WO2009141152A1 - Procédé et dispositif de réalisation d'une pièce, en particulier d'un outil de façonnage ou d'une partie d'outil de façonnage - Google Patents

Procédé et dispositif de réalisation d'une pièce, en particulier d'un outil de façonnage ou d'une partie d'outil de façonnage Download PDF

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Publication number
WO2009141152A1
WO2009141152A1 PCT/EP2009/003628 EP2009003628W WO2009141152A1 WO 2009141152 A1 WO2009141152 A1 WO 2009141152A1 EP 2009003628 W EP2009003628 W EP 2009003628W WO 2009141152 A1 WO2009141152 A1 WO 2009141152A1
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WO
WIPO (PCT)
Prior art keywords
metal
heat
mold
containing material
resistant
Prior art date
Application number
PCT/EP2009/003628
Other languages
German (de)
English (en)
Inventor
Isaac Valls Angles
Original Assignee
Rovalma, S.A.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rovalma, S.A. filed Critical Rovalma, S.A.
Priority to JP2011509897A priority Critical patent/JP2011523592A/ja
Priority to US12/994,345 priority patent/US20110129380A1/en
Publication of WO2009141152A1 publication Critical patent/WO2009141152A1/fr

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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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
    • B22D27/13—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of gas pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/15—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
    • B22D31/002—Cleaning, working on castings
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • Method and device for producing a workpiece in particular a forming tool or a
  • the present invention relates to a method of manufacturing a workpiece, in particular a forming tool or a forming tool part. Moreover, the present invention relates to an apparatus for producing a workpiece, in particular a forming tool or a shaping tool part.
  • Methods and devices of the type mentioned for producing a workpiece, in particular a forming tool or a forming tool part, are known from the prior art in different embodiments.
  • Two of the most common methods of producing, for example, forming tools or forming tool parts, are the casting and (mechanical) machining of forged blocks.
  • an alloy having the desired composition is first melted.
  • the melt is then poured into a mold whose shape is already close to the desired final shape of the forming tool or forming tool part.
  • the molten alloy is solidified in the mold, it is first coarsely worked, then heat treated and then finely finished.
  • the liquid melt is first poured into a billet.
  • the ingot is frozen, it is extracted, then reheated and then - usually in several steps - forged into rods or blocks.
  • the bars or blocks obtained in this way are then reheated to initiate an annealing process, which simplifies the subsequent post-processing.
  • the rods have healed, they are usually cut into blocks of the desired dimensions.
  • These blocks are then formed in a roughing step into a shape that is already close to the final shape of the forming tool or forming tool part. This is followed by a heat treatment and a fine machining, as in the casting method described above, in order to complete the production of the forming tool or forming tool part.
  • the processing of the bars or blocks is relatively complex, so that the processing costs in this process are many times higher than the cost of materials.
  • Forming tool or molding tool part is desired, an even more complex method is often used.
  • This is the so-called powder metallurgy (PM for short).
  • the melt is not filled in a cast block, but in a nebulizer, which usually has at least one nozzle, in which a gas is burned against the liquid metal stream, which causes the metal to small, substantially spherical particles (powder) is evaporated.
  • the metal powder thus obtained is then poured into steel containers which are substantially cylindrically shaped.
  • the steel containers are then evacuated to maintain a degree of vacuum and introduced into a hot isostatic press apparatus in which high temperatures and pressures are generated to deform the steel containers and cause the metal powder to densify to form a billet is obtained.
  • forging increases the toughness / ductility of the forming tool or forming tool part, but on the other hand induces some undesirable properties, the most important of which is anisotropy. Namely, the forging creates a material structure which leads to different properties in the forging direction compared to the directions running transversely to the forging direction. This anisotropy may be particularly detrimental during the heat treatment of the forming tool or part, as it leads to a workpiece distortion, so that more material for the finishing must be left.
  • Another method for producing a forming tool or a forming tool part is the sintering of a metal powder.
