Method of spray forming metal deposits using a metallic spray fo

Details Method of spray forming metal deposits using a metallic spray fo Method of spray forming metal deposits using a metallic spray fo

1998-11-04

2000-12-05

Batten, Jr., J. Reed

Metal founding

Process

Shaping a forming surface

164 35, 164 46, B22C 702, B22D 2300

Patent

active

061553301

ABSTRACT:
A spray forming pattern of a first metal having a melting point at a first temperature is formed. The spray forming pattern has a surface defining a cavity that has the shape of a master pattern. Steel particles having a carbon content in the range of 0.01-0.9% by weight are sprayed onto the spray forming pattern to form a deposit on the spray forming pattern. The deposit has a thickness of at least 0.5 inches and the temperature of the steel particles increases as the thickness of the steel deposit increases. The spraying conditions are controlled so that the steel particles coming into contact with the spray forming pattern results in a surface temperature of the spray forming pattern of less than about 80.degree. C. The deposit and the spray forming pattern are heated to a second temperature, which is higher than the first temperature, to melt the spray forming pattern from the deposit. The resulting deposit has the general shape of the master pattern.

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