TOOL, METHOD FOR MAKING THE SAME, METHOD FOR MAKING A COMPONENT AND USE OF A METAL COMPOSITE MATERIAL

Abstract

Tool (1; 100; 200) comprising at least one first tool part (2), wherein the first tool part (2) is intended to produce, shape, form, deform, separate, join, or change material properties of a component (13), wherein the first tool part (2) is made of steel and a metal composite material (4) is integrated into the first tool part (2) by material bonding with the steel, wherein the metal composite material (4) comprises a first metal and a second metal, and the first metal and the second metal exhibit a miscibility gap between the first metal and the second metal in a temperature range of 200 to 1080 °C.

Description

[0001] The invention relates to a tool with very good thermal conductivity and high thermal and mechanical stability, as well as a method for its manufacture. The invention also relates to methods for manufacturing a component and the use of a metal composite material.

[0002] Steel components containing a cavity are known from the prior art. If the steel component is designed as a tool, such as a die-casting mold, a cooling or heating medium can be guided through the cavity to cool or heat the tool. However, since a cavity can weaken the component, its placement depends on the externally applied load, which in turn requires sufficiently dimensioned material volumes within the component to resist this load. Therefore, thin component areas, such as those containing a cooling medium, are generally not suitable for use with a cavity. Furthermore, the load-dependent material volume required to ensure the mechanical stability of the component competes with the potential proximity of the cavity and the component's contour.This would prove particularly disadvantageous when using the cavity in conjunction with a cooling medium. However, if the cavity is filled with, for example, copper, the previously described problem can be improved, allowing even thin component areas or heavily stressed functional surfaces to be provided with filled cavities close to the component surface and still withstand mechanical stress. The use of, for example, copper to line cavities results in better heat distribution and conduction.

[0003] WO 2007 / 038385 A2 describes a tool for forming an object in a forming operation, wherein a body is designed with a forming surface for shaping the object. A heat transfer material is attached to the tool body, at a distance from the forming surface, and consists of a material whose thermal conductivity coefficient is higher than that of the tool body. The heat transfer material and / or the tool body together form a channel for transporting a fluid for heat transfer to the forming surface. Another tool for forming an article in a forming operation is disclosed, comprising a tool body consisting of a plurality of laminate sheets made of a first material. The tool body includes a forming surface and a cavity. A heat transfer material with a higher thermal conductivity coefficient than the first material is arranged in the cavity to transfer heat from the forming surface.

[0004] DE 102014223922 A1 describes a die-casting mold for the production of metallic die-cast components, comprising at least one shell element that defines and shapes the mold cavity and at least one supporting structure to which the shell element is attached. The shell element has a layered structure with two layers made of different materials and bonded together, wherein the outer layer, which comes into direct contact with the molten metal, is made of a wear-resistant material and the underlying support layer is made of a material with good thermal conductivity properties.

[0005] WO00 / 50209 A1 concerns molds and methods for manufacturing such molds. The molds consist of a first part, which forms a mold surface made of steel, and a second part, which is made of a material such as a copper alloy that has a higher thermal conductivity than the first part, and a third part of nickel in the form of a thin layer or coating between the first and second parts. The nickel coating allows metallic connections to be made between the first and second parts.

[0006] When copper and steel are joined, copper's high thermal conductivity can be combined with steel's excellent wear resistance. However, the steel-copper connection has the disadvantage that these two materials have different coefficients of thermal expansion. While steel has a low coefficient of thermal expansion, copper has a high coefficient. At high temperatures, the copper expands significantly more, which can lead to thermal stresses within the component and also to cracking. In particular, cracking occurs in the material with the lower coefficient of thermal expansion, in this example, the steel. Alternatively, or additionally, cracking can also occur at the interface between the two materials.

[0007] To join materials with different coefficients of thermal expansion, such as steel and copper, WO 00 / 50209 A1 proposes applying a nickel layer between the steel and the copper, which forms a bond with both. The disadvantage of this method is that it requires an additional material for bonding, and thermal stresses are still not adequately prevented. Furthermore, this material is more complex to manufacture, as two separate layers—a nickel layer and a copper layer—must be applied to the steel.

[0008] The object of the invention is to provide a tool and a method for its manufacture, which is characterized by very good thermal conductivity combined with high thermal and mechanical resistance. Furthermore, it is an object of the present invention to provide methods for manufacturing a component using the tool, which can be implemented with consistently high quality. Finally, it is an object of the invention to provide a use for a metal composite material.

[0009] These problems are solved by the features of the independent claims. The dependent claims contain advantageous further developments and embodiments of the invention.

[0010] To solve the aforementioned problems, the tool according to the invention comprises at least one first tool part. The number, shape, size, and design of the tool parts are not limited in detail and depend on the intended use, i.e., the purpose of the tool. In general, the tool according to the invention, and thus also the first tool part, serves to manufacture, shape, form, deform, separate, join, or modify the material properties of a component, which includes heating or cooling the component.

[0011] For example, the tool may only comprise a first tool part if the first tool part includes a functional surface on which, for example, a component is heated or cooled and thus generally temperature-controlled.