  • a metal powder or alternatively a mixture of several metal powders is pressed in order to obtain a body with the desired geometric shape and with a suitable nature, so that it can subsequently be further processed.
  • Such a body is often referred to as a "green body.”
  • the green body is then sintered at high temperature for a sufficiently long period of time to promote diffusion bonding.
  • a final hot isostatic pressing step is performed Method are, for example, in DE 198 252 23 C2, WO 02/20863 A1, DE 195 08 959 C2, DE 197 52 505 C1, DE 698 148 96 T2, EP 1 281 461 A1 and EP 0 919 635 A2.
  • a molded body made of a ceramic, powder metallurgy or composite material is known. Further, a method for producing such a molded article is disclosed in the aforementioned document.
  • the material composition and / or the structure changes in one, two or all three spatial directions. The changes can be continuous or discontinuous.
  • one or more starting powders are processed into one or more moldable masses. This moldable mass / masses is / are processed in one, two or all three spatial directions continuously or discontinuously to give a shaped body and then cured, the application of the moldable mass or masses being effected as a function of the degree of property to be finally achieved.
  • the present invention has the object to provide a device for producing a corresponding workpiece, in particular a forming tool or forming tool part available.
  • a method according to the invention for producing a workpiece comprises the following steps:
  • thermoplastic mold having a first mold part and at least one second mold part in an evacuable chamber, wherein the heat-resistant mold consists of concrete, cement or mortar with an admixture of at least one ceramic material,
  • the workpieces such as forming tools or forming tool parts, under vacuum conditions by compacting the heated metal-containing material, which may be present for example as a solid metal-containing body, produced in a heat-resistant form.
  • the production of the workpiece takes place in an evacuable chamber in which the vacuum can be generated and in which optionally also an inert gas atmosphere and / or a reducing gas atmosphere can / can be generated.
  • the inventive method allows in particularly advantageously, the production of near-end, locally isotropic workpieces (for example, shaping tools or forming tool parts), as can be obtained by the casting methods known from the prior art, with mechanical properties, as can be obtained by the known powder metallurgy methods.
  • the oxygen content in the residual gas can be reduced within the evacuatable chamber, so that oxygen contamination of the surface of the metal-containing material largely prevented, but at least significantly reduced, and thus workpieces, such as forming tools or forming tool parts of particularly high Quality can be produced.
  • a number of flushings of the evacuatable chamber be carried out with a reducing gas and / or an inert gas, before the vacuum is generated in the evacuable chamber.
  • a vacuum can be generated in the evacuatable chamber between two flushings with the inert gas or reducing gas (at least for a short time). The vacuum does not need to be a high vacuum. Due to the generation of the vacuum following the flushes, the residual gas level within the evacuatable chamber is relatively low.
  • a high vacuum is generated and the hot pressing of the heated metal-containing material below High vacuum conditions is performed.
  • the pressure range of the high vacuum that is created within the evacuable chamber is advantageously in the order of between about 10 "3 and about 10 -7 mbar.
  • an alternative method according to the invention for the production of a workpiece, forming tool or forming tool part comprises the following steps:
  • thermoplastic mold having a first mold part and at least one second mold part in an evacuable chamber, wherein the heat-resistant mold consists of concrete, cement or mortar with an admixture of at least one ceramic material,
  • Heating the metal-containing material Compacting the heated metal-containing material in the heat-resistant form by hot pressing in the inert gas atmosphere or reducing gas atmosphere.
  • the densification of the heated metal-containing material in the heat-resistant form by hot pressing thus takes place not under vacuum conditions, but in an inert gas atmosphere or reducing gas atmosphere.
  • an oxygen contamination of the metal-containing material can also be effectively prevented.
  • This method according to the invention also makes it possible in a particularly advantageous manner to produce near-net shape, locally isotropic shaping tools or forming tool parts, as can be obtained by the casting method, with strength properties such as can be obtained by a powder metallurgy method.
  • a workpiece (forming tool or forming tool part) produced by the method presented here has a notched impact strength of more than 50 J / cm 2 , while the degree of hardness is preferably greater than 58 HRC.
