Composite Mold Material With High-Melting Overlay for Hot Durability
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Solution Overview
Problem
Existing high-melting-point metals are difficult to produce structures like molds due to thermal stress cracking and high production costs, and using a single type of metal limits practicality and usability.
Innovation Solution
A composite material is created with an overlaid part of high-melting-point metal particles scattered on a low-melting-point alloy member, where the high-melting-point metal particles account for 50% to 95% by mass, produced by applying thermal energy to scatter high-melting-point metal powders on the low-melting-point alloy member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-melting-point metal is used to produce molds, then heat resistance and durability are improved, but production cost and specific gravity increase significantly
Solution Approach 1:
The patent creates a composite material consisting of high-melting-point metal particles dispersed within a low-melting-point alloy matrix. This composite structure allows the mold to achieve heat resistance and durability comparable to pure high-melting-point metals while significantly reducing production costs and specific gravity, as the inexpensive low-melting-point alloy serves as the primary matrix material
Solution Approach 2:
The patent applies high-melting-point metal particles locally within the mold structure where thermal stress and heat exposure are most critical. This localized application of high-melting-point material provides targeted heat resistance and durability improvements without requiring the entire mold to be made from expensive high-melting-point metal, thus reducing overall production cost
2Ease of manufacture
If sintering is used to produce high-melting-point metal structures, then production is simplified, but thermal stress cracking occurs due to differences in thermal expansion coefficients among different metals
Solution Approach 1:
The patent changes the fundamental parameters of the material system by using a low-melting-point alloy matrix with thermal expansion properties that are more compatible with common mold materials. The dispersed high-melting-point metal particles are incorporated in a way that minimizes thermal expansion mismatch issues, thereby reducing thermal stress cracking while maintaining production simplicity
3Duration of action of stationary object
If high-melting-point metal is used for mold production, then durability in hot environments is improved, but the material becomes very expensive and has very high specific gravity
Solution Approach 1:
The composite material structure allows the mold to achieve durability in hot environments through the dispersed high-melting-point metal particles that provide thermal stability and resistance to thermal stress. Simultaneously, the low-melting-point alloy matrix keeps the overall specific gravity low, as it is significantly lighter than pure high-melting-point metals
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite material provides durability in hot environments, reduces production costs, and allows for easy production of molds suitable for high-temperature use.
Implementation Method 1
applying a thermal energy to the surface of a low-melting-point alloy member having a melting point of 1600° C. or lower to melt the low-melting-point alloy member
Data Source
AI summary
A composite material that is durable in a hot environment and easily produced. The composite material has an overlaid part comprising high-melting-point metal in at least a part on the surface of a low-melting-point alloy member having a melting point of 1600° C. or lower. The overlaid part comprising high-melting-point metal comprises high-melting-point metal particles comprising high-melting-point metal elements having a melting point of 2400° C. or higher scattered therein and comprises the high-melting-point metal elements that account for 50% by mass to 95% by mass thereof.