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公开(公告)号：US06308765B1
公开(公告)日：2001-10-30
申请号：US09185762
申请日：1998-11-04
IPC分类号： B22C904
摘要： The present invention relates to a method of making a molding tool comprising a core die and a cavity die. The method comprises (a) providing a first metal deposit comprising one of the cavity die or the core die, the first metal deposit having a die face, (b) providing a spray forming pattern on a portion of the die face of the first metal deposit,(c) spraying metal particles onto the first metal deposit and the spray forming pattern to form a second metal deposit comprising the other of the cavity die or the core die, and (d) removing the spray forming pattern from the first and second metal deposits.
摘要翻译： 本发明涉及一种制造包括芯模和模腔的模具的方法。 该方法包括（a）提供包括腔模或芯模之一的第一金属沉积物，第一金属沉积物具有模头面，（b）在第一金属的模面上的一部分上提供喷射形成图案 沉积，（c）将金属颗粒喷涂到第一金属沉积物和喷射形成图案上，以形成包括另一个模腔或芯模的第二金属沉积物，以及（d）从第一和第二金属沉积物中去除喷射形成图案 金属矿床。
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2.发明授权Method of spray forming metal deposits using a metallic spray forming pattern 有权使用金属喷雾形成图案喷射形成金属沉积物的方法
公开(公告)号：US6155330A
公开(公告)日：2000-12-05
申请号：US186031
申请日：1998-11-04
摘要： A spray forming pattern of a first metal having a melting point at a first temperature is formed. The spray forming pattern has a surface defining a cavity that has the shape of a master pattern. Steel particles having a carbon content in the range of 0.01-0.9% by weight are sprayed onto the spray forming pattern to form a deposit on the spray forming pattern. The deposit has a thickness of at least 0.5 inches and the temperature of the steel particles increases as the thickness of the steel deposit increases. The spraying conditions are controlled so that the steel particles coming into contact with the spray forming pattern results in a surface temperature of the spray forming pattern of less than about 80.degree. C. The deposit and the spray forming pattern are heated to a second temperature, which is higher than the first temperature, to melt the spray forming pattern from the deposit. The resulting deposit has the general shape of the master pattern.
摘要翻译： 形成熔点为第一温度的第一金属的喷雾形成图案。 喷射形成图案具有限定具有主图案形状的空腔的表面。 将碳含量在0.01-0.9重量％范围内的钢颗粒喷涂到喷涂成形图案上，以在喷涂成形图案上形成沉积物。 沉积物具有至少0.5英寸的厚度，并且钢颗粒的温度随着钢沉积物的厚度增加而增加。 控制喷涂条件使得与喷雾形成图案接触的钢颗粒导致喷雾形成图案的表面温度低于约80℃。将沉积物和喷雾形成图案加热至第二温度， 其高于第一温度，以从沉积物熔化喷射形成图案。 所得到的沉积物具有主图案的一般形状。
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公开(公告)号：US06179039B2
公开(公告)日：2001-01-30
申请号：US09275997
申请日：1999-03-25
申请人： Grigoriy Grinberg , Charles Chen , David Robert Collins , Jeffrey Alan Kinane , Paul Earl Pergande
发明人： Grigoriy Grinberg , Charles Chen , David Robert Collins , Jeffrey Alan Kinane , Paul Earl Pergande
IPC分类号： B22D2300
摘要： A method of reducing distortion in a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of building a thermal model of the desired tool from a solid model of the ceramic pattern and applying thermal boundary conditions to the thermal model based on known conditions. The method also includes the steps of running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value. The method further includes thermally spraying a metal material against the ceramic pattern to form the desired tool if there are no temperature deviations in the temperature distribution above the predetermined value.
摘要翻译： 减少喷射形成的快速工具中的变形的方法包括以下步骤：制造所需工具的模型并构造陶瓷图案作为模型的倒数。 该方法还包括从陶瓷图案的实体模型构建所需工具的热模型并基于已知条件将热边界条件应用于热模型的步骤。 该方法还包括运行热模型以产生所需工具的温度分布并确定温度分布中的任何温度偏差高于预定值的步骤。 该方法还包括如果不存在温度分布高于预定值的温度偏差，则将金属材料热喷涂到陶瓷图案上以形成期望的工具。
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4.发明授权公开(公告)号：US06470954B2
公开(公告)日：2002-10-29
申请号：US09875847
申请日：2001-06-06
申请人： Jeffrey Alan Kinane , David Robert Collins , Matthew John Zaluzec , Paul Earl Pergande , Grigoriy Grinberg
发明人： Jeffrey Alan Kinane , David Robert Collins , Matthew John Zaluzec , Paul Earl Pergande , Grigoriy Grinberg
IPC分类号： B22D2300
CPC分类号： B22F3/1283 , B22C9/061 , B22D23/003 , B22F3/115 , B33Y80/00
摘要： A method of spray forming a weldable metal deposit. The method comprises (a) providing a ceramic spray forming pattern, (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in deposited carbon steel having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern, (c) spraying metallic particles onto the spray forming pattern heated to the sustained temperature, and (d) allowing the sprayed metallic particles to cool to form a metal deposit. The metallic particles have a carbon content which is sufficient to result in metal particles having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern. The resulting deposit has a carbon content of less than about 0.3 weight percent.