  • the hot pressing be carried out with a constant expansion rate.
  • the strain rate can be determined, for example, by changing the Feed rate of a metal cylinder, by means of which a pressure is exerted on the mold and thus on the metal-containing material, kept constant.
  • the metal-containing material is filled in the form of at least one layer of a metal-containing powder or a metal-containing powder mixture in the heat-resistant mold.
  • the method then comprises in particular the step of hot-pressing the metal-containing powder or the metal-containing powder mixture in the heat-resistant form, which preferably has only a small amount of water added.
  • the metal-containing powder used to make the workpiece may be made entirely of a material.
  • the metal-containing powder may, for example, also be a mixture of a metal powder with ceramic particles, wherein the ceramic particles in turn may have a coating.
  • the ability to use mixtures of different metal-containing powders or multiple layers of different metal-containing powders and to introduce them into the refractory form may be particularly advantageous.
  • Shaping tool parts with tailored mechanical and / or physical properties that may also be graded within their volume.
  • workpieces can also be produced, have within their volume in one, two or even all three spatial directions different mechanical and / or physical properties.
  • the property gradients may be continuous or discontinuous.
  • coated particles that can be mixed with the metal-containing powder, however, are usually relatively expensive.
  • the methods described herein allow the use of such particles without degrading their intrinsic properties, and further allow only the minimum required amount of these particles to be used. Namely, the particles can be placed only in those areas of the forming tool part where they are actually required, so that the manufacturing cost of the workpiece can be kept as low as possible.
  • Some coated particles require controlling certain diffusion parameters (especially temperature and time) during the process to avoid deterioration of the intrinsic properties or to obtain optimal properties, the methods presented here being particularly well suited for this.
  • the densification of the heated metal-containing material takes place in a superplastic state of the material.
  • the heating of the metal-containing material in the heat-resistant form to achieve the superplastic state is preferably carried out comparatively slowly.
  • the superplastic state of a metal-containing material is (depending on the material and depending on the strain rate) usually achieved at a temperature of about 800 0 C to about 1050 ° C.
  • the densification of the heated metal-containing material in the superplastic state is particularly advantageous if the material is in the form of a preformed body in its geometry. This is the case, for example, for a pre-compacted, dimensionally stable green body. If the metal-containing material is in powder form, the hot pressing may also take place in a non-superplastic state, although compacting in the superplastic state is also particularly advantageous here.
  • a particularly preferred method variant provides that the metal-containing material is further heated to its diffusion acceleration temperature after the superplastic state has been reached.
  • This diffusion acceleration temperature is alloy-dependent and is, for example, about 1 150 ° C for a tool steel.
  • alloys of molybdenum have a higher diffusion acceleration temperature over 1800 ° C
  • alloys of copper have one
  • Diffusion acceleration temperature lower than 900 ° C.
  • the diffusion acceleration temperature becomes over a longer period of time, usually over a period of more kept as 30 minutes.
  • the holding time depends in particular on the diffusion acceleration temperature and the pressure exerted. It can possibly be several hours or even several days.
  • the metal-containing material is at least partially melted and compacted in an at least partially liquid state.
  • the metal-containing material need not be completely melted.
  • This embodiment of the method may be advantageous for some applications.
  • the pressure during the hot pressing (for example by means of a metal cylinder) on the heated metal-containing material is preferably greater than 20 MPa.
  • the pressure during compaction of the metal-containing material may, depending on the load capacity of the molding material, be in particular between about 20 MPa and about 250 MPa.
  • a cold pressing step can be carried out before the heating of the metal-containing material. This is particularly advantageous when using a metal-containing powder or a metal-containing powder mixture.
  • the porosity of the metal-containing powder or the metal-containing powder mixture can be closed to leave as little coherent porosity as possible in the material.
  • the evacuatable chamber can optionally be rinsed with a reducing atmosphere before proceeding with the remaining process steps.
