Internal Oxidation Laminated Structure for Mold Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for regenerating noble metal protection films on mold surfaces are time-consuming and costly, and existing barrier layers against cobalt diffusion in cemented carbide molds are ineffective, leading to inefficiencies in mold regeneration and diamond nucleation.
Innovation Solution
A laminated structure is formed through internal oxidation, with an alloy coating layer having a columnar grain structure composed of easily oxidizable and stable metal elements, allowing for alternate layers of oxides and metals that can be easily regenerated and serve as protection or buffer layers, and providing enhanced barrier properties against cobalt diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a noble metal protection film is coated on mold surface, then chemical stability and erosion resistance are improved, but cost and processing time increase significantly when regeneration is needed
Solution Approach 1:
The protection film is segmented into multiple thin layers with different compositions (first metal element layer and second metal element layer) instead of using a single noble metal layer. This segmentation allows selective removal of the damaged outer layer while preserving the underlying buffer layer, significantly reducing regeneration time and cost.
Solution Approach 2:
A buffer layer composed of a second metal element is preliminarily deposited on the mold surface before the protection film. This preliminary action creates a sacrificial buffer layer that can be easily removed during regeneration, eliminating the need to remove and recoat the entire noble metal protection film.
2Device complexity
If a single-layer barrier layer is coated to prevent cobalt diffusion, then the structure is simple, but barrier ability against cobalt diffusion is insufficient
Solution Approach 1:
The single-layer barrier is segmented into a multi-layer structure with a first metal element layer and a second metal element layer. The first metal element layer provides superior barrier properties against cobalt diffusion, while the second metal element layer serves as a buffer. This segmentation achieves effective cobalt diffusion prevention without excessive complexity.
Solution Approach 2:
The barrier layer is formed as a composite structure combining different metal elements with complementary properties. The first metal element (e.g., Ru, Rh, Pd, Pt, Ir) provides high barrier ability against cobalt diffusion, while the second metal element (e.g., Mo, W, Ta) provides buffer functionality and structural stability, creating a synergistic composite barrier system.
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 enables efficient regeneration of protection layers without the need for costly noble metal re-coating and significantly reduces cobalt diffusion, improving mold regeneration efficiency and extending the lifespan of mold surfaces.
Implementation Method 1
a thermal oxidation treatment process is performed to the alloy coating layer, so as to form a plurality of oxide layers and a plurality of metal layers stacked alternately with each other from a surface portion of the alloy coating layer
Implementation Method 2
The alloy coating layer has a columnar grain structure and includes a first metal element and a second metal element, and the first metal element is oxidized more easily than the second metal element
Data Source
AI summary
A forming method of a laminated structure by internal oxidation is provided. An alloy coating layer is formed. The alloy coating layer has a columnar grain structure and includes a first metal element and a second metal element, and the first metal element is oxidized more easily than the second metal element. Thereafter, a thermal oxidation treatment process is performed to the alloy coating layer, so as to form a plurality of oxide layers and a plurality of metal layers stacked alternately with each other from a surface portion of the alloy coating layer. A material of the oxide layers includes an oxide of the first metal element, and a material of the metal layers includes the second metal element.