摘要翻译： 喷射形成可焊接金属沉积物的方法。 该方法包括（a）提供陶瓷喷射形成图案，（b）将喷涂成型图案加热到足够的持续温度，以防止在沉积在其上的碳含量小于约0.3重量％的沉积碳钢中形成内部应力 加热喷雾形成图案，（c）将金属颗粒喷射到加热到持续温度的喷雾形成图案上，和（d）允许喷射的金属颗粒冷却以形成金属沉积物。 金属颗粒的碳含量足以在沉积在加热的喷雾形成图案上时产生碳含量小于约0.3重量％的金属颗粒。 所得沉积物的碳含量小于约0.3重量％。
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5.发明授权公开(公告)号：US06257309B1
公开(公告)日：2001-07-10
申请号：US09186032
申请日：1998-11-04
申请人： Jeffrey Alan Kinane , David Robert Collins , Matthew John Zaluzec , Paul Earl Pergande , Grigoriy Grinberg
发明人： Jeffrey Alan Kinane , David Robert Collins , Matthew John Zaluzec , Paul Earl Pergande , Grigoriy Grinberg
IPC分类号： B22D2300
CPC分类号： B22F3/1283 , B22C9/061 , B22D23/003 , B22F3/115 , B33Y80/00
摘要： A method of spray forming a weldable metal deposit. The method comprises (a) providing a ceramic spray forming pattern, (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in deposited carbon steel having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern, (c) spraying metallic particles onto the spray forming pattern heated to the sustained temperature, and (d) allowing the sprayed metallic particles to cool to form a metal deposit. The metallic particles have a carbon content which is sufficient to result in metal particles having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern. The resulting deposit has a carbon content of less than about 0.3 weight percent.
摘要翻译： 喷射形成可焊接金属沉积物的方法。 该方法包括（a）提供陶瓷喷射形成图案，（b）将喷涂成型图案加热到足够的持续温度，以防止在沉积在其上的碳含量小于约0.3重量％的沉积碳钢中形成内应力 加热喷雾形成图案，（c）将金属颗粒喷射到加热到持续温度的喷雾形成图案上，和（d）允许喷射的金属颗粒冷却以形成金属沉积物。 金属颗粒的碳含量足以在沉积在加热的喷雾形成图案上时产生碳含量小于约0.3重量％的金属颗粒。 所得沉积物的碳含量小于约0.3重量％。
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公开(公告)号：US5947179A
公开(公告)日：1999-09-07
申请号：US124779
申请日：1998-07-30
CPC分类号： B22D23/003 , C23C4/02 , C23C4/18
摘要： Method of sprayforming bulk metal deposits that replicate a master pattern: (i) casting and solidifying ceramic about a master pattern to form a spraying pattern; (ii) after removing the spraying pattern from the master pattern, heating the ceramic spraying pattern to a sustained temperature to effect an isothermal diffusion dependent microstructural transformation; (iii) while in such heated condition, thermally spraying allotropic metal particles onto the heated spraying pattern to form a deposit having a bulk thickness, the particles impacting the spraying pattern, or previously deposited particles, at a temperature above the sustained temperature of the spraying pattern; (iv) holding the deposit on the heated spraying pattern sufficiently long enough to allow the particles of the deposit to undergo a diffusion reaction that relieves internal stresses due to deposition and solidification; and (v) thereafter gradually cooling the deposit to room temperature to produce a unitary article with essentially no distortion relative to the spraying pattern.
摘要翻译： 复制主图案的散射金属沉积物的喷射成形方法：（i）围绕主图案铸造和固化陶瓷以形成喷涂图案; （ii）在从主图案中除去喷涂图案之后，将陶瓷喷涂图案加热至持续温度，以实现等温扩散依赖性显微结构转化; （iii）在这种加热条件下，将同素异形金属颗粒热喷涂到加热的喷涂图案上以形成具有大体积厚度的沉积物，在高于喷涂持续温度的温度下冲击喷涂图案或预先沉积的颗粒的颗粒 模式; （iv）将加热的喷涂图案上的沉积物保持足够长的时间以使沉积物的颗粒经受扩散反应，从而减轻沉积和固化所引起的内部应力; 然后（v）逐渐将沉积物冷却至室温以产生相对于喷涂图案基本上没有变形的整体制品。
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7.发明授权
公开(公告)号：US6060117A
公开(公告)日：2000-05-09
申请号：US144618
申请日：1998-08-31
CPC分类号： C23C4/01
摘要： Method of making a mask assembly by providing a heat resistance mask substrate having an exposed surface with a surface smoothness less than 2000 micro inches, uniformly spraying a thermoset epoxy organic coating onto such exposed surface in one or more layers to provide a coating having (e.g., a thickness equal to or less than about 0.005 inches), a smoothness characterized by an average profilometer reading (Ra) of no greater than 1.5 micrometers, said coating being devoid of pores that exceed about 0003 inch in size, and flame polishing all or a portion of such coating to effect a surface finish of about 1.0 micrometers. A mask assembly which is useful in masking areas from thermal spray particles, comprising a heat resistance substrate presenting an exposed grit blasted surface having a smoothness of less than 2000, and a thin thermoset epoxy coating bonded to said exposed surface and having a surface smoothness characterized by an average profilometer reading (Ra) no greater than 1.5.