[0012] Furthermore, by way of example, the tool according to the invention can also comprise a first and at least one second tool part, for instance to form a component that is inserted between the tool parts. Thus, the tool comprises at least two functional surfaces that cooperate to form the component. One or both tool parts can be temperature-controlled for manufacturing the component.

[0013] The first tool component and optional additional tool components can be designed identically or differently. The specific design depends on the type of tool and thus its intended use.

[0014] The first tool component is made of steel and therefore exhibits high mechanical resistance. The type of steel is not limited. Suitable steels have the following material numbers: 1.2343, 1.2344, 1.2367, 1.2379, 1.4404, 1.2333, 1.4313, 1.2083, and 1.4901.

[0015] A metal composite material is incorporated into the first tool component by means of a material bond, thus integrating it into the first tool component. The metal composite material is therefore permanently and firmly bonded to the steel. This results in a one-piece or monolithic formation of the first tool component, in which the metal composite material and the steel are firmly bonded due to the material bond. The metal composite material is thus an integral part of the first tool component, and in the area(s) where the metal composite material and the steel exhibit a material bond, there is no gap between the steel and the metal composite material, and the metal composite material and the steel are seamlessly connected.

[0016] Preferably, the metal composite material is surrounded on all sides by the first tool part and bonded to the steel on all sides. All sides of the metal composite material surrounded by steel are thus seamlessly connected to the steel. The metal composite material is an integral part of the first tool part and not merely reversibly arranged within it, as is the case, for example, when manufacturing a metal composite material within a tool. To achieve the objective of the invention, the steel of the first tool part and the metal composite material interact.

[0017] Both areas of the steel and the metal composite material can form a functional surface that serves for manufacturing, shaping, primary forming, forming, separating, or joining a component, or for changing the material properties of a component. The first tool component according to the invention has at least one functional surface intended for manufacturing, shaping, primary forming, forming, separating, joining, or changing the material properties of a component, but may also include further functional surfaces. A functional surface is understood to be a surface that is reversibly connected to the component to be manufactured, shaped, primary formed, separated, or joined, or to the component whose material properties are to be changed.

[0018] The metal composite material comprises a first metal and a second metal, with the first and second metals exhibiting a miscibility gap in the phase diagram within a temperature range of 200 to 1080 °C. This miscibility gap is understood as a two-phase region formed by the solid solutions of the constituent components. The marginal solubility of the solid solutions should not exceed 3 wt% for either the first or the second metal within the considered temperature range. The metal composite material may also contain additional metals besides the first and second metals. In this case, the additional metal(s) are further second metals and also exhibit a miscibility gap with respect to the first metal within the temperature range of 200 to 1080 °C.

[0019] Preferably, at least one of the metals (for example, the first metal) has a higher thermal conductivity than steel. The other metal (for example, the second metal) has a lower coefficient of thermal expansion than both steel and the first metal. Crucially, the first and second metals do not form an alloy but rather a metal composite. This allows the properties of each individual metal to be utilized more effectively, and the thermal conductivity and coefficient of thermal expansion can be selectively tailored.

[0020] A metal composite material according to the invention is thus a material consisting of at least the first metal and the second metal, and optionally further metals, wherein the metal composite material possesses different material properties than its individual components. Rather, either the first metal or the second metal is present in particulate form distributed within the corresponding second metal or first metal. Both metals can also be present in particulate form. In particular, however, one of the metals is present in particulate form distributed within the other metal, with the other metal serving as a matrix, but without any alloy being formed between the first metal and the second metal.

[0021] To suppress alloying, which would be detrimental to the thermal conductivity and coefficient of thermal expansion of the composite material, it is essential that the first and second metals exhibit the miscibility gap described above within a temperature range of 200 to 1080 °C. This ensures that neither metal tends to alloy within this temperature range and form further precipitates, which would lead to temporal instability of the composite material under temperature influence. This, in turn, guarantees that the properties of the composite material with respect to its overall thermal expansion and conductivity remain unchanged within the specified temperature range.

[0022] Consequently, in particular, one of the metals (first metal or second metal) can be used to selectively adjust the thermal conductivity to be higher than that of steel, while at the same time the coefficient of thermal expansion can be adjusted by the second metal so that it corresponds approximately to that of the steel used or deviates from it only to a predicted extent, so that cracking and stress cracking are efficiently avoided when the first tool part is heated or cooled.The essential aspect of the invention is that the metal composite material, and in particular its composition, is explicitly tailored to the thermal properties (i.e., the thermal expansion) of the steel used for the first tool part, so that at maximum thermal conductivity of the metal composite material a defined difference in the coefficients of thermal expansion of the metal composite material and the steel used is achieved, so that the metal composite material and the steel expand or shrink as intended during tempering.

[0023] Advantageously, one of the metals is intended to improve the thermal conductivity compared to steel, and the other of the metals is intended to level out the thermal expansion and thus adapt it to the coefficient of thermal expansion of the steel used.

[0024] The tool according to the invention is characterized by the interaction of the steel and the metal composite material, resulting in very good heat-conducting properties with high thermal and mechanical resistance and stability of the tool.

