CA1172015A - Method of forming an article - Google Patents

Method of forming an article

Info

Publication number
CA1172015A
CA1172015A CA000390869A CA390869A CA1172015A CA 1172015 A CA1172015 A CA 1172015A CA 000390869 A CA000390869 A CA 000390869A CA 390869 A CA390869 A CA 390869A CA 1172015 A CA1172015 A CA 1172015A
Authority
CA
Canada
Prior art keywords
preform
final
article
cavity
dimension
Prior art date
Legal status (The legal status 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 status listed.)
Expired
Application number
CA000390869A
Other languages
French (fr)
Inventor
Walter J. Rozmus
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kelsey Hayes Co
Original Assignee
Kelsey Hayes Co
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 Kelsey Hayes Co filed Critical Kelsey Hayes Co
Application granted granted Critical
Publication of CA1172015A publication Critical patent/CA1172015A/en
Expired legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B30PRESSES
    • B30BPRESSES IN GENERAL
    • B30B11/00Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/005Control arrangements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02Compacting only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12Both compacting and sintering

Abstract

ABSTRACT OF THE DISCLOSURE

A method of forming an article to a final form in a final cavity between two dies by forming a preform having the general shape of the final form of the article and thereafter measuring the amount of material contained in the preform and removing any material from the preform in excess of the amount of material required to completely fill the volume of the final cavity and then enclosing the preform in the final cavity to completely surround the preform and conform the preform to the shape of the final cavity to produce the final form of the article.
Preferably, the preform is first formed by compacting powder metal so as to have a greater dimension in one di-rection than the final form and a lesser dimension in a transverse direction. After weighing the preform and re-moving excess material from the exterior of the preform, the preform is placed between two dies of a press which close to initially apply pressure to the greater dimension of the preform to reduce that dimension to the final desired dimension while increasing the lesser dimension to the final desired dimension of the final preform.

Description

P-342 11'7'~ 5 BACKGROUND OF THE INVENTION
This invention relates to a method of forming an article to a final form in a cavity which surrounds the article to define the final desired form of the article.
Such forming is accomplished in forging and like processes.
Although applicable to forging and like processes, the subject invention has particular utility and will be described in connection with forming an article by the hot consolidation of powder material.
Hot consolidation can be accomplished by filling a container with a powder to be consolidated. The con-tainer is usually evacuated prior to filling and then hermetically sealed. Heat and pressure are applied to the filled and sealed container. At elevated temperatures, the container functions as a pressure-transmitting medium to subject the powder to the pressure applied to the container. Simultaneously, the heat causes the powder to fuse by sintering. In short, the combination of heat and pressure causes consolidation of the powder into a substantially fully densified and fused mass in which the individual powder particles change shape as they are forced together and are united into a substantially homogeneous mass.
After consolidation, the container is removed from the densified powder compact or preform and the preform is then further processed through one or more steps, such as forging, machining, grinding and/or heat treating.
Because the volume of the cavity in the P-342 ~ 15 container for hot consolidation may vary from container to container, the final configuration may vary from compacted part to compacted part. Another variable is that the density of the powder may vary from one fill to the next.
In addition, the particle size may differ from one fill to the next. All of these factors can contribute to parts being below or above tolerances when it is, of course, desirable to consistently produce part after part with the same shape or form with the same amount of material or mass in each part. ~nother problem which occurs is ~hat when the part is compacted between two dies, flash may occur on the part at the parting line of the two dies.
This flash, of course, must be removed in a subsequent operation.

5UM~RY OF THE I~IVENTION
These problems may be overcome by the subject invention which provides a method of forming an article to a final form in a final cavity completely surrounding and having the final form of the article. The method in-cludes the steps of forming a preform having the generalshape of the final form of the article, measuring the amount of material contained in the preform, removing any material from the preform in excess of the amount of material required to completely fill the volume of the final cavity and enclosing the preform in the final cavity to completely surround the preform and conform the preform to the shape of the cavity to produce the final form of the article.