  • the metal-containing powder or the metal-containing powder mixture can also be entered in a controlled atmosphere environment. Regardless of which process is pursued, it is important to avoid the presence of oxygen between powder grains as much as possible.
  • the process heat after the compression of the metal-containing material preferably by means of a cooling device, is deliberately dissipated.
  • One purpose of such targeted heat removal may be to speed up the overall manufacturing process.
  • the microstructural properties of the workpiece can be adjusted by the targeted heat dissipation. It is particularly advantageous if the pressure exerted on the metal-containing material pressure during the targeted removal of the process heat (cooling phase) is maintained. Through this Measure geometry deviations, in particular shrinkage of the workpiece can be largely prevented.
  • the step of compacting the metal-containing material or the removal of the process heat is followed by at least one post-processing step.
  • This at least one post-processing step may in particular comprise the implementation of a finishing and / or hard-machining method. For example, grinding, high-speed milling or thermally-assisted laser machining can be used.
  • the at least one post-processing step is not carried out under vacuum conditions or under a gas atmosphere.
  • Shaping tool part a custom tailoring of functionalities that can be derived directly from the metallurgical and microstructural composition of the metal-containing material used (in particular a tool steel).
  • a heat-resistant mold which is housed in the evacuable chamber and having a first mold part and at least a second mold part, which form a mold cavity, wherein a metal-containing material, in particular a metal-containing powder or a metal-containing powder mixture into which the mold cavity can be filled, the heat-resistant mold consisting of concrete, cement or mortar with an admixture of at least one ceramic material,
  • the device according to the invention is particularly suitable for carrying out a method according to one of claims 1 to 9, so that workpieces, such as, for example, shaping tools or shaping tool parts, can be manufactured with the advantageous properties described above.
  • the heat-resistant mold used to make the workpiece should, in terms of its mechanical design, be capable of withstanding the pressure required to flow a metal-containing powder or metal-containing powder mixture.
  • the pressure acting on the metal-containing material during compaction may be between about 20 MPa and about 250 MPa, depending on the load capacity of the molding material.
  • the device moreover comprises means for generating an inert gas atmosphere and / or a reducing gas atmosphere.
  • the densification of the metal-containing material can at a Such an embodiment of the device in an inert gas atmosphere or a reducing gas atmosphere are performed. As a result, an oxygen contamination of the surface of the metal-containing material can be prevented.
  • the heat-resistant form may be a ceramic-containing and / or graphite-containing form.
  • the pressures acting on the molding material from which the heat-resistant mold is made are generally greater than 20 MPa, often greater than 30 MPa to 40 MPa, so that concrete, mortar or cement with a low water content and containing at least one Ceramic material as materials for producing the heat-resistant form are particularly advantageous.
  • Al 2 O 3 , zirconium oxide, silicon carbide or SiO 2 are the preferred filler materials for the production of the heat-resistant mold.
  • the concrete, cement or mortar may have a content of at least 40%, preferably of at least 60%, in particular of at least 80% Al 2 O 3 . It may, for example, also be provided that the concrete, cement or mortar has a strength which is higher than 150 MPa (preferably higher than 200 MPa).
  • the means for heating the metal-containing material may in a particularly advantageous embodiment comprise at least one heating element, which may for example be embedded in the heat-resistant mold.
  • the at least one heating element extends in the circumferential direction of at least one of the mold parts (preferably at a distance of about 10 to 20 mm from the mold cavity), so that a uniform heating of the metal-containing material can be achieved.
  • the at least one heating element may for example consist of a Ni-Cr resistance wire or an Fe-Cr-Al resistance wire. Other Resistance heating wires, which may be made of molybdenum or tungsten, for example, may also be used. An inductively operating heating element can also be used.
  • At least one cooling device can be provided, which may advantageously also be embedded in the heat-resistant form, suitable for selectively cooling the metal-containing material within the heat-resistant form.
  • the cooling device may, for example, comprise a number of cavities which are introduced into the heat-resistant mold when defined. Through these cavities, a liquid or gaseous cooling fluid can flow, which can be conveyed by means of a supply device or the like in order to be able to specifically cool the metal-containing material in the heat-resistant form after compression.