[0025] To control the temperature of the tool according to the invention, it can be cooled by an external cooling device (or, more generally, a cooling element) and / or by a cooling channel carrying a cooling medium, according to the desired temperature control. For this purpose, it is advantageous if the metal composite material used according to the invention is arranged in close proximity to the cooling device or the cooling channel, as this allows for particularly good heat distribution in the first tool part. Preferably, the metal composite material is in direct contact with the cooling device or the cooling channel, or is connected to it by only a very thin (in particular, a maximum thickness of 50 mm) steel layer, as this allows for very good heat exchange. The cooling device does not have to be part of the tool and can be connected to it if required.The temperature control channel would be part of the tool and can be located within it.

[0026] According to an advantageous embodiment, the tool comprises at least one second tool part, wherein the first tool part and the second tool part interact during the production, forming, primary forming, deformation, separation, or joining of the component, or during the modification of the component's material properties. The second tool part can be designed like the first tool part in terms of type, shape, size, and material properties. Alternatively, the first tool part and the second tool part can have complementary shapes. This is particularly relevant when the tool is intended, for example, for welding or laminating materials, or for forming or deformation of a component. Thus, the first tool part and the second tool part each have at least one functional surface that together serve for the production, forming, primary forming, deformation, separation, or joining of the component, or for modifying the component's material properties.The second tool component can also comprise a metal composite material as described above, as an integral part firmly and materially bonded to the first tool component. This results in the same advantages for the second tool component as for the first, namely very good heat distribution combined with high mechanical and thermal resistance due to the well-matched thermal expansion properties between the steel used for the respective tool component and the metal composite material.

[0027] According to a further advantageous embodiment, the first tool part and the second tool part define a cavity between them. The areas of the first tool part and the second tool part forming the cavity have functional surfaces that interact and are intended to produce a component, in particular to form a component (e.g., as a press tool, press hardening tool, die-casting tool, gravity die-casting tool, or injection mold), to shape, to reshape, or to change the material properties of the component.

[0028] According to a further advantageous embodiment, the metal composite material is free of alloys between the first metal and the second metal.

[0029] The metal composite material can contain additives in addition to the primary and secondary metals and optionally other metals, such as ceramic components (inorganic oxides, nitrides, carbides) and binders (polymeric binders). The maximum amount of one or more additives is approximately 20% by mass, based on the total mass of the metal composite material. If two or more additives are present, the maximum content refers to the sum of these additives.

[0030] To make it particularly easy to adjust the thermal conductivity and coefficient of thermal expansion of the metal composite, the composite consists of the first metal and the second metal, and optionally at least one additive. The adjustment of the thermal conductivity and the coefficient of thermal expansion in the described metal composite is achieved by changing the mixing ratio of the first and second metals. Therefore, other metals, especially those not already present in the first and second metals, are preferably not included.

[0031] According to an advantageous embodiment, the first metal is copper. Copper is characterized by a higher thermal conductivity than steel and is therefore particularly preferred for the tool according to the invention, since the heat-conducting properties and the heat distribution can thus be achieved more quickly and uniformly.

[0032] Copper, the first metal characterized by high thermal conductivity, has a higher coefficient of thermal expansion than steel, which can lead to thermally induced stress cracks in the steel when the component is heated. To maintain the highest possible thermal conductivity while reducing thermal expansion, a further advantageous embodiment provides for the selection of a second metal from the group consisting of chromium, tungsten, molybdenum, niobium, vanadium, cobalt, and tantalum. These second metals exhibit a miscibility gap with the first metal, copper, within a temperature range of 200 to 1080 °C and thus level the coefficient of thermal expansion so that it approaches that of steel, thereby preventing cracking under thermal stress on the tool even more effectively.

[0033] For a particularly uniform property profile of high thermal conductivity and moderate coefficient of thermal expansion in the composite material, it is advantageous if the first and second metals are homogeneously distributed within each other. For this purpose, it is beneficial if the particle size of the second metal is in the range of 5 to 800 µm, particularly 10 to 700 µm, and especially 15 to 500 µm. This ensures that the first metal is permeated by relatively homogeneous particles of the second metal. The particle size can be determined from microscopic images of a cross-sectional sample of the metal composite, whereby, for non-spherical particles, the largest diameter is used as the particle size.

[0034] A particularly mechanically stable metal composite material can be advantageously obtained if the metal composite material comprises 5 to 70 mass% of the second metal and the remainder the first metal, based on 100 mass% of metallic elements in the metal composite material.

[0035] In a particularly preferred embodiment, the metal composite material in the first tool part is surrounded on all sides by steel and firmly and metallurgically bonded to the steel. The metal composite material is thus an integral part of the steel and is not intended to be removed from it. The first tool part is therefore monolithic. Due to the metallurgical bond between the steel and the metal composite material, the metal composite material cannot be removed from the steel without damage. Simple removal of the metal composite material from the steel is not possible.The embodiment in which the metal composite material is surrounded on all sides by steel is particularly advantageous for tools whose functional surface (in this case, at least one of the steel surfaces) is subject to high mechanical stress, since the steel sheath around the metal composite material thus also protects the metal composite material without significantly impairing the heat-conducting properties in the first tool part.

[0036] In an alternative embodiment, the metal composite material is in contact with the cavity formed in the tool. This allows for faster, more stable, and immediate temperature control within the cavity, enabling, for example, faster heating or cooling of components of a manufactured part, thus allowing for temperature control.