P-342 11'7Z~S
BRIEF DESCRIPTION OF THE DRAWING
Other advantages o the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing which is a flow diagram illustrating the major steps involved in the method of the subject invention.
DESCRIPTION OF THE INVENTION
It will be appreciated that the subject invention may be utilized for shaping parts by forging or in any other process where a part is to be conformed to the shape of a cavity. However, the invention has particular utility and will be described in connection with the hot consolidation of various metallic powders and nonmetallic powders, as well as combinations thereof, to form a densified powder article.
The invention may be utilized to consolidate metallic powder into complex shapes by utilizing a "fluid die~' or "thick-walled" container of the type described in United States Patent 4,142,888 granted March 6, 1979 in the name of Walter J. Rozmus. By way of definition, a thick-walled container is of sufficient thickness so that the exterior surface of the walls do not closely follow the contour or shape of the cavity. This insures that sufficient container material is provided so that, upon the application of heat and pressure, the container material will act like a fluid to apply hydrostatic pressure to the powder in the cavity. The use of a thick-walled 1 ~'7;~t~15 container produces a near-net shape having close dimen-sional tolerances with a minimum of distortion.
The drawing illustrates the steps of the method of forming an article to a final form in a final cavity completely surrounding and having the final form of the article. Step 1 is the forming of a preform having the general shape and mass of the final form of the article.
Step 2 includes measuring the amount of material or mass of the material contained in the preform resulting from Step 1. Step 3 includes removing any material or mass from the preform in excess of the amount of material or mass required to completely fill the volume of the final cavity. Step 5 is tne enclosing of the preform in the final cavity to completely surround the preform and con-form the preform to the shape of the final cavity toproduce the final form of the article.
Step 1 shows a thick-walled container formed by at least two mating container parts 12 and 14. The container parts 12 and 14 define a cavity 16 in which powder 18 is disposed for consolidation. As illustrated, the container parts 12 and 14 define the cavity 16 when they are mated together at the mating surfaces 20, as by welding.
The densified or compacted preform 18 may be of various complex shapes. As illustrated in Step 1, there is shown a cross section through the container and the compacted preform illustrating a cross section of the preform which is elongated or oval. The final shape or form of the article, by way of illustration, will be 11'72~115 circular as illustrated in Step 5. Although it will be appreciated that various shapes may be produced in accordance with the subject invention and that the shapes along the longitudinal axis of a given part may change significantly.
In Step 1 a quantity of powder 18 is encapsu-lated in a cavity 16 in a thick walled container defined by the parts 12 and 14 with the container having walls entirely surrounding the cavity 16 and of sufficient thickness so as not to closely follow the contour of the cavity 16 and of a material which is substantially fully dense and incompressible and capable of plastic flow at elevated temperatures. The container defined by the parts 12 and 14 is generally rectangular in cross section and does not follow the contour of the cavity 16 as there are different thicknesses of the container about the cavity 16.
The container parts 12 and 14 and the powder are heated to a temperature at which the powder 18 will densify. External pressure is applied to the entire exterior surface of the container parts 12 and 14 thereby causing plastic flow of the container parts 12 and 14 to subject the powder to hydrostatic pressure which causes the powder to densify into a preform. The pressure is applied to the container parts 12 and 14 by placing the container parts within a constraining cavity in a press die 22 and applying downward pressure to the con-tainer parts 12 and 14 by a ram 24 of a press. This is accomplished in accordance with the teachings of the P-342 1~7Z(~15 aforemen-tioned United States Patent 4,142,888.
The preform 18 is then removed from the container parts 12 and 14. This may be accomplished by various means such as etching, pickling, machining, etc. One very satisfactory method of removing the preform 18 from the container parts 12 and 14 is by melting the container material from about the preform 18. The container parts 12 and 14 may be formed from a material which melts at a combination of temperature and time at that temperature which combination would not undesirably or adversely affect the properties of the powder preform 18, i.e., after having been consolidated to define the densified powder compacted preform 18. For example, the container may be made from a metal such as a copper.
After compaction of the preform 18 and the removal of the preform 18 from the container parts 12 and 14, the amount of material or mass contained in the preform is measured. This may be accomplished by weighing the preform in Step 2. Thereafter, the method includes the step of removing any material about the exterior of the preform 18 which is in excess of the amount of material in the final desired form of the article. The material may be removed in Step 3 by passing the preform 18 through an etching bath.
The preform would be submerged in a solution in an etching bath under , P-342 ~ 2~ 1 5 predetermined conditions to remove the proper amount of material or mass from the preform. The predetermined con-ditions would include the temperature of the solution, the electrical current passing through the solution and the time the preform is submerged within the solution~
Step 4 illustrates the enclosing of the preform 18 in the final cavity 26 to completely surround the preform 18 and conform the preform 18 to the shape of the final cavity 26 to produce the final form of the article 28. The preform 18 is enclosed in the final cavity 26 by placing the heated preform between dies 30 of a press.
The dies 30 define the final cavity 26 and the closing of the dies 30 apply pressure to the preform 18 to form it into th~ final form of the article 28. The dies 30 may be placed in a variety of well-known presses.
As the drawing illustrates, the preform 18 is formed so as to have a greater dimension in a first direction therethrough ~vertical as shown~ than the final desired dimension in the first (vertical~, direction through the ~inal form 28. The preform 18 is also formed to have a lesser dimension in a second direction (hori-zontal) transverse to the first direction than the final desired dimension in the second direction (horizontal) through the final form 28. As illustrated, the cross-sectional configuration of the preform 18 is oblong oroval whereas the cross-sectional configuration of the final form is circular.
The preform 18 is enclosed in the dies 30 by closing the dies 30 to initially apply pressure to the ~ 7 -11'~2Vl~P-342 preform 18 in the first direction which is vertical as illustrated. In other words, the dies 30 first contact the ends of the oblong shape to initially apply pressure to the preform 18 in the first or vertical direction to decrease the dimension in the first or vertical direction to the final desired dimension of the article 28. As this occurs, there is also an increase in the dimension in the second or horizontal direction of the preform 18 to the final desired dimension of the article 28. In other words, as the dies 30 move together, they initially engage the praform at the intentionally oversize dimension in the direction of the closing of the dies and, since the other transverse dimension between the sides is smaller than required, that dimension grows or increases. Since the preform 18 has been measured and any mass or material in excess of that required to precisely fill the cavity 26 has been removed, the sides of the preform 18, when increasing in dimension horizontally, contact the walls of the cavity 26 at the same time the dies 30 engage one another at the parting line therebetween. As will be appreciated, in this manner there is no resulting flash in the final article 28, i.e., there is no material of the article 28 squeezed outwardly between the dies 30 between the parting faces thereof and outside the cavity 26. Accordingly, not only is there a precise article in terms of shape resulting from the method but the wear of the dies 30 at the parting faces therebetween adjacent the cavity 26 should be eliminated.
In many instances it will be desirable to P-342 11~7Z~ 5 initially form the preform 18 with a greater amount of material or mass than the amount of material in the final form of the article 28. This will prevent forming pre-forms 18 which are unusable because of less material or mass than desired in the final article 28.
It will be appreciated that the final cavity 26 is final only in that it provides the final shape of the desired article but the term does not mean that the article 28 may not be processed further to undergo fur-ther processing. It should also be appreciated that inthe removal step, particularly when processing articles of complex shapes, different portions of the articles may have proportionally different amounts of material removed therefrom than other portions of the article. The impor-tance being to remove material from the preform 18 so that the different portions of the preform are in pro-portion to the final cavity 26 and that the total volume in terms of material or mass of the preform is precisely the same as the volume of the final cavity 26.
It should also be appreciated that the preform may also be formed in an autoclave instead of a press.
The invention has been described in an illus-trative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that with-in the scope of the appended claims wherein reference ~ g _ P-342 li'7~0~S
numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.

