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Spray metal tooling

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rapid prototyping spray metal tooling & 3d keltool

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Spray metal tooling

  1. 1. SPRAY METAL TOOLING • This process applies a zinc/aluminum alloy with an arc spray to a pattern or model. The pattern or model can be a stereolithography part or a model made from wood or metal. • 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.
  2. 2. Spray Metal steps • Providing a master pattern • Melting the metal at the gun • Spraying the liquid metal onto the prepared substrate by means of compressed air • Molten particles are projected onto the cleaned substrate.
  3. 3. 3D Keltool • The word "Keltool" refers to the proprietary powder metal sintering process, which involves penetrating a fused metal part with copper alloy. • This process is based on metal sintering process. • This process converts RP master patterns into production tool inserts with very good definition and surface finish. • 3D Keltool inserts are built of Sterlite of A6 composite tool steel. The material properties allow the inserts using this process to withstand more than 10lakh mould cycles. • The Keltool part (mold) is limited to 6 inches in all directions. Therefore, any parts produced would be limited to about 4 inches in all directions.
  4. 4. 3D Keltool Process • Fabricating the master patterns of core and cavity. • Producing RTV silicon rubber mould from the pattern. • Filling the silicon rubber mould with metal mixtures to produce green parts duplicating the masters. • Firing the green parts in a furnace to remove the plastic binder and sintering the metal particles together. • Infiltrating the sintered parts (70% dense inserts) with copper in the second furnace cycle to fill the 30% void space. • Finishing the core and cavity.
  5. 5. THANK YOU

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