[0037] Furthermore, advantageous in light of the aforementioned temperature control, the metal composite material forms at least part of a functional surface of the first tool part.

[0038] According to a further advantageous embodiment, the tool comprises at least one cooling channel, wherein the metal composite material adjoins the cooling channel or is connected to it by a steel layer, the steel layer having a thickness of 0.5 to 50 mm. This embodiment allows a medium guided through the cooling channel to exchange its temperature with the tool more quickly and over a shorter distance, so that the metal composite material promotes temperature distribution and simultaneously improves the stability of the tool.

[0039] Due to its very good thermal conductivity properties combined with very good mechanical and thermal stability, the tool made of the described metal composite material is preferably designed as a tool for thermally stressed processes, such as die casting tools or press hardening tools.

[0040] The invention also discloses a method for manufacturing a tool as described above. Due to the combination of steel with the metal composite material, the tool is characterized by very good thermal conductivity properties and high mechanical and thermal strength, so that simple, targeted, and rapid temperature control can be achieved through its use.

[0041] The metal composite material described above according to the invention, which is produced, for example, using conventional methods such as a sintering process, is inserted into this cavity so that the metal composite material fills the cavity and protrudes from the open side of the cavity. The metal composite material is then removed to form a flat surface with the steel surrounding the now filled cavity. Finally, a steel covering can be applied to the newly created flat surface. A cold gas spraying process has proven particularly advantageous for closing or sealing the cavity with steel.

[0042] After filling the cavity and, if necessary, providing a covering, the resulting structure is finally subjected to thermal treatment to produce a monolithic tool consisting of tool steel and metal composite material, in which the metal composite material is integrally bonded to the steel of the first tool part.

[0043] The production of the metal composite material can alternatively be carried out in situ during cavity filling. Here, a particulate mixture of the first and second metals is filled into the cavity, preferably by cold gas spraying. In this case as well, the cavity is overfilled and then milled away until a flat surface of tool steel surrounding the now filled cavity is created. This can then be followed by a step of covering the filled cavity with steel.

[0044] Finally, the first tool component undergoes another heat treatment, forming a metallurgical bond between the metal composite and the steel. In this alternative process, at least a partial metallurgical bond between the metal composite and the steel is already formed during the production of the metal composite within the cavity, and this bond can be further enhanced by the heat treatment.

[0045] To achieve the most homogeneous structure possible in the metal composite material, the first metal preferably used has a particle size of 5 to 200 µm, and particularly 5 to 150 µm, before being introduced into the cavity. For the same reason, a second metal is preferably used, with a particle size of 5 to 150 µm, and particularly 5 to 100 µm. These particle sizes refer to the state of the metals before they are introduced into the cavity, i.e., before the metal composite material is formed.

[0046] A cold gas spraying process has proven particularly advantageous for closing or sealing the cavity with steel.

[0047] Furthermore, according to the invention, a first method for manufacturing a component with the tool according to the invention is also described. As already described above, the tool comprises at least one first, temperature-controlled tool part, wherein the first tool part is made of steel and a metal composite material is integrated into the first tool part by a metallurgical bond with the steel, wherein the metal composite material comprises a first metal and a second metal and the first metal and the second metal exhibit a miscibility gap between the first metal and the second metal in a temperature range of 200 to 1080 °C.

[0048] With regard to the design of the first tool part, the metal composite material contained therein and bonded to the steel, and the effects achieved thereby, reference is made to the descriptions of the tool according to the invention. The first tool part comprises at least one functional surface on which the component is machined or processed.

[0049] The process comprises a step of applying a material to the functional surface of the first tool part. Optionally, the application can also be achieved by bringing the material close to the functional surface of the first tool part using a vacuum. After the material has been applied to the functional surface, it is tempered at the functional surface to produce the component; in this case, it is heated and thermoformed.

[0050] By using the tool according to the invention for the aforementioned method of manufacturing a component by thermoforming, the thermoforming process can be carried out with a short cycle time and thus high throughput, which is made possible by the tool's very good thermal conductivity. Furthermore, the process can be carried out consistently with high quality, since the tool according to the invention prevents stress cracks in the tool, resulting in a long tool life due to its very good thermal and mechanical stability.

[0051] According to an advantageous embodiment of the first method according to the invention for manufacturing a component, the metal composite material is in contact with the functional surface of the first tool part or forms at least a part of the functional surface. This allows the heat transfer required for thermoforming to occur more quickly and uniformly.

[0052] Furthermore, according to the invention, a second method for manufacturing a component from a first material and a second material is also described. For the sake of completeness, it is mentioned that the component can ultimately comprise several materials. The materials are not limited in detail and can, in particular, be metallic or plastic-based materials. Combinations of different types of materials are also possible.

[0053] The second method according to the invention also uses the tool already described. To carry out the second method according to the invention, the tool comprises a temperature-controlled first tool part and a second temperature-controlled tool part, wherein the first tool part or the second tool part or the first and the second tool part is / are made of steel, and a metal composite material as described above is integrated into the first tool part or the second tool part or the first tool part and the second tool part (at least into the tool part made of steel) by way of metallurgical bonding with the steel, wherein the metal composite material in turn comprises a first metal and a second metal, and the first metal and the second metal have a miscibility gap between the first metal and the second metal in a temperature range of 200 to 1080 °C.