Claims (4)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
The embodiments of the invention in which an exclusive or privilege is claimed are defined as follows:
1. A method of forming an article to a final form and of desired dimensions in a final cavity completely surrounding and having the final dimensions and form of the article including the steps of: forming a preform having the general shape of the final form of the article with a greater amount of material than the amount of material in the final form of the article and with a greater dimension in a first direction therethrough than the final desired dimension in the first direction through the final form and a lesser dimension in a second direction transverse to the first direction than the final desired dimension in the second direction through the final form, measuring the amount of material contained in the preform and removing material from the preform in excess of the amount of material required to completely fill the volume of the final cavity, and enclosing the preform in the final cavity to completely surround the preform by initially applying pressure to the preform in the first direction to the final desired dimension while increasing the dimension in the second direction to the final desired dimension to conform the preform to the shape of the final cavity to produce the final desired dimensions and form of the article.
2. The method of claim 1 further comprising enclosing the preform in the final cavity by placing the preform between dies in a press which define the final cavity and closing the dies to initially apply pressure to the preform in the first direction.
3. The method as set forth in claim 1 further comprising removing the excess material by placing the preform in an etching bath.
4. The method as set forth in claim 1 further comprising measuring the amount of material in the preform by weighing the preform.
CA000390869A 1980-12-16 1981-11-25 Method of forming an article Expired CA1172015A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US21684480A 1980-12-16 1980-12-16
US216,844 1980-12-16

