Resin Core Material for Green Compact Recesses
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Solution Overview
Problem
The existing powder metallurgy methods for producing titanium-based green compacts with recesses, such as through holes or non-through depressions, often result in surface irregularities due to the use of rigid core materials like steel, which fail to transmit pressure evenly, leading to raised portions on the compact surface.
Innovation Solution
The method employs a resin core material with a stress of 0.3 MPa to 3.5 MPa at 20% strain in uniaxial compression, made from materials like silicone or fluoro resins, within a resin mold to ensure even pressure transmission and prevent surface irregularities during cold isostatic pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a highly rigid core material such as steel is used to form recesses in green compacts, then the structural strength and shape definition are improved, but the surface of the green compact becomes raised and irregular near the core material
Solution Approach 1:
The patent changes the physical parameters of the core material from highly rigid (steel) to elastic (resin with specific stress characteristics). The resin core material has a stress of 0.3-3.5 MPa at 20% strain in uniaxial compression, allowing it to deform elastically during pressing to maintain surface flatness while still defining the recess shape.
Solution Approach 2:
The patent employs a flexible resin core material that can elastically deform during the pressing process. This flexible core adapts to the pressing forces and allows uniform pressure transmission to the powder, preventing surface raising while maintaining the recess geometry.
2Shape
If a highly rigid core material is used, then the recess shape is well-defined, but the pressure transmission to the surrounding powder is uneven
Solution Approach 1:
The patent changes the mechanical parameters of the core material to achieve optimal pressure transmission. The resin core material's elastic properties and specific stress range (0.3-3.5 MPa at 20% strain) enable it to deform under pressure and transmit force uniformly to the surrounding powder, ensuring consistent density throughout the green compact.
Solution Approach 2:
The resin core material acts as an intermediary between the pressing force and the powder. Its elastic nature allows it to mediate the pressure distribution, converting the applied force into uniform compression across the powder while still maintaining the recess shape definition.
3Manufacturing precision
If a resin core material is used, then pressure is evenly transmitted and surface irregularities are suppressed, but the core material must have specific mechanical properties
Solution Approach 1:
The patent establishes specific parameter ranges for the resin core material to balance performance and manufacturability. The stress of 0.3-3.5 MPa at 20% strain in uniaxial compression provides a concrete design criterion that ensures proper pressure transmission and surface flatness while simplifying material selection and quality control.
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 approach effectively suppresses the formation of raised portions on the green compact surface, allowing for precise dimensional accuracy and efficient production of titanium-based or iron-based compacts, which can be further sintered into dense sintered bodies.
Implementation Method 1
the resin core material is elastically deformed during pressing, and the pressure is properly transmitted to the raw material powder
Data Source
AI summary
A method for producing a metallic green compact 61 relates to a method for producing the green compact 61 having at least one recess 62, including a step of subjecting a raw material powder filled in a resin mold 1 to cold isostatic pressing while placing a resin core material 11 having a shape corresponding to the recess 62 at a position corresponding to the recess 62 in the resin mold 1.