[0054] The tool used for the second method according to the invention is thus conformal to the embodiment of the tool according to the invention in which the tool comprises both a first and a second tool part. The first tool part and the second tool part do not form a cavity between them. This means that the functional surfaces of the first tool part and the second tool part, which interact in the method, are complementary, so that they can be moved against each other.

[0055] This is necessary for the second method according to the invention for manufacturing a component, as explained below.

[0056] With regard to the design of the first and second tool parts and the metal composite material integrated therein by material bonding with the steel, further reference is made to the descriptions of the tool according to the invention.

[0057] The process initially comprises a step of introducing the first material and the second material (and optionally other materials to be joined) between the first tool part and the second tool part, so that the first material and the second material (and optionally other materials to be joined) overlap at least partially.

[0058] The first and second tool parts are then brought together so that the first and second materials (and any other optional materials) are heated at least in part of the overlapping areas and joined together in a metallurgical bond. This joining can be achieved, for example, by welding plastic or metal materials under heat.

[0059] The materials to be joined are not limited and can be made of the same or different materials. As an example, a partial welding of a polymeric plastic hose is described, where the welding takes place on the inside of the hose, and the hose thus provides both the first and second materials.

[0060] To facilitate the joining of the materials, at least the first tool part or the second tool part, but preferably both tool parts, are heated. By using a metal composite material as described above in the first tool part, and optionally also in the second tool part, the heat distribution on the functional surfaces of the tool parts is improved, promoting uniform and rapid heating of the materials to be joined. Furthermore, the high thermal and mechanical stability of the tool used ensures a consistently high throughput.

[0061] Furthermore, a third inventive method for manufacturing a component is also described, which uses the inventive tool as described above.

[0062] The tool is designed such that it comprises a first temperature-controlled tool part and a second temperature-controlled tool part, which define a cavity between them, wherein the first tool part or the second tool part or the first tool part and the second tool part are made of steel and a metal composite material as described above is integrated into the first tool part or the second tool part or the first tool part and the second tool part (at least into the tool part made of steel) by means of a metallurgical bond with the steel, wherein the metal composite material comprises a first metal and a second metal and the first metal and the second metal have a miscibility gap between the first metal and the second metal in a temperature range of 200 to 1080 °C.

[0063] With regard to the design of the tool parts and the metal composite material, further reference is made to the explanations concerning the tool according to the invention and the preceding methods.

[0064] The third method according to the invention comprises a step of introducing the component(s) of the part to be manufactured into the cavity. For introducing the components, the cavity can be open, or the components can be introduced into the cavity defined by the first and second tool parts via feeders. In this case, the tool is closed. The component(s) are temperature-controlled for manufacturing the part, i.e., heated or cooled depending on the method. After the part has been manufactured, it can be demolded by opening the cavity.

[0065] The following methods for manufacturing components that can be produced using the method according to the invention are given as examples: As one example of such a process, the injection molding of a (plastic) component can be mentioned. For this, as described above, one or more components forming the final component, such as a thermoplastic polymer, are injected under pressure into the cavity formed by the first and second mold parts. The thermoplastic polymer is heated to a sufficient viscosity to line and fill the cavity. The polymer is then cooled and thus hardened. After hardening, the plastic component can be demolded from the cavity.

[0066] Another example is the production of a chemical compound from individual elements or components. For instance, a polyurethane polymer can be formed from polyol and diisocyanate and corresponding polymerization initiators using the process according to the invention, wherein the polymerization reaction is initiated and promoted by heating the components in the cavity.

[0067] The inventive method can also be used for metal die casting, which is similar to plastic injection molding, but in this case a molten metal is introduced into the cavity under pressure, cooled there, causing it to solidify and harden in the desired shape.

[0068] Furthermore, the inventive method can also be used for die casting, wherein liquid metal is filled into the cavity and subsequently cooled, thus solidifying in the shape.

[0069] Furthermore, the method according to the invention can also be used for hot forming or cold forming or for press hardening, wherein the material to be formed or press hardened is introduced into the cavity formed by the first tool part and the second tool part and is formed there under appropriate temperature control (i.e. heating in the case of hot forming and cooling in the case of press hardening and cold forming).

[0070] In these methods according to the invention, the tool enables targeted temperature control, for example, heating the components that form the part or cooling the part produced from the components. For this purpose, at least one of the tool parts forming the tool is brought to a corresponding temperature. This tool part comprises the metal composite material, which is bonded to and integrated within the steel of the tool part, and through which the temperature control of the tool part is achieved quickly and uniformly. By using the tool according to the invention, a component of consistently high quality can be produced with a permanently low cycle time and short production time due to the high mechanical and thermal stability of the tool.

[0071] As a further aspect of the invention, the use of a metal composite material is also described, wherein the metal composite material comprises a first metal and a second metal, wherein the first metal and the second metal have a miscibility gap in a temperature range of 200 to at least 1080 °C, wherein the metal composite material serves to improve the thermal conductivity and adapt the thermal expansion in a tool with a first tool part, wherein the first tool part is made of steel, and wherein the metal composite material and the steel of the first tool part are metallurgically bonded to each other.

