Rapid hard tooling by plasma spraying for injection molding and sheet metal forming
Thin Solid Films
Haiou Zhang ;Guilan Wang ;Yunhua Luo ;Takeo Nakaga
Amidst the harsh competition over the development of new products around the world, rapid prototyping, especially rapid tooling methods have received widespread attention. Amongst the rapid hard tooling methods, thermal spraying can manufacture metal molds without limitation of pattern size. However, it has the disadvantage that only soft metals with low melting points such as zinc alloy can be sprayed to original mold, such as a rapid prototyping model or a natural material pattern, due to their lack of heat resistance and shrinkage of spray metals. So the, wear resistance of spray tool is poor, it can be used only for trial or small-lot production. In this study, attempts were made to improve the heat resistance by using composite materials made of ceramic and metal powders as the sprayed original mold materials, and using stainless steel, tungsten carbide alloy, iron-nickel-chromium alloy with excellent wear resistance as spraying materials, respectively. The results show that injection molding spray mold and sheet metal forming spray die can be made by transferring from natural patterns and rapid prototyping models. As the durability and dimensional accuracy of the sprayed tools has sharply improved, the tools can be used for mass production.
keywords:Rapid hard spray tooling Plasma spraying Injection molding mold Sheet metal forming die
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