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Mold manufacture with plasma spraying

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Abstract

A process has been developed to produce molds or tooling using a steel or chrome- plated steel model. The investigation examined the effect of coating and model materials, model temperature and spray angle on the coating separation from the model surface, coating delamination, and surface quality. A polished model disk was heated and then plasma sprayed with iron, nickel, Ni- Al, or Ni- Cr- B- Si. It was found that the minimum temperature to facilitate entire coating removal was lower for steel models and varied be tween 200 and 450 °C depending on the material. However, at higher temperatures the higher bond strength produced by oxidation on the steel resulted in significant coating pullout. A chrome- plated model, heated to 600 to 700 °C, is required to produce a defect- free coating. The effect of substrate angle on open porosity is most critical for the Ni- Cr- B- Si alloy and least important for Ni- Al coatings. The sur face roughness of the plasma- sprayed molds is comparable to the corresponding models, permitting good surface detail reproducibility. Several molds and tools were produced for use in the glass, rubber, and plastics industries.

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Author notes

  1. K. A. Grossand

    Present address: Department of Materials Science, University of Technology, Sydney, P.O. Box 123, 2007, Broadway, NSW, Australia

Authors and Affiliations

  1. Aerosol Physics Laboratory, Department of Physics, Tampere University of Technology, Box 692, FIN 33101, Tampere, Finland

    K. A. Grossand

  2. TERPA, Daugavpils Street 58, LV-1003, Riga, Latvia

    A. Kovalevskis

Authors
  1. K. A. Grossand
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  2. A. Kovalevskis
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Grossand, K.A., Kovalevskis, A. Mold manufacture with plasma spraying. JTST 5, 469–475 (1996). https://doi.org/10.1007/BF02645278

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