[0072] Further details, advantages and features of the present invention will become apparent from the following description of exemplary embodiments with reference to the drawing. It shows: Fig. 1 a tool according to an initial advantageous further training on average, Fig. 2 a tool according to a second advantageous further training in the cut and Fig. 3 a tool according to a third advantageous further training on average.

[0073] The figures show only the essential features of the present invention. All other elements, parts, and components have been omitted for clarity. Furthermore, identical reference numerals denote identical parts or elements.

[0074] Fig. Figure 1 is a sectional view of a tool 1 according to a first embodiment. The tool 1 comprises a first tool part 2 and a second tool part 3. The first tool part 2 and the second tool part 3 are positioned opposite each other, so that a material, here represented as a first material 10 and a second material 11, which can also be the same material, can be conveyed between the tool parts 2 and 3 in the conveying direction F.

[0075] The first tool part 2 has a functional surface 6 and the second tool part 3 has a functional surface 7. To produce a component 13 from the first material 10 and the second material 11, the functional surface 6 and the functional surface 7 work together.

[0076] The tool 1 is made of Fig. 1 manufactured component 13 still comprises the first material 10 and the second material 11, but has a weld 12 at regular intervals.

[0077] The welding 12 is achieved by moving the first tool part 2 and the second tool part 3 together in direction of movement B, thereby bringing the functional surface 6 and the functional surface 7 closer together.

[0078] Both the first tool part 2 and the second tool part 3 are made of steel and are heated. Heating is achieved via temperature control elements 5. A temperature control element 5 can, for example, comprise a temperature control medium that is conveyed through the first tool part 2 and the second tool part 3.

[0079] In order to distribute the heat emitted via the tempering element 5 to the functional surfaces 6, 7 as quickly and evenly as possible, a metal composite material 4 is bonded to the steel in the steel base bodies of the first tool part 2 and the second tool part 3.

[0080] The metal composite material 4 comprises a first metal and a second metal. The first metal and the second metal exhibit a miscibility gap in their phase diagrams over a temperature range of 200 to 1080 °C. Preferably, the first metal is copper and the second metal is chromium. The metal composite material 4 may also contain additives in a maximum quantity of 20% by mass, based on the total mass of the metal composite material. The metal composite material 4 is free of alloying elements of the first metal and the second metal.

[0081] In the first tool part 2 and the second tool part 3, which are made of steel, the metal composite material 4 is completely surrounded by steel and is in contact with the cooling element 5, with only a thin layer of steel present between the metal composite material 4 and the cooling element 5. The metal composite material 4 is metallurgically integrated into the steel of the respective tool part 2, 3 and is thus an integral part of the corresponding tool part 2, 3 and firmly bonded to the steel.

[0082] The metallurgical composite material 4 is integrated into the respective tool part 2, 3, resulting in improved heat distribution from the temperature control element 5 to the respective functional surface 6, 7. Due to the material composition of the metallurgical composite material 4, which is adapted to the steel of the corresponding tool part 2, 3 with regard to its thermal expansion properties, it exhibits a thermal expansion similar to that of steel. Therefore, during temperature control of the tool parts 2, 3, the metallurgical composite materials 4, which are metallurgically bonded to the steel, expand less than conventional copper inlays, thus preventing stress cracks from forming in the surrounding steel.

[0083] Tool 1 is therefore characterized by excellent heat-conducting properties combined with very good thermal and mechanical stability, so that tool 1 operates at a high quality and can be used reliably over a long period of time.

[0084] Fig. Figure 2 shows a tool 100 according to a second embodiment in section. The tool 100 consists of a first tool part 2 and may also include a punch 9. The punch 9 is movable in the direction of movement B. A material 14, such as a plastic film, is inserted between the punch 9 and the first tool part 2. The first tool part 2 may include a structured functional surface 6 and also one or more openings 8 through which a vacuum can be applied to the surface of the first tool part 2 to draw in a material 14.

[0085] The tool 100 allows the material 14 to be thermoformed, or in other words, deep-drawn. This requires first heating the material 14 and then deep-drawing it, for example, using the punch 9. After shaping, the material 14, now in its new form, is cooled to retain its final shape. Cooling is achieved via the functional surface 6. The functional surface 6 is cooled by a metal composite material 4, which is in contact with a cooling channel or cooling element 5 integrated into the first tool part 2 and transfers heat to or is cooled by it.

[0086] The metal composite material 4 ensures rapid and uniform temperature control of the functional surface 6 of the first tool part 2. Furthermore, the use of the metal composite material 4 prevents cracking in the surrounding steel of the first tool part 2, particularly thermally induced stress cracking. Tool 100 can also be used for extended periods and operates with high quality and reliability.

[0087] Fig. Figure 3 shows a cross-sectional view of a tool 200 according to a third embodiment. The tool 200 can, for example, be designed as an injection mold. For this purpose, the tool 200 comprises a first tool part 2 and a second tool part 3, which define a cavity K between them.

[0088] The first tool part 2 and the second tool part 3 again have corresponding functional surfaces 6, 7, between which, for example, a plastic component is formed.

