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Injection molding
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Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 220-225, May 4–6, 2022,
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In metal die casting as well as plastic injection molding, controlling the heat balance during the injection and solidification process can lead to fewer defects and a better component quality. An appropriate cooling channel design for the mold can help to control the solidification to a certain extent. But the heat control achievable by cooling channels is limited due to the high effective thermal mass, and therefore near-cavity energy input is of interest. In this paper, a simulation study is performed demonstrating the use of plasma sprayed ceramic coating as a heating coating at the cavity of the mold. The goal is to apply heat faster and locally focused during the solidification process in metal die casting as well as before the injection phase in plastic injection molding. The heat generation of these ceramic coatings is modelled using experimentally measured values and the effects of this approach on defects such as distortion and hot tearing is discussed.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 215-220, May 21–23, 2014,
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This work evaluates an in-mold spraying process for the production of injection molded plastic parts with integrated Cu pathways. Prior to injection, Cu is cold sprayed on mold insert surfaces, forming a metal layer that is subsequently transferred to the plastic part. The success of the process hinges on the bond strength of the Cu to the mold, which depends on surface conditions, mold material, and spray parameters. In this study, Cu powder is cold sprayed on carbon tool steel coupons prepared by grit blasting using different grit sizes. The coupons were sprayed at longer stand-off distances using lower gas flow rates than usual to reduce particle impact velocity and thus bonding strength. Coating cross-sections were examined and surface roughness, bond strength, and residual stress were measured. The results show that bond strength varies almost linearly with root-mean-square surface roughness, R∆q, and that reducing line distance or scanning step size can improve the transferability of the Cu layer.
Proceedings Papers
ITSC1999, Thermal Spray 1999: Proceedings from the United Thermal Spray Conference, 15-19, March 17–19, 1999,
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Atmospheric Rheo-Spraying (ARS) using the HVOF process enables injection-molded structures and thick-film coatings from steels and from high-temperature Ni-based alloys with layer thicknesses down to the centimeter. The ARS process control is based on the thermal spraying of particles in the solid state at a maximum average speed of more than 600 m/s. The coating consolidation to porosity values below 1% occurs through the particle impact with high kinetic energy. Because of the low particle oxidation, the mechanical properties of the heat-treated injection-molded structures are comparable to those of forged alloys. In this paper, ARS injection molding is successfully implemented in combination with an innovative manufacturing technique in rocket engine technology to produce a model composite combustion chamber with a thermally sprayed internal pressure jacket. Paper includes a German-language abstract.
Proceedings Papers
ITSC1999, Thermal Spray 1999: Proceedings from the United Thermal Spray Conference, 25-26, March 17–19, 1999,
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Only one material is used for thermally sprayed layers in medical technology: hydroxyapatite. This is considered to be stable for long-term and is being used more and more in endoprosthetics. This paper presents and examines a previously unused material, calcium carbonate, for its suitability for injection-molding processing. The first in-vitro results round off the very positive results so far. Paper includes a German-language abstract.
Proceedings Papers
ITSC1998, Thermal Spray 1998: Proceedings from the International Thermal Spray Conference, 1223-1228, May 25–29, 1998,
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The manufacture of tooling using the electric arc spray process to spray steel directly onto a master pattern offers substantial reductions in the lead times required to make complex tooling for polymer injection moulding and other applications. The process of spray forming is fast, efficient, and low cost, and has been shown to be dimensionally accurate with proper control over the residual stresses that develop during spraying. Poor dimensional control because of high internal stresses in thick arc sprayed steel coatings is well known, but these problems can be avoided by the use of correct spraying conditions. This paper describes the steps of the spray forming process used to make tooling for polymer injection moulding. The spray forming route competed directly with a traditional method for toolmaking and considerably reduced the lead time from order to completion. The tooling produced by spray forming has been operating commercially in production in the U.S. and has to date produced in the region of half a million parts without appreciable wear. The incorporation of contoured cooling channels during spraying has enabled plastic injection moulding cycle times to be decreased by 15%.