  • the cooling device may comprise at least one tube embedded in the refractory mold and through which a liquid or gaseous cooling fluid may circulate.
  • the evacuable chamber may also be flooded with a gaseous cooling fluid (for example with nitrogen or argon).
  • a gaseous cooling fluid for example with nitrogen or argon.
  • the gaseous cooling fluid from a pressure tank or a compressed gas cylinder can flow into the cavities, the tube or the evacuable chamber, since the gas continues to cool as it expands.
  • the cooling device forms a cooling circuit, within which the cooling fluid can circulate and within which, for example, a heat exchanger or a compression stage can be provided.
  • at least one temperature detection means and control means may be provided to control the temperature of the metal-containing material in the mold.
  • a model with the desired geometry of the workpiece for example, a forming tool or
  • This mold model can be made of different materials (for example polystyrene, polypropylene, wood or aluminum). Many other thermoplastics, metals or even ceramics may be used to make the mold model. In order to obtain the mold model, conventional process techniques or so-called rapid prototyping techniques (for example, mechanical processing, stereo lithography, three-dimensional wax pressure, casting and so on) can be used.
  • process techniques or so-called rapid prototyping techniques for example, mechanical processing, stereo lithography, three-dimensional wax pressure, casting and so on
  • the mold can be produced by, for example, casting the heat-resistant molding material, especially when the molding material contains a powder or powder mixture, concrete, mortar or the like.
  • the mold is manufactured in this way, it is very easy to embed at least one heating element (in particular a resistance heating element or an induction heating element), a cooling element and possibly also temperature detection means in the mold.
  • the mold is produced by a three-dimensional ceramic printing technique or by a comparable technique which allows to obtain the heat-resistant mold directly, ie without further intermediate steps, no corresponding mold model has to be produced. The same is true when the heat-resistant mold is obtained by directly machining a solid block of a heat-resistant molding material.
  • the concrete when making the heat-resistant mold from concrete, the concrete is poured into the mold model along with a small amount of water and preferably an admixture of a ceramic material.
  • the filling of the mold model should take place as quickly as possible.
  • the mold is cured at a high temperature (for example, about 1200 ° C), so that the residual moisture can escape from the concrete. It is also possible to vibrate the mold model during filling of the molding material, for example, on a vibrating table or the like. It has been found that this can significantly reduce the porosity of the mold.
  • the mold cavity can be at least partially filled with the metallic material, in particular with a metal-containing powder or with a metal-containing powder mixture. This is followed by the remaining process steps for the production of the workpiece.
  • the surface of the mold cavity of the heat-resistant mold has, at least in sections, a ceramic layer and / or a release and lubricant layer.
  • the ceramic layer may be, for example, an oxide layer (for example, zirconia) or a carbide layer (for example, silicon carbide). Any other ceramic that does not react with hot metal can also be used.
  • the release and lubricant layer can be made of, for example, graphite, molybdenum disulfide, sulfur, phosphorus, Boron nitride, mica or other material that can withstand the relatively high process temperatures.
  • the molding material used has a relatively low thermal conductivity so that it can serve as an insulator between the heating zone in which the metal-containing powder and the metal-containing powder mixture is heated, and the outside of the mold, in particular, when the heat-resistant mold in an advantageous embodiment has a prestressed reinforcing ring made of metal.
  • a prestressed reinforcing ring can create compressive stresses in the mold to compensate for the tensile stresses created when compacting the heated metal-containing material.
  • the surface of the mold cavity may, in a particularly advantageous embodiment, at least in sections have a color layer or dispersion layer.
  • the surface of the mold cavity can be made chemically inert. Also lubricants can be used for this purpose. It may also be advantageous to increase the emissivity of the surface of the ceramic mold in order to make the process more energetically efficient and to keep the heat where it is needed.
  • the active material of the paint or dispersion may be, for example, zirconia, boron nitride, molybdenum disulfide or other graphite, phosphorus or sulfide based components (to name a few).
