Patent ID: 6155330
Filing Date: 2000-12-05
Classification: B22C,B22D,B33Y,C23C

Abstract:
A method of spray forming a metal deposit that replicates a master pattern, said method comprising the steps of:(a) providing the master pattern;(b) forming a spray forming pattern of a first metal having a melting point at a first temperature, said spray forming pattern having a surface defining a cavity within the spray forming pattern, said cavity having the shape of the master pattern;(c) spraying steel particles having a carbon content in the range of 0.01-0.9% by weight onto said spray forming pattern to form a steel deposit on said spray forming pattern, said deposit having a thickness of at least 0.5 inches, the temperature of the steel particles increasing as the thickness of said steel deposit increases;(d) controlling said spraying step (c) so that the steel particles coming into contact with said spray forming pattern result in a surface temperature of said spray forming pattern of less than about 80.degree. C.; and(e) heating said deposit and said spray forming pattern to a second temperature, higher than said first temperature, to melt said spray forming pattern from said deposit, said deposit having the general shape of the master pattern.