[0089] To ensure rapid and uniform heating of the components in cavity K, the functional surfaces 6, 7 are tempered via metal composite materials 4 connected to tempering elements 5. The steel layer thickness between the metal composite material 4 and the adjacent tempering element 5 is approximately 0.5 to 50 mm, allowing for good heat transfer from the tempering element 5 to the metal composite material 4.

[0090] The in Fig. The 3 tools shown, 200, can be used for different processes.

[0091] A first exemplary process is the injection molding of a (plastic) component. For this purpose, one or more components forming the final component, such as a thermoplastic polymer, are introduced into the cavity K in the mold 200, which is formed by the first and second mold parts 2, 3. The thermoplastic polymer is heated to a sufficient viscosity to line and fill the cavity K. The polymer is then cooled and thus hardened. After hardening, the plastic component can be demolded from the cavity K. The thermoplastic polymer is cooled by the metal composite material 4, which is in heat exchange with the cooling element 5. Due to the composition of the metal composite material 4, heat can be dissipated from the polymer very quickly, allowing it to solidify rapidly and uniformly into the desired component.

[0092] A second exemplary process is the production of a chemical compound from individual elements or components. For example, a polyurethane polymer can be formed from polyol and diisocyanate and corresponding polymerization initiators in the tool 200, whereby the polymerization reaction is initiated and promoted by heating the components in the cavity K through heat exchange with the metal composite material 4.

[0093] A third exemplary process is a so-called die-casting process, in which a metal component is manufactured using tool 200. Specifically, this is a metal die-casting process similar to plastic injection molding; however, in this case, molten metal is injected under pressure into cavity K, cooled there, causing it to solidify and harden in the desired shape. The cooled and shaped metal component can then be demolded from cavity K.

[0094] Furthermore, the tool 200 can also be used for the production of a component in die casting, whereby liquid metal is filled into the cavity and then cooled, thus solidifying in shape.

[0095] Furthermore, the tool 200 can also be used for hot forming or cold forming or for press hardening, whereby the material to be formed or press hardened is placed in the cavity K, which is formed by the first tool part 2 and the second tool part 3, and is shaped there under appropriate temperature control.

[0096] In each of the exemplary processes mentioned, the use of tool 200 achieves targeted temperature control, for example, heating the components that form the part or cooling the part produced from these components. Temperature control is achieved via the metal composite material 4 provided in the first tool part 2 and / or the second tool part 3. For this purpose, the metal composite material 4 is brought to the desired temperature by a temperature control element 5, such as a temperature control medium located in a temperature control channel. Because the metal composite material 4 has better thermal conductivity than steel, improved heat exchange occurs between the metal composite material 4 and the components located in the cavity K that form the final part.Furthermore, the metal composite material 4 effectively prevents cracking in the steel of the tool part 2, 3 that incorporates the metal composite material 4, because the thermal expansion properties of the metal composite material 4 have been adapted to those of the steel used for the tool 200. In other words, the incorporated composite material 4 enables faster heat conduction to the cooling channel / element 5. The tool according to the invention is thus able to dissipate heat more quickly to the cooling element 5 without unduly restricting the mechanical stability of the tool, or even to reach areas that cannot be reached by a cooling element 5.

[0097] In addition to the above written description of the invention, explicit reference is hereby made to the graphic representation of the invention in the figures for its supplementary disclosure. Reference symbol list 1 tool 2 first tool part 3 second tool part 4 Metal composite material 5 temperature control element 6 functional surfaces 7 functional surfaces 8 Opening 9 stamps 10 first material 11 second material 12 Welding 13 Component 14 Material B Direction of movement F Conveyor direction K cavity