  • the heat-resistant mold with metal particles and / or metal rods and / or metal wires and / or metal wire fabrics is reinforced.
  • the material can be iron or steel.
  • refractory metals such as tungsten or molybdenum and their alloys, as well as nickel or cobalt based alloys may be more advantageous.
  • textile fibers and / or polymer fibers and / or ceramic fibers and / or glass fibers and / or long-fiber fabric of these materials can be used to reinforce the heat-resistant form.
  • the means for compacting the metal-containing material may in particular comprise a metal cylinder, which is in operative connection with the second molded part of the heat-resistant mold.
  • the metal cylinder may exert a sufficiently high pressure on the heat-resistant mold or a part of the heat-resistant mold, thereby to densify the metal-containing material in the mold.
  • Fig. 1 is a schematically simplified view of a
  • Device which is suitable for carrying out a method for producing a workpiece, in particular a forming tool or a forming tool part.
  • An apparatus for carrying out a method for producing a workpiece, in particular a shaping tool or a shaping tool part comprises an evacuable chamber 1 with a vacuum system, by means of which a vacuum, preferably a high vacuum in the order of 10 ⁇ 3 and 10 "7 mbar can be generated in the interior of the evacuatable chamber 1.
  • the vacuum system can, for example, be a rotary vane pump and The rotary vane pump generates a pre-vacuum for the turbomolecular pump, and pressure-sensing means are provided to allow the pressure within the evacuatable chamber 1 to be measured and continuously monitored.
  • the device further comprises a heat-resistant mold 2, which may be, for example, containing ceramic and / or graphite and a first (lower) mold part 2a with a mold cavity and a second (upper), relative to the first mold part 2a movably guided molding 2b comprises.
  • a heat-resistant mold 2 which may be, for example, containing ceramic and / or graphite and a first (lower) mold part 2a with a mold cavity and a second (upper), relative to the first mold part 2a movably guided molding 2b comprises.
  • the inner diameter of the first mold part 2a is larger than the outer diameter of the second mold part 2b, so that the second mold part 2b can be inserted into the mold cavity of the first mold part 2a.
  • the two heat-resistant molded parts 2a, 2b are preferably made of concrete and a ceramic material (for example Al 2 O 3 ) and have only a small amount of water added.
  • a heating element 3 is embedded, so that the first mold part 2a can be heated in the implementation of the method.
  • the distance of the heating element 3 from the inner surface of the mold cavity of the first mold part 2a is about 10 to 20 mm.
  • the heating element 3 is required to reach the temperature required for the production of the workpiece. It is advantageous if the heating element 3 is embedded directly in the heat-resistant mold 2 as in the embodiment shown here.
  • the heating element 3 may, for example, a Resistance heating element or an induction heating element, the latter variant is more advantageous because of shorter heating times and better insulation, although it is somewhat difficult to calibrate.
  • a cooling device (not explicitly shown in FIG. 1) may be provided by means of which cooling of the metal-containing workpiece in the mold 2 is also possible.
  • the first molded part 2a may also be of modular construction and may have, for example, an inner contact layer adjacent thereto, the heating element 3 and finally an insulation shield.
  • a temperature detection means 4 embedded in the first molded part 2a is a temperature detection means 4, which may in particular comprise a conventional thermocouple. This allows the process temperature to be continuously monitored during the performance of the process. By providing the at least one heating element 3, (optionally a cooling device), the temperature detection means 4 and a control device, the process temperature during the implementation of the method can be controlled very precisely.
  • the device has a metal cylinder 5, by means of which a pressure in the direction of the arrow can be exerted on the second (upper) molded part 2b.
  • the surface of the mold cavity of the heat-resistant mold 2 can advantageously be coated with a ceramic layer and / or with a release and lubricant layer.
  • the ceramic layer may be, for example, an oxide layer (for example, zirconia) or a carbide layer (for example, silicon carbide). Any other ceramic material that does not react with the hot metal within the mold cavity may also be used.