摘要翻译： 通过提供具有表面平滑度小于2000微英寸的暴露表面的耐热掩模基板来制造掩模组件的方法，在一层或多层中均匀地将热固性环氧有机涂层喷涂到这样暴露的表面上以提供涂层（例如 ，等于或小于约0.005英寸的厚度），其特征在于平均轮廓仪读数（Ra）不大于1.5微米的平滑度，所述涂层没有超过大约0003英寸的孔，并且火焰抛光全部或 这种涂层的一部分实现约1.0微米的表面光洁度。 一种掩模组件，其可用于掩蔽来自热喷雾颗粒的区域，包括具有平滑度小于2000的暴露的喷砂表面的耐热基材和结合到所述暴露表面的具有表面平滑度的薄的热固性环氧涂料 通过平均轮廓仪读数（Ra）不大于1.5。
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公开(公告)号：US5900282A
公开(公告)日：1999-05-04
申请号：US9511
申请日：1998-01-20
申请人： David Robert Collins , Paul Earl Pergande , Matthew John Zaluzec , Armando Mateo Joaquin , Jeffrey Alan Kinane
发明人： David Robert Collins , Paul Earl Pergande , Matthew John Zaluzec , Armando Mateo Joaquin , Jeffrey Alan Kinane
CPC分类号： B05D1/10
摘要： A method of depositing a dielectric coating, comprising the steps of forming an unroughened or roughened, as-cast or wrought substrate surface to receive the coatings; and flame spraying a single premixed thermoplastic epoxy/hardener powder onto the surface, the resultant in-flight heated powder being chemically activated to impact the surface and form a chemically adhering coating, the coating being cured in-situ to be dielectric and thermally conductive.
摘要翻译： 一种沉积电介质涂层的方法，包括以下步骤：形成未增韧或粗糙的铸态或锻造的基底表面以接纳涂层; 并且将单一预混合热塑性环氧树脂/硬化剂粉末火焰喷涂到表面上，所得到的飞行中加热的粉末被化学活化以冲击表面并形成化学粘附的涂层，该涂层原位固化为介电和导热的。
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公开(公告)号：US06276431B1
公开(公告)日：2001-08-21
申请号：US09515733
申请日：2000-02-29
IPC分类号： B22D2300
CPC分类号： B22D11/0405 , B33Y80/00
摘要： A method of making a spray formed rapid tool includes the steps of making a model of a desired tool and directly constructing a sand pattern as the inverse of the model. The method also includes the steps of thermally spraying metal material against the sand pattern to form the desired tool.
摘要翻译： 制造喷雾形成的快速工具的方法包括以下步骤：制造所需工具的模型并直接构造沙模，作为模型的倒数。 该方法还包括以下步骤：将金属材料热喷涂到砂图案上以形成期望的工具。
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公开(公告)号：US06331680B1
公开(公告)日：2001-12-18
申请号：US08689164
申请日：1996-08-07
申请人： David John Klassen , Morgan Merritt Whitney, Jr. , Thomas Randall Peterman , Paul Earl Pergande , David Robert Collins
发明人： David John Klassen , Morgan Merritt Whitney, Jr. , Thomas Randall Peterman , Paul Earl Pergande , David Robert Collins
IPC分类号： H01R1204
CPC分类号： C23C4/02 , C23C4/01 , H05K3/143 , H05K3/467 , Y10S428/901
摘要： A multilayer, monolithic electrical interconnection device includes a substrate and a plurality of overlaying, alternating conducting and insulating layers deposited atop the substrate and one another. The layers are deposited by thermal spraying of respective insulating or conducting material through defined apertures in respective spray masks. Interlayer electrical connections are intrinsically formed by direct metallurgical bonding between the conducting material of an overlaying layer and the conducting material of a previously sprayed layer.
摘要翻译： 多层单片电互连器件包括衬底和沉积在衬底上彼此之上的多个重叠的交替导电绝缘层。 通过相应的绝缘或导电材料的热喷涂通过相应喷雾掩模中的限定的孔沉积这些层。 层间电连接通过在覆盖层的导电材料和预先喷涂层的导电材料之间的直接冶金结合本质上形成。
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