Method of fabricating composite tooling using closed-loop direct-metal deposition

• US 7,139,633 B2
• Filed: 08/29/2003
• Issued: 11/21/2006
• Est. Priority Date: 08/29/2002
• Status: Active Grant

• Current Assignee: Frank A. Dipietro, Jyoti Mazumder
• Original Assignee: Frank A. Dipietro, Jyoti Mazumder
• Inventors: Mazumder, Jyoti, DiPietro, Frank A.
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): SONI, KETAN S
• Application Number:
  US10/652,260
• Publication Number:
  US 20050038551A1
• Time in Patent Office: 1,180 Days
• Field of Search: 700/119, 700/123, 700/166, 118/624, 219/121.65, 427/554
• US Class Current: 700/123
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/38 to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2005/002 Tools other than cutting tools
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 7/04 with one or more layers not made from powder, e.g. made from solid metal
• CPC Class Codes: B23K 2103/08 Non-ferrous metals or alloys
• CPC Class Codes: B23K 2103/10 Aluminium or alloys thereof
• CPC Class Codes: B23K 2103/18 Dissimilar materials
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/32 taking account of the properties of the material involved
• CPC Class Codes: B23K 26/34 Laser welding for purposes other than joining
• CPC Class Codes: B23K 31/025 Connecting cutting edges or the like to tools; Attaching reinforcements to workpieces, e.g. wear-resisting zones to tableware
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

Manufacturing tools having a base and a working surface, such as trim steels, flange steels and die inserts, are formed by fabricating or casting a substrate out of a relatively ductile, low wear-resistant metal and forming the working surfaces such as cutting edges, flanging surfaces, die surfaces and die inserts by depositing layers of relatively hard, wear-resistant materials to the substrate by closed-loop direct-metal deposition or laser cladding. A multi-axis numerically controlled robot may be used to position and move a beam and deposition material over large substrates in forming such tooling.

Claims

1. A method of fabricating or improving an object, comprising the steps of:

providing a substrate composed of aluminum, the substrate having a working surface forming a tool;

depositing a layer of molybdenum or an alloy thereof on the working surface using a closed-loop direct-metal deposition (DMD) process of the type wherein powder is fed to a laser-induced melt pool to create a deposit having a dimension that is optically monitored; and

wherein the layer of molybdenum or an alloy thereof has a very low solubility in the aluminum.

2. The method of claim 1, wherein the substrate forms part of a die cast die, stamping die, trim steel, flange steel or die insert.

3. The method of claim 1, wherein the working surface includes a cutting edge, flanging surface, die surface, or die insert.