  • the release and lubricant layer may be, for example, graphite, molybdenum disulfide, sulfur, phosphorus, boron nitride, mica or other material that can withstand the high process temperatures.
  • a glass powder as a release agent. Glass has the advantage that forms a glass separating layer at high temperatures, which can effectively prevent adverse surface reactions with the ambient atmosphere.
  • a metal-containing material in the form of a metal-containing solid body or at least one layer or portion of a metal-containing powder or a metal-containing powder mixture from which the workpiece is to be produced is introduced into the mold cavity of the first mold part 2a and under it according to a first embodiment
  • High vacuum conditions using the at least one heating element 3 is heated.
  • the generation of a high vacuum in the interior of the evacuatable chamber 1 during compaction is particularly advantageous. Characterized in that the heating is carried out under high vacuum conditions in the evacuatable chamber 1, an oxygen contamination of the metal-containing material can be effectively prevented, but at least significantly reduced. This is of particular importance when using a metal-containing powder or a metal-containing powder mixture in order to obtain optimum tool properties.
  • the generation of a high vacuum is quite difficult with most mold materials from which the mold can be made, since they tend to outgas especially at higher temperatures. It is very important, if possible no oxygen which deteriorates the quality of the powder surface and prevents the complete densification and diffusion bonding of the metal-containing powder or powder mixture.
  • One way to obtain better process conditions is to cure the refractory mold 2 in a reducing gas atmosphere so as to ensure that voids within the molding material are filled with the reducing gas atmosphere.
  • the heat-resistant mold 2 may be heated in the evacuable chamber 1 prior to filling the metal-containing material, then a vacuum is generated, and then the chamber 1 is filled with a reducing atmosphere to fill the voids within the mold material.
  • a vacuum in the evacuatable chamber 1 can be generated at least for a short time between two flushes.
  • a vacuum is created in the chamber 1 can be evacuated and maintained for a certain period Wa k uu m after filling the metalliferous material in the heat-resistant mold first. After the period Wa k uu m an inert gas atmosphere or reducing gas atmosphere is generated in the evacuatable chamber 1 and the metal-containing material is heated. The densification of the heated metal-containing material in the heat-resistant mold 2 is then carried out by Hot pressing in the inert gas atmosphere or reducing gas atmosphere.
  • the metal-containing material is heated in both embodiments after filling into the mold cavity of the first mold part 2a of the heat-resistant mold 2 and optionally placed in a superplastic state, which is achieved (depending on the material) at temperatures between about 800 0 C and about 1050 0 C.
  • the hot pressing is preferably carried out in this superplastic state.
  • the hot pressing is advantageously carried out at a constant rate of expansion and a constant feed rate of the metal cylinder 5.
  • the pressure which is generated during the hot pressing of the metal cylinder 5 and acts on the second material part 2 b on the metal-containing material within the first mold part 2 a can between about 20 MPa and be about 250 MPa.
  • the pressure can act continuously or only in phases on the metal-containing material within the heat-resistant mold 2.
  • the hot pressing can also take place under non-superplastic conditions. However, it is particularly advantageous to densify the metal-containing powder or the metal-containing powder mixture by hot pressing in the superplastic state. Subsequently, the metal-containing powder or the metal-containing powder mixture can be heated to its diffusion acceleration temperature over a certain period of time (for example about two hours). By this measure, the largest possible material density can be generated in the workpiece.
  • the diffusion acceleration temperature is Depending on the alloy, for example, it is approximately 1 150 ° C for a tool steel. Alloys made of molybdenum have a higher alloy
  • Diffusion acceleration temperature above 1800 ° C and alloys of copper have a diffusion acceleration temperature lower than 900 ° C.
  • the diffusion acceleration temperature lower than 900 ° C.
  • Diffusion acceleration temperature for a long period of time usually held for a period of more than 30 minutes.
  • the holding time which may possibly be several days, depends in particular on the diffusion acceleration temperature and the pressure exerted.
