent wherein the mould is no longer able to produce bottles which meet the required dimensional specification.
In accordance with the invention, the lifespan of the mould 10 can be extended by, broadly, machining the entire moulding surface 12 of the mould 10 by using a milling cutter, to remove a surface layer of metal. Thereafter, the machined moulding surface is clad by depositing a layer of molten filler metal onto the machined moulding surface wherein the layer of molten filler metal has a thickness which is greater than the thickness of the layer of molten filler metal removed during machining. Finally, the exposed surface of the deposited layer of filler metal is again machined so as to remove excess filler metal, thereby to return the moulding cavity to its design dimensions.
The lifespan of an undamaged cast iron metal cavity mould for moulding glass bottles, can be extended by following the steps of the broad method described hereinabove.
With reference to Figures 4 to 6 of the drawings, the manner in which the lifespan of a metal cavity mould can be extended by repairing a crack in the moulding surface of the mould, is illustrated. In order to inspect the moulding surface for cracks, a developing solution is sprayed onto the moulding surface and an ultraviolet light is directed onto the moulding surface which shows up any cracks which may have formed in the mould surface. In Figure 4 of the drawings, a relatively deep crack 18 is shown in the moulding surface 12. In order to repair the crack, the entire moulding surface 12 of the mould 10 is machined in a milling process using a milling cutter 20, to remove a surface layer 0.5mm thick to thereby remove surface deformities in and carbon deposits on the moulding surface. In Figures 5A to 5F, the moulding surface 12 which corresponds to the design dimensions of the mould cavity 14, is represented by the reference letter "A", whereas the moulding surface after a surface layer of metal has been removed in the milling process, is represented by the reference letter "B". The mould is then heated to the working temperature of the mould, i.e. to approximately 450 °C and while at this elevated temperature, the crack 18 is ground open to remove a surface layer of metal surrounding the crack. The ground crack is then bevelled to an angle of approximately 60° (see Figure 5C).
While the temperature of the mould is maintained at 450 °C, the bevelled crack is filled in by depositing molten filler metal 20 into the crack (see Figure 5D). Typically, this involves depositing molten filler metal into the cracks in a stick welding operation using a 3mm diameter nickel welding rod. The weld area is then peened to remove porosity in the weld and thereafter ground smooth while the temperature of the mould is maintained at 450 °C. The mould is thereafter allowed to slow cool in ambient air to room temperature. Thereafter, the mould is annealed by heating the mould to a temperature of approximately 600 °C and allowed to slow cool in ambient air to room temperature. After the mould has slow cooled, the machined mould surface is clad by depositing a cladding layer of molten filler metal onto the machined moulding surface of the mould (see Figure 5E), to a thickness which is greater than the thickness of the surface layer of metal removed during machining. The surface of the cladding layer of the deposited molten filler metal is represented by the reference letter "C" in Figure 5E and 5F. The metal selected as the filler metal for forming the cladding layer in this instance, is selected so as to have a relatively greater hardness than that of the cast iron of the metal cavity mould 10 and also to have a relatively lower thermal conductivity than that of the cast iron of the mould. Furthermore, the filler metal for forming the cladding layer must also be metallurgically compatible with the cast iron of the mould. The Applicant has found martensitic Stainless Steel 304 or 316 which exhibits both of these material properties, to be suitable cladding metals.
After the cladding layer has fused to the underlying machined moulding surface, the exposed surface of the cladding layer of filler metal is machined in a milling process to remove excess filler metal, thereby to form a cladding layer 24 returning the mould cavity 14 of the mould 10 to its design dimensions. The cladding layers 24 and 28 provide the mould 10 with increased hardness and resistance to wear thereby extending the lifespan of the mould. In typical examples, the cladding layers may be V∑mm - 1 mm thick.
