Patterned Composite Metal Plate Forming Without Twisting Limits
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Solution Overview
Problem
Existing methods for producing damascene patterned metal objects are limited to small sizes due to the need for size reduction and distortion of elongated structures, restricting their application to small objects like knives and jewelry.
Innovation Solution
A method involving the use of at least two different metal powders filled in a container with non-parallel or non-straight layers, subjected to hot isostatic pressing and hot deformation to form a patterned composite metal plate without the need for twisting, allowing for larger size production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional lamination techniques with size reduction and distortion steps are used, then damascene patterned objects can be produced, but the size is limited to small objects only
Solution Approach 1:
The invention applies preliminary action by filling the container with metal powders in non-parallel or non-straight layers before consolidation. This pre-positioning of layers in a three-dimensional configuration eliminates the need for subsequent distortion steps, allowing direct formation of the desired pattern in large-sized plates without the size limitations of conventional methods
Solution Approach 2:
The invention inverts the conventional approach by instead of creating parallel layers and then distorting them to form patterns, it directly places non-parallel or non-straight layers during container filling. This inversion eliminates the distortion step and enables production of large-sized patterned plates
2Shape
If twisting and flat rolling steps are performed to create damascene pattern, then decorative pattern is obtained, but the object size remains small
Solution Approach 1:
The decorative pattern is formed by preliminary arrangement of metal powders in non-parallel or non-straight layers during container filling, before consolidation. This pre-forming of the pattern geometry eliminates the need for subsequent twisting and flat rolling steps, enabling direct production of large-sized plates with decorative patterns
Solution Approach 2:
The invention transitions from two-dimensional parallel layering to three-dimensional non-parallel or non-straight layering. By utilizing the third dimension in container filling, the pattern is formed in space before consolidation, allowing large-scale production without restrictive distortion steps
3Ease of manufacture
If parallel elongated layers are used in container filling, then consolidation is straightforward, but distortion steps are required increasing process complexity
Solution Approach 1:
The container is filled with metal powders in non-parallel or non-straight layers as a preliminary action, pre-establishing the desired pattern geometry. This eliminates the need for subsequent distortion steps, reducing the total number of process steps while maintaining ease of consolidation through hot isostatic pressing
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
Enables the production of large-sized patterned composite metal plates with high cleanliness and precise control over particle sizes, enabling the creation of decorative metal objects of various sizes beyond the limitations of previous techniques.
Implementation Method 1
subjecting the container to hot isostatic pressing in order to form a consolidated body comprising non parallel and/or non straight metal and/or metal alloy layers
Implementation Method 2
subjecting the container to hot isostatic pressing in order to form a consolidated body comprising non parallel and/or non straight metal and/or metal alloy layers, e) optionally subjecting the consolidated body to hot deformation in order to form an intermediate body having a thickness of 50 to 200 mm
Implementation Method 3
hot rolling the consolidated or the intermediate body in two perpendicular directions in order to form a plate
Data Source
AI summary
A method of producing a patterned composite metal plate includes a) providing at least two different metal and/or metal alloy powders, b) filling a container, b1) with the powders in different individual layers, or b2) making a three dimensional non-solid body of one of the powders, inserting said body in the container and filling the cavities in and around the said body completely with the other powder, c) sealing and evacuating the container, d) subjecting the container to hot isostatic pressing, e) optionally subjecting the consolidated body to hot deformation to form an intermediate body having a thickness of 50 to 200 mm, f) hot rolling the intermediate body in two perpendicular directions in order to form a plate, and optionally one or more of g) cold rolling the hot rolled plate to form a cold rolled plate h) slitting the plate and i) etching the plate.