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Method for enhancing adhesion of metal particles to ceramic models

a technology of metal particles and ceramic models, applied in the direction of metallic material coating process, plasma technique, textiles and papermaking, etc., can solve the problems of metal deposit not resembled the general shape characteristics of master patterns, metal deposit may not adhere sufficiently to ceramic models, metal deposit must be scrapped, etc., to enhance the adhesion of sprayed metal

Inactive Publication Date: 2004-09-30
FORD MOTOR CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0011] One preferred method embodiment includes providing a ceramic model having a spray surface and modifying at least a portion of the spray surface of the ceramic model to enhance the adhesion of sprayed metal to the spray surface.
[0033] The metal or carbon fiber can be added to the ceramic mixture (i.e., slip or slurry). The concentration of metal or carbon fiber that can be added varies based on application and can be in the range of between about 1% by weight to about 10% by weight, preferably about 3% by weight to about 7% by weight, and most preferably 5% by weight. During subsequent steps in the ceramic forming process, the metal or carbon fibers are cast into the ceramic model which includes the spray surface. Many of the metal or carbon fibers extend beyond the spray surface to form a network of protrusions on the spray surface. These protrusions enhance the adhesion of sprayed metal to the spray surface.

Problems solved by technology

During the spraying step, the metallic particles may not adhere sufficiently to the ceramic model.
Consequently, the metal deposit may not resemble the general shape characteristics of the master pattern.
In some extreme cases, the metal deposit must be scrapped due to the severity of separation between the metal deposit and the ceramic model.

Method used

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  • Method for enhancing adhesion of metal particles to ceramic models
  • Method for enhancing adhesion of metal particles to ceramic models

Examples

Experimental program
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Effect test

example 1

[0045] Example 1 discloses a method of forming ice crystals on the spray surface of a castable ceramic to enhance surface adhesion. It should be understood that other ceramics, i.e., technical ceramics and other castables, can be used with the method of forming ice crystals to enhance surface adhesion in accordance with The slurry used to produce the castable ceramic is comprised of the following:

1 TABLE 1 Component Volume % Ceramic 89.8% Water 10.2% Wetting Agent <0.1%

[0046] The preferred ceramic is TG Fine, available from Ceradyne Thermo Materials of Scottsdale, Ga. The preferred wetting agent is Cascade Rinse Aid, available from Proctor and Gamble of Cincinnati, Ohio.

[0047] The slurry is then poured into and sets in a 12'.times.12'.times.2' mold constructed of Renboard 476. After about 19 hours, the slurry is sufficiently set to be removed from the mold. A release agent, preferably Replicast spray release agent available from Cetronics Corp. of Brooklyn, N.Y., can be used to eas...

example 2

[0049] Example 2 discloses a method of forming ice crystals on the spray surface of a castable ceramic to enhance surface adhesion. It should be understood that other ceramics, i.e., technical ceramics and other castables, can be used with the method of forming ice crystals to enhance surface adhesion in accordance with Example 2. The slurry used to produce the castable ceramic is comprised of the following:

2 TABLE 2 Component Volume % Ceramic 89.8% Water 10.2% Wetting Agent <0.1%

[0050] The preferred ceramic is TG Fine and the preferred wetting agent is Cascade Rinse Aid.

[0051] The slurry is poured into a mold of a 5.4 litre lower crank case. After about 18 hours, the slurry is sufficiently set to be removed from the mold. Preferably, Replicast spray release agent can be used to ease removal of the castable ceramic from the mold.

[0052] The spray surface of the castable ceramic in wet form is then covered with shredded dry ice for about 1 hour. The spray surface is then uncovered and...

example 3

[0054] Example 3 discloses a method of applying an acid to the spray surface of a castable ceramic to enhance surface adhesion. It should be understood that other ceramics, i.e., technical ceramics and other castables, can be used with the method of applying an acid to enhance surface adhesion in accordance with Example 3. The slurry used to produce the castable ceramic is comprised of the following: ceramic material (preferably TG Fine), water, and wetting agent (preferably Cascade Rinse Aid).

[0055] The slurry is then poured into and sets in a 5.4 litre lower crank case mold. After about 18 hours, the slurry is sufficiently set to be removed from the mold. Preferably, Replicast spray release agent can be used to facilitate easy removal of the castable ceramic from the mold. The spray surface is then treated with vinegar prior to the firing stage.

[0056] The adhesion characteristics of the spray surface of Example 3 relative to an untreated spray surface are enhanced as a result of t...

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Abstract

One method of the present invention relates to a method for enhancing adhesion of sprayed metal to a ceramic model. The method is comprised of providing the ceramic model having a spray surface, and modifying at least a portion of the spray surface of the ceramic model to enhance adhesion of spray metal to the spray surface.

Description

BACKGROUND OF INVENTION[0001] 1. Field of the Invention[0002] At least one aspect of this invention relates to a method for enhancing adhesion of metal particles to ceramic models and, more particularly, a method for enhancing adhesion of sprayed metal to ceramic model spray surfaces using spray forming techniques.[0003] 2. Background Art[0004] Spray forming techniques for producing steel prototype tooling, such as dies and molds, are commonly utilized in the automotive industry as well as other industries.[0005] One typical spray forming technique includes the following steps: (1) casting a ceramic model containing a spray surface about a mold containing a master pattern of the tool to be produced; (2) spraying metal particles onto the spray surface so that the metal particles adhere; (3) allowing the sprayed metal particles to cool thereby forming a metal deposit having the general shape characteristics of the master pattern; and (4) separating the metal deposit from the ceramic m...

Claims

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Application Information

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IPC IPC(8): C04B41/51C04B41/88C23C4/02C23C4/18
CPCC04B41/009C04B41/51C04B41/88C23C4/02C23C24/04C23C4/185C04B41/4527C04B41/53C04B33/00C04B35/10C04B35/14C04B35/16Y10T428/249953Y10T428/249962
Inventor ROCHE, ALLEN DENNISNICHOLSON, JOHN MICHAELALLOR, RICHARD L.WORTHEY, DAVID WARREN
Owner FORD MOTOR CO