With reference to Figures 7 to 9 of the drawings, the manner in which the lifespan of a metal cavity mould can be extended by repairing a relatively shallow surface defect in the form of a depression which has been formed due to localised wear in the moulding surface, as illustrated. In Figure 7 of the drawings, a shallow depression 26 is shown in the moulding surface 12. In order to repair the mould, the entire moulding surface 12 of the mould 10 is machined in the milling process using a milling cutter 20, to remove a surface layer of metal to a depth sufficient to remove the depression 26 in the moulding surface. In Figures 8A and 8B, the moulding surface 12 which corresponds to the design dimensions of the mould cavity 14, is represented by the reference numeral "K", whereas the moulding surface after a surface layer of metal has been removed in the milling process, is represented by the reference numeral "L". The machined mould surface is thereafter clad by depositing a cladding layer of molten filler metal onto the machined moulding surface of the mould (see Figure 8C), to a thickness which is greater than the thickness of the surface layer of metal removed during machining. The surface of the cladding layer of the deposited molten filler metal is represented by the reference numeral "M" in Figure 8C and 8D. As for the repair of a crack in the moulding surface as described hereinabove, the metal selected as the filler metal for forming the cladding layer, is selected so as to have a relatively greater hardness than that of the cast iron of the metal cavity mould and also to have a relatively lower thermal conductivity than that of the cast iron of the mould. Furthermore, the filler metal for forming the cladding layer must also be metallurgically compatible with the cast iron of the mould. In this instance, the Applicant has found martensitic Stainless Steel 304 or 316 which exhibit these material properties, to be suitable cladding metals.
After the cladding layer has fused to the underlying machine to moulding surface, the exposed surface of the cladding layer of filler metal is machined in a milling process to remove excess filler material, thereby to form a cladding layer 28 having a thickness returning the mould cavity 14 of the mould 10 to its design dimensions. The cladding layers 24 and 28 provide the mould 10 with increased hardness and resistance to wear thereby extending the lifespan of the mould. In typical examples, the cladding layers may be V∑mm - 1 mm thick.
The Applicant has found that metal deposition processes which are suitable for cladding the machined mould surface, include laser cladding, laser casing and arc welding. In a laser cladding process, a metallic consumable typically provided in the form of metallic powder or metal wire feedstock, is melted and consolidated by means of a laser beam thereby to form a cladding layer which is metallurgically bonded to the underlying machined moulding surface.
In a laser cusing process, a metallic powder compound is melted using a laser, in layers of approximately 0.001 mm. As such, layers of the molten metallic powder are deposited onto the machined moulding surface so as to build up the cladding layer to a desired thickness. The cladding layer forms a metallurgical bond to the underlying machined moulding surface.
In an arc welding process, the filler metal is deposited in a number of passes so as to form a metallurgical bond with the underlying machined moulding surface of the mould.
In a continuous glass bottle moulding process, the feed rate is maintained at a feed rate at which the working temperature of the metal cavity moulds, is not exceeded by a significant amount. If the feed rate is too high, the moulds overheat and are prone to damage. Furthermore, when overheated, the moulds expand excessively, resulting in an enlargement of the mould cavities to an extent wherein the moulds are no longer able to produce glass bottles of the required dimensional specification. By cladding the moulding surfaces with filler metal having a lower thermal conductivity than that of cast iron, the feed rate of feed stock in a glass bottle moulding process can be increased, as the working temperature of the moulds in accordance with the method of the present invention, is reduced compared to the working temperature of an unclad cast iron mould. In particular, the Applicant has found that by cladding the moulding surface with martensitic Stainless Steel 304 of 316, the feed rate of feedstock in a continuous glass bottle moulding process, can be increased by up to 25% compared to the feed rate for similar unclad cast iron moulds, without exceeding the working temperature of the mould.

