Composite Part Production via Simultaneous Pressing and Solid Insertion
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Solution Overview
Problem
Current methods for producing composite components are time-consuming and costly, and the bonding between solid and powder-metallurgical parts is not reliable, especially when solid parts are introduced subsequently.
Innovation Solution
A method involving a press that simultaneously presses powdered material into a green body and introduces a solid part within the same operation, allowing for the production of a composite component with improved bonding through controlled surface treatment and sintering, utilizing a press with a transfer stamp to maintain a joining space filled with powdered substance for the solid part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solid parts are introduced subsequently into the green compact, then the composite component can be manufactured, but the manufacturing process becomes time-consuming and costly
Solution Approach 1:
The patent combines multiple operations (pressing powdered material and introducing solid parts) into a single simultaneous operation within the same press stroke. The transfer stamp introduces solid parts into the working chamber at the same time the pressing operation forms the green compact, eliminating sequential processing steps and reducing manufacturing time while maintaining ease of manufacture.
Solution Approach 2:
The transfer stamp is pre-positioned and ready to introduce solid parts into the working chamber before the pressing operation begins. The solid parts are introduced at the optimal moment during the press stroke, ensuring they are in place before the green compact is formed around them, which streamlines the overall manufacturing process.
2Reliability
If solid parts are introduced subsequently into the green compact, then the composite component can be manufactured, but the bonding reliability between solid and powder-metallurgical parts deteriorates
Solution Approach 1:
By combining the introduction of solid parts and the pressing operation into a single simultaneous process, the patent ensures that solid parts are embedded in the powdered material under controlled conditions. This simultaneous operation creates reliable mechanical contact and bonding between the solid parts and the powder-metallurgical matrix, improving bonding reliability while avoiding the complexity of multiple separate operations.
Solution Approach 2:
The transfer stamp acts as an intermediary tool that precisely positions and introduces solid parts into the working chamber. This intermediary mechanism ensures proper placement and initial contact between solid parts and powdered material, facilitating reliable bonding during the subsequent pressing and sintering operations.
3Ease of manufacture
If multiple separate operations are used to manufacture composite components, then each operation can be optimized, but the overall manufacturing cost increases
Solution Approach 1:
The patent merges the pressing operation and solid part introduction into a single integrated process step. This consolidation eliminates the need for multiple separate operations, reducing manufacturing cost through fewer process steps, less equipment usage, and lower operational complexity, while simultaneously improving productivity by completing what would have been sequential operations in a single simultaneous action.
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
This method significantly reduces manufacturing costs and enhances the reliability of the bond between the solid and powder-metallurgical parts, enabling efficient production of composite components with improved mechanical contact and reduced processing steps.
Implementation Method 1
the powdered material is pressed into a powder metallurgy part or a green compact
Implementation Method 2
The composite component is sintered and/or pre-sintered after demolding from the press
Data Source
Figure 1A~2H
Figure 3~4
Figure 5A~5Q
AI summary
The invention relates to a method for producing a composite part, the composite part comprising at least one powder metal part compacted from a powdery material and at least one solid part. The powdery material is compacted to a powder metal part inside the working chamber of a press, especially a pressing tool of a press, and the solid part is at least partially fed to the working chamber in the same step, especially in the same working cycle of the press so that the composite part is produced within one working cycle.