Arc spraying metal onto a master pattern is an emerging method for making molds and dies. The process, called arc spray metal tooling, involves several steps, which are shown in this paper. Three sheet metal forming dies of varying complexity were made to demonstrate and assess the process. Press tests were performed at a mold and die making facility. Arc-sprayed metal shells produced from carbon steel wire were found to have a tensile strength of approximately 23 kg/mm2, a Vickers hardness of 330 HV, and a dimensional accuracy of about ± 0.1 mm.

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