  • the metal-containing material is at least partially melted and compacted in an at least partially liquid state.
  • the metal-containing material need not be completely melted. For example, there is the possibility that only one phase of the metal-containing material is melted before compacting. This embodiment of the method may be advantageous for some applications.
  • a layer structure with at least two layers allows in a particularly advantageous manner, the production of a workpiece (for example, a forming tool or
  • Shaping tool part with graded tool properties using the method presented here.
  • a property grading in volume can be in one, two, or all three spatial directions (continuous or discontinuously) are generated.
  • a comparatively hard and wear-resistant tool surface is desired, whereas a softer tool base body, on the other hand, is sufficient or even particularly advantageous.
  • a layer or region-wise different material composition is also advantageous.
  • the optimum tooling properties which are usually associated with high costs, can be provided only where they are actually needed. The remaining part of the
  • Shaping tool or forming tool part can be constructed of a material with sufficient properties and significantly lower material costs. It can also be provided that the process heat is removed selectively after the densification of the metal-containing material by means of the optionally provided cooling device. One purpose of such targeted heat removal may be to speed up the overall manufacturing process. In addition, the microstructural properties of the workpiece can be adjusted by the targeted heat dissipation. It is particularly advantageous if the pressure during the targeted removal of the process heat (cooling phase) is maintained. As a result, geometry deviations, in particular shrinkages of the workpiece, can be largely prevented in an advantageous manner.
  • the cooling device may, for example, comprise a number of cavities which are introduced into the heat-resistant mold 2 in a defined manner.
  • a liquid or gaseous cooling fluid can flow, which can be conveyed by means of a supply device in order to be able to specifically cool the metal-containing material in the heat-resistant mold 2.
  • the cooling device may, for example, also comprise at least one tube embedded in the heat-resistant mold 2 and through which a liquid or gaseous cooling fluid may circulate.
  • the evacuatable chamber 1 can also be flooded with the cooling fluid (for example with nitrogen or argon).
  • the gaseous cooling fluid from a pressure tank or a compressed gas cylinder can flow into the cavities, the tube or the evacuatable chamber 1, since the gas additionally cools down during the expansion.
  • the cooling device forms a cooling circuit, within which the cooling fluid can circulate and within which, for example, a heat exchanger or a compression stage can be provided.

Abstract

La présente invention concerne un procédé de réalisation d'une pièce, en particulier d'un outil de façonnage ou d'une partie d'outil de façonnage, consistant à : fournir un moule (2) résistant à la chaleur, comprenant une première partie de moule (2a) et au moins une deuxième partie de moule (2b) dans une chambre (1) dans laquelle le vide peut être fait; remplir le moule (2) résistant à la chaleur avec un matériau contenant du métal; produire un vide dans la chambre (1); chauffer le matériau contenant du métal; comprimer le matériau chaud contenant du métal à l'intérieur du moule (2) résistant à la chaleur, par compression à chaud dans des conditions de vide. L'invention concerne également un dispositif de réalisation d'une pièce, en particulier d'un outil de façonnage ou d'une partie d'outil de façonnage.
PCT/EP2009/003628 2008-05-23 2009-05-22 Procédé et dispositif de réalisation d'une pièce, en particulier d'un outil de façonnage ou d'une partie d'outil de façonnage WO2009141152A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
JP2011509897A JP2011523592A (ja) 2008-05-23 2009-05-22 工作物、特に成形工具または成形工具部分を製造する方法および装置
US12/994,345 US20110129380A1 (en) 2008-05-23 2009-05-23 Method and device for producing a workpiece, particularly a shaping tool or a part of a shaping tool

Applications Claiming Priority (2)

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EP08382020.9 2008-05-23
EP08382020A EP2123377A1 (fr) 2008-05-23 2008-05-23 Procédé de fabrication d'une pièce à usiner, en particulier un outil de bloc de jeu de construction ou une pièce d'outil de bloc de jeu de construction

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WO2009141152A1 true WO2009141152A1 (fr) 2009-11-26

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