Development of precision spray forming for rapid tooling

Yunfeng Yang, Simo-Pekka Hannula (Corresponding Author)

Research output: Contribution to journalArticleScientificpeer-review

32 Citations (Scopus)

Abstract

The aim of the work is to improve the capability of the precision spray forming (PSF) rapid tooling process so that it can be extended to various applications. This work comprises the upgrading of the current spray-forming machine from single atomizer to twin atomizers, so that the capability is much improved in terms of insert size and complexity. As a result, the insert size is increased from about 200 mm to 400 mm in diameter, and the process is more reliable to make complex structures. Know-how is accumulated for making large and/or complex inserts with controllable surface and internal soundness. A process of spray forming conformal cooling channels in die inserts or other components used at elevated temperatures is also developed and various mould inserts are spray formed. In this paper the plant modification is described. It is shown that the twin atomizers are more reliable in spray forming small inserts of about 200 mm in diameter and of high complexity than the single atomizer system. Spray forming of disc type inserts up to 400 mm diameter is demonstrated. Influence of deposition temperature and substrate moving speed, as well as the treatment of the ceramic mould surface is determined and the technical measures to prevent surface defects related to large insert spray forming are specified.

Original languageEnglish
Pages (from-to)63-68
JournalMaterials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing
Volume477
Issue number1-2
DOIs
Publication statusPublished - 2008
MoE publication typeA1 Journal article-refereed
Event3rd International Conference on Spray Deposition and Melt Atomization - Bremen, Germany
Duration: 4 Sep 20066 Sep 2006

Fingerprint

tooling
inserts
sprayers
Atomizers
atomizers
Surface defects
upgrading
surface defects
Cooling
Temperature
Substrates
ceramics
cooling
temperature

Keywords

  • Rapid tooling
  • Spray forming
  • Die insert
  • Tool steel

Cite this

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Development of precision spray forming for rapid tooling. / Yang, Yunfeng; Hannula, Simo-Pekka (Corresponding Author).

In: Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing, Vol. 477, No. 1-2, 2008, p. 63-68.

Research output: Contribution to journalArticleScientificpeer-review

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AB - The aim of the work is to improve the capability of the precision spray forming (PSF) rapid tooling process so that it can be extended to various applications. This work comprises the upgrading of the current spray-forming machine from single atomizer to twin atomizers, so that the capability is much improved in terms of insert size and complexity. As a result, the insert size is increased from about 200 mm to 400 mm in diameter, and the process is more reliable to make complex structures. Know-how is accumulated for making large and/or complex inserts with controllable surface and internal soundness. A process of spray forming conformal cooling channels in die inserts or other components used at elevated temperatures is also developed and various mould inserts are spray formed. In this paper the plant modification is described. It is shown that the twin atomizers are more reliable in spray forming small inserts of about 200 mm in diameter and of high complexity than the single atomizer system. Spray forming of disc type inserts up to 400 mm diameter is demonstrated. Influence of deposition temperature and substrate moving speed, as well as the treatment of the ceramic mould surface is determined and the technical measures to prevent surface defects related to large insert spray forming are specified.

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