Claims

CLAIMS:
1. A method of extending the lifespan of a metal cavity mould, the method including:
machining the entire moulding surface of the mould to remove a surface layer of metal;
depositing a layer of molten filler metal onto the machined moulding surface, wherein the layer of molten filler metal has a thickness which is greater than the thickness of the surface layer of molten filler metal removed during machining; and
machining an exposed surface of the deposited layer of filler material so as to remove excess filler metal, thereby to return the moulding cavity of the mould to its design dimensions.
2. The method as claimed in claim 1 , which is applied to the repair of a metal cavity mould, wherein the mould has at least one relatively shallow surface defect in the mould surface, the method including the steps of:
machining the entire moulding surface of the mould to remove a surface layer of metal to a depth sufficient to remove the surface defect in the moulding surface;
depositing a layer of molten filler metal onto the machined moulding surface, wherein the layer of molten filler metal has a thickness which is greater than the thickness of the surface layer of metal removed during machining; and
machining an exposed surface of the deposited layer of filler metal so as to remove excess filler metal, thereby to return the moulding cavity of the mould to its design dimensions.
3. The method as claimed in claim 1 , which is applied to the repair of a metal cavity mould wherein the mould has at least one relatively deep crack in the moulding surface, the method including the steps of:
machining the entire moulding surface of the mould to remove the surface layer of metal to a depth which reduces the depth of the crack but does not remove the crack entirely;
enlarging the crack by removing metal surrounding the crack;
heating the mould to a temperature at or above the working temperature of the mould;
while the mould is at said temperature at or above the working temperature of the mould, filling in the enlarged crack by depositing molten filler metal into the enlarged crack and allowing time for the mould to slow cool;
annealing the mould by heating the mould to a temperature above the working temperature of the mould and allowing the mould to slow cool;
depositing a layer of molten filler metal onto the machined moulding surface of the mould, to a thickness which is greater than the thickness of the surface layer of metal removed during machining; and
machining an exposed surface of a deposited layer of filler metal to remove excess filler metal, thereby to return the mould cavity of the mould to its design dimensions.
4. The method as claimed in any one of claims 1 to 3, wherein the metal cavity mould is specifically adapted for use in moulding glass articles.
5. The method as claimed in claim 4, wherein the metal cavity mould is specifically adapted for use in moulding glass bottles.
6. The method as claimed in any one of claims 1 to 5, wherein the metal cavity mould is of cast iron and wherein the filler metal which is deposited onto the machined moulding surface, is of a metal having a relatively greater hardness than that of the cast iron of the metal cavity mould.
7. The method as claimed in any one of claims 1 to 6, wherein the filler metal which is deposited onto the machined moulding surface, is of a metal having a relatively lower thermal conductivity than that of the cast iron of the metal cavity mould.
8. The method as claimed in any one of claims 1 to 7, wherein the layer of molten filler metal is deposited onto the machined moulding surface by one of a laser cladding, laser cusing and an arc welding process.
9. A metal cavity mould wherein the lifespan of the metal cavity mould has been extended in accordance with the method as claimed in any one of claims 1 to 8.
PCT/IB2009/050178 2008-01-18 2009-01-19 A method of extending the lifespan of a metal cavity mould WO2009090622A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
ZA2008/00552 2008-01-18
ZA200800552 2008-01-18

Publications (1)

Publication Number Publication Date
WO2009090622A1 true WO2009090622A1 (en) 2009-07-23

Family

ID=40885091

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2009/050178 WO2009090622A1 (en) 2008-01-18 2009-01-19 A method of extending the lifespan of a metal cavity mould

Country Status (1)

Country Link
WO (1) WO2009090622A1 (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012013851A1 (en) 2010-07-28 2012-02-02 Universidad Del Pais Vasco - Euskal Herriko Unibertsitatea Method for supplying metallic materials
EP2540433A1 (en) 2011-06-30 2013-01-02 Etablissements Chpolansky Method for refilling a mold for glas using powder laser buildup
ES2517740A1 (en) * 2013-04-29 2014-11-03 Construcciones Y Reparaciones Mecánicas Sivó, S. L. Process for the recovery of moulds for the manufacturing of glass parts and containers
ITMI20131271A1 (en) * 2013-07-29 2015-01-30 D G Weld S R L Method for the coating in metal material of ductile iron bodies and surfaces for molds for aluminum die-casting machines made with this method
JP2015150593A (en) * 2014-02-17 2015-08-24 小山鋼材株式会社 Die cast metal mold and heat treatment method for the same
CN104894557A (en) * 2015-05-28 2015-09-09 机械科学研究总院先进制造技术研究中心 Composite molding method of metal mold
US9764425B2 (en) 2012-04-16 2017-09-19 Magna International Inc. Process for laser-assisted tool build and repair

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1368846A (en) * 1973-06-08 1974-10-02 Foseco Int Repair of moulds
JPH08174215A (en) * 1994-12-27 1996-07-09 Honda Motor Co Ltd Method for repairing metallic mold
JP2001288554A (en) * 2000-03-31 2001-10-19 Toshiba Corp Repairing material, method for repairing heat resisting alloy member, and hot zone parts repaired by the method

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1368846A (en) * 1973-06-08 1974-10-02 Foseco Int Repair of moulds
JPH08174215A (en) * 1994-12-27 1996-07-09 Honda Motor Co Ltd Method for repairing metallic mold
JP2001288554A (en) * 2000-03-31 2001-10-19 Toshiba Corp Repairing material, method for repairing heat resisting alloy member, and hot zone parts repaired by the method

