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/mm 2 , a Vickers hardness of 330 HV, and a dimensional accuracy of about ± 0.1 mm.

This paper assesses the potential of thermal spraying in the context of rapid production tooling. The tooling described, which is intended for sheet metal forming, overcomes the limitations of rapid tooling techniques by leveraging the benefits of rapid prototyping and thermal spray technologies. Paper text in German.

The aim of this study is to investigate the development of thermally sprayed coatings for thixoforming dies and assess the effects of hot isostatic pressing on plasma sprayed coatings applied to TZM, stainless steel, and hot work steel substrates. As-deposited and compacted layers are analyzed with regard to their suitability for thermal, mechanical, and chemical protection. Paper includes a German-language abstract.