Publications (1)

Publication Number Publication Date
CA1172015A true CA1172015A (en) 1984-08-07

Family

ID=22808724

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000390869A Expired CA1172015A (en) 1980-12-16 1981-11-25 Method of forming an article

Country Status (3)

Country Link
EP (1) EP0054404A1 (en)
JP (1) JPS5853043B2 (en)
CA (1) CA1172015A (en)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6117058U (en) * 1984-07-06 1986-01-31 株式会社吉野工業所 Bottle lid structure
JPH0226849Y2 (en) * 1984-09-07 1990-07-20
JPS61123052U (en) * 1985-01-21 1986-08-02
JPH0414364Y2 (en) * 1986-11-13 1992-03-31
JPH031865U (en) * 1989-05-29 1991-01-10
EP0540771B1 (en) * 1991-11-05 1995-01-18 Ucar Carbon Technology Corporation A process for isostatic molding
CN108555302B (en) * 2018-01-22 2019-08-30 华中科技大学 A kind of cold increasing material/warm and hot forging combined shaping method of amorphous alloy part

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1758849B2 (en) * 1968-08-20 1974-08-08 Sintermetallwerk Krebsoege Gmbh, 5608 Krebsoege Process for the powder-metallurgical production of molded parts
US3866303A (en) * 1973-06-27 1975-02-18 Bethlehem Steel Corp Method of making cross-rolled powder metal discs
GB1495705A (en) * 1973-12-18 1977-12-21 Dain R Making steel articles from powder
JPS51144361A (en) * 1975-06-09 1976-12-11 Komatsu Mfg Co Ltd Forging metal mold unit
US4142888A (en) * 1976-06-03 1979-03-06 Kelsey-Hayes Company Container for hot consolidating powder
DE2724524B2 (en) * 1976-06-03 1979-04-05 Kelsey-Hayes Co., Romulus, Mich. (V.St.A.) Container for hot-pressing molded bodies of entangled shape from powder
FR2399394A1 (en) * 1977-08-05 1979-03-02 Thomson Csf Pressure sintering ferrite(s) - without a die, using over-large punch pistons then cutting moulding to size
JPS55156631A (en) * 1979-05-25 1980-12-05 Mitsubishi Heavy Ind Ltd Forming method of axis-symmetrical parts

Also Published As

Publication number Publication date
JPS57126902A (en) 1982-08-06
EP0054404A1 (en) 1982-06-23
JPS5853043B2 (en) 1983-11-26

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