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012013851A1 (en) 2010-07-28 2012-02-02 Universidad Del Pais Vasco - Euskal Herriko Unibertsitatea Method for supplying metallic materials
EP2540433A1 (en) 2011-06-30 2013-01-02 Etablissements Chpolansky Method for refilling a mold for glas using powder laser buildup
FR2977177A1 (en) * 2011-06-30 2013-01-04 Chpolansky Ets Method for recharging a piece
FR3001166A1 (en) * 2011-06-30 2014-07-25 Chpolansky Ets Method for recharging a piece
US9889525B2 (en) 2011-06-30 2018-02-13 Etablissements Chpolansky Method of hardfacing a part
EP2540433B1 (en) 2011-06-30 2016-08-17 Etablissements Chpolansky Method of refilling a mold for glas using powder laser buildup
US9764425B2 (en) 2012-04-16 2017-09-19 Magna International Inc. Process for laser-assisted tool build and repair
US10456866B2 (en) 2012-04-16 2019-10-29 Magna International Inc. Process for laser-assisted tool build and repair
ES2517740A1 (en) * 2013-04-29 2014-11-03 Construcciones Y Reparaciones Mecánicas Sivó, S. L. Process for the recovery of moulds for the manufacturing of glass parts and containers
WO2014177965A1 (en) * 2013-04-29 2014-11-06 Construcciones Y Reparaciones Mecánicas Sivó, S. L. Process for the recovery of moulds for the manufacturing of glass parts and containers
CN105592966A (en) * 2013-07-29 2016-05-18 D.G.韦尔德有限责任公司 Method for coating, with metallic material, bodies made of spheroidal cast iron; back plate for dies for aluminium die casting made with said method
US20160167150A1 (en) * 2013-07-29 2016-06-16 D.G. Weld S.R.L. Method for coating, with metallic material, bodies made of spheroidal cast iron, and plans for moulds of machines for aluminium die casting made with said method
ITMI20131271A1 (en) * 2013-07-29 2015-01-30 D G Weld S R L Method for the coating in metal material of ductile iron bodies and surfaces for molds for aluminum die-casting machines made with this method
WO2015015323A1 (en) * 2013-07-29 2015-02-05 D.G. Weld S.R.L. Method for coating, with metallic material, bodies made of spheroidal cast iron; back plate for dies for aluminium die casting made with said method
JP2015150593A (en) * 2014-02-17 2015-08-24 小山鋼材株式会社 Die cast metal mold and heat treatment method for the same
CN104894557A (en) * 2015-05-28 2015-09-09 机械科学研究总院先进制造技术研究中心 Composite molding method of metal mold

Similar Documents

Publication Publication Date Title
Kattire et al. Experimental characterization of laser cladding of CPM 9V on H13 tool steel for die repair applications
CA2946844C (en) Method and device for preparing aluminium-coated steel sheets intended for being welded and then hardened under a press; corresponding welded blank
ES2525453T3 (en) A process for the production of articles made of a nickel-based superalloy reinforced by gamma-raw precipitation by selective laser fusion (SLM)
Dinovitzer et al. Effect of wire and arc additive manufacturing (WAAM) process parameters on bead geometry and microstructure
US9393984B2 (en) Utility knife blade
Li et al. Interfacial phenomena and characteristics between the deposited material and substrate in selective laser melting Inconel 625
Bhaduri et al. Laser polishing of 3D printed mesoscale components
US10260585B2 (en) Brake disc and manufacturing method thereof
US8703044B2 (en) Machine components and methods of fabricating and repairing
EP0176942B1 (en) Method for repairing metal in an article
DE60009823T2 (en) Process for repairing an injection molded steel tool
Lamikiz et al. Laser polishing of parts built up by selective laser sintering
US20150224607A1 (en) Superalloy solid freeform fabrication and repair with preforms of metal and flux
JP5887052B2 (en) Method of welding a single crystal turbine blade tip with an oxidation resistant filler material
JP4445923B2 (en) Turbine component repair method, restored turbine component manufacturing method, restored turbine component, and gas turbine engine
D'Oliveira et al. Microstructural features of consecutive layers of Stellite 6 deposited by laser cladding
EP1105243B1 (en) Turbine rotor modernization and repair method
US10493550B2 (en) Earth-boring tools having particle-matrix composite bodies and methods for welding particle-matrix composite bodies
KR20150113149A (en) Selective laser melting/sintering using powdered flux
EP0740976A1 (en) Method of repairing single crystal metallic articles
CN1071168C (en) Cutting die and method of forming
US10092975B2 (en) Solid state additive manufacturing system
CN103668182B (en) Without the need to the laser repairing process of the vehicle mould of annealing
JP5944835B2 (en) System and method for forming and processing alloy ingots
JP5894087B2 (en) System and method for processing alloy ingots

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 09702329

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase in:

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 09702329

Country of ref document: EP

Kind code of ref document: A1