Claims

[1] Tool (1; 100; 200) comprising at least one first tool part (2), wherein the first tool part (2) is intended to produce, shape, form, deform, separate, join, or change material properties of a component (13), wherein the first tool part (2) is made of steel and a metal composite material (4) is integrated into the first tool part (2) by material bonding with the steel, wherein the metal composite material (4) comprises a first metal and a second metal, and the first metal and the second metal exhibit a miscibility gap between the first metal and the second metal in a temperature range of 200 to 1080 °C. [2] Tool (1; 200) according to claim 1, comprising a second tool part (3), wherein the first tool part (2) and the second tool part (3) cooperate in the manufacture, shaping, primary forming, forming, separating or joining of the component (13) or in changing the material properties of the component (13). [3] Tool (200) according to claim 2, wherein the first tool part (2) and the second tool part (3) define a cavity (K) between them. [4] Tool (1; 100; 200) according to one of the preceding claims, wherein the metal composite material (4) is free of alloys of the first metal and the second metal. [5] Tool (1; 100; 200) according to one of the preceding claims, wherein the metal composite material (4) comprises at least one additive and wherein, in particular, a proportion of the additive is a maximum of 20% by mass based on the total mass of the metal composite material (4). [6] Tool (1; 100; 200) according to one of claims 1 to 4, wherein the metal composite material (4) consists of the first metal and the second metal and optionally at least one additive. [7] Tool (1; 100; 200) according to any one of the preceding claims, wherein the first metal is copper. [8] Tool (1; 100; 200) according to one of the preceding claims, wherein the second metal is selected from the group consisting of: chromium, tungsten, niobium, vanadium, cobalt, tantalum and molybdenum. [9] Tool (1; 100; 200) according to one of the preceding claims, wherein the particle size of the second metal is in a range of 5 to 800 µm, in particular 10 to 700 µm and in particular 15 to 500 µm. [10] Tool (1; 100; 200) according to one of the preceding claims, wherein the metal composite material (4) contains the second metal with 5 to 70 mass% and the first metal as a remainder, based on 100 mass% of metallic elements in the metal composite material (4). [11] Tool (1; 100; 200) according to one of the preceding claims, wherein the metal composite material (4) in the first tool part (2) is surrounded on all sides by steel. [12] Tool (200) according to one of claims 3 to 10, wherein the metal composite material (4) is in contact with the cavity (K). [13] Tool (200) according to one of claims 1 to 10 and 12, wherein the metal composite material (4) forms at least a part of a functional surface (6) of the first tool part (2). [14] Tool (1; 100; 200) according to one of claims 1 to 10, further comprising at least one cooling channel, wherein the metal composite material (4) adjoins the cooling channel or is connected to it by a steel layer, wherein the steel layer in particular has a layer thickness of 0.5 to 50 mm. [15] Tool (1; 100; 200) according to any of the preceding claims, designed as a die-casting tool or as a press-hardening tool. [16] Method for manufacturing a tool (1; 100; 200) according to any one of the preceding claims, comprising the steps: - Providing a first tool part (2), wherein the first tool part (2) is made of steel and has a cavity, - Manufacturing a metal composite material (4) from a first metal and a second metal, - Introducing the metal composite material (4) into the cavity so that the metal composite material (4) is integrated into the first tool part (2), - thermal treatment of the metal composite material (4) integrated into the first tool part (2) and - material-bonding connection of the metal composite material (4) with the steel of the first tool part (2). [17] Method according to claim 16, wherein the particle size of the first metal is 5 to 200 µm and in particular 5 to 150 µm before being introduced into the cavity. [18] Method according to claim 16 or 17, wherein the particle size of the second metal is 5 to 150 µm and in particular 5 to 100 µm before being introduced into the cavity. [19] Method according to any one of claims 16 to 18, comprising a step of closing the cavity with steel, in particular by cold gas spraying. [20] Method for producing a component (13) with a tool (100) comprising at least one temperature-controlled first tool part (2), wherein the first tool part (2) is made of steel and a metal composite material (4) is integrated into the first tool part (2) by metallurgical bonding with the steel, wherein the metal composite material (4) comprises a first metal and a second metal and the first metal and the second metal exhibit a miscibility gap between the first metal and the second metal in a temperature range of 200 to 1080 °C, wherein the method comprises a step of applying a material (14) to a functional surface (6) of the first tool part (2), and the material (14) is temperature-controlled and thermoformed at the functional surface (6) to produce the component (13). [21] Method according to claim 20, wherein the metal composite material (4) is in contact with the functional surface (6) or forms at least a part of the functional surface (6). [22] Method for producing a component (13) from a first material (10) and a second material (11) using a tool (1) comprising a temperature-controlled first tool part (2) and a temperature-controlled second tool part (3), wherein - the first tool part (2) or - the second tool part (3) or - the first tool part (2) and the second tool part (3) are made of steel and - into the first tool part (2) or - into the second tool part (3) or - a metal composite material (4) is integrated into the first tool part (2) and into the second tool part (3) by material bonding with the steel, wherein the metal composite material (4) comprises a first metal and a second metal and the first metal and the second metal exhibit a miscibility gap between the first metal and the second metal in a temperature range of 200 to 1080 °C, wherein the method comprises: - a step of introducing the first material (10) and the second material (11) between the first tool part (2) and the second tool part (3), such that the first material (10) and the second material (11) overlap at least partially, and - a step of bringing together the first tool part (2) and the second tool part (3) so that the first material (10) and the second material (11) are tempered at least on a part of the overlapping area and joined together in a material-bonded manner. [23] Method for manufacturing a component with a tool (200) comprising a temperature-controlled first tool part (2) and a temperature-controlled second tool part (3) defining a cavity (K) between them, wherein - the first tool part (2) or - the second tool part (3) or - the first tool part (2) and the second tool part (3) are made of steel and - into the first tool part (2) or - into the second tool part (3) or - a metal composite material (4) is integrated into the first tool part (2) and into the second tool part (3) by material bonding with the steel, wherein the metal composite material (4) comprises a first metal and a second metal and the first metal and the second metal exhibit a miscibility gap between the first metal and the second metal in a temperature range of 200 to 1080 °C, wherein the method comprises: - a step of introducing components of the part to be manufactured into the cavity (K) and - Manufacturing the component while temperature-controlling the components in the cavity (K). [24] Use of a metal composite material (4) comprising a first metal and a second metal, wherein the first metal and the second metal have a miscibility gap in a temperature range of 200 to 1080 °C, for improving thermal conductivity and matching thermal expansion in a tool (1; 100; 200) with a first tool part (2), wherein the first tool part (2) is made of steel, and wherein the steel of the first tool part (2) and the metal composite material (4) are metallurgically bonded together in the first tool part (2).

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