A COATED MOULD AND PROCESS FOR PRODUCING THE MOULD

Abstract: An improved mould (10) for use in the production of glass containers such as bottles, jars and the like, the mould (10) includes at least one mould surface defining a cavity (14) which is adapted to receive molten glass, and in which the mould (10) surface is provided with a coating (16) over substantially the whole of the surface, the coating comprising an alloy. The mould (10) is made of segments or partial sections - preferably of two half bodies (12 12a) - with a hollow space (14) in each segment or half body (12, 12a). In the hollow space (14) the coating (16) - comprising an alloy of cobalt and nickel - is metallurgically bonded to the mould (10). The process for producing the mould (10) includes that the coating (16) is fused to the mould (10) by using a two-stage process in which a powder containing the constituent elements of the alloy coating (16) is initially provided, the powder comprises a specially formulated alloy powder in which each particle essentially comprises the elements of the final alloy coating (16) or the coating (16) comprises one or more different powders which maybe mixed together.

Description: A COATED MOULD AND PROCESS FOR PRODUCING THE MOULD AN IMPROVED MOULD AND PROCESS FOR PRODUCING THE MOULD This invention relates to an improved mould for use in the production of glass containers such as bottles, jars or the like. And the invention relates to a process for producing such a mould. Glass articles can be produced simply and quickly on an industrial scale by blowing air into a gob of molten glass, often provided on the end of a tube down which air can pass. To provide accurate control of the shape of the finished article it is blown whilst placed in a mould. Generally molten glass is produced in a first part of a furnace and then allowed to run into a second part of the furnace known as the working chamber where it is allowed to cool slightly. The cooled glass is then passed along a feeder channel whereafter it is formed into a gob which is passed into a rough mould. The gobs are then pressed or blown by compressed air into an intermediate shape defined by the inner surface of the mould. This is roughly the same shape as the finished container but smaller and thicker and is known as a parison. This is then pressed or blown in a finishing mould to produce the final desired shape. Because of the very high temperatures to which the moulds are subjected as the heated glass is introduced, the high temperature gradients throughout the moulds and the rapid temperature cycling, it is common to use cast iron as the mould material, although other more expensive alloys may also be used in some cases. Cast iron is used because it is cheap and easily machined and has good heat conducting properties and can withstand relatively high temperatures. Although it has these advantages, cast iron is limited in some respects. Firstly, at high temperatures cast iron undergoes a metallurgical change and is mechanically and thermally degraded. Secondly, when subjected to rapid thermal cycling cast iron will eventually crack. The cracking tends to develop initially on the edges of cavities but later will occur in the main body of the cavity. Cracking results in surface imperfections in the finished glass article, which is both cosmetically unacceptable and in the case of articles such as containers introduces unacceptable structural weaknesses which are especially significant with thin walled containers. Other limitations on the life of a mould are its ability to resist wear and to maintain its dimensions and surface finish over time. Wear is often caused by the need to clean the mould at regular intervals, perhaps by sand blasting. To ensure crisp, clean castings and to maintain high uninterrupted production rates the cavity surfaces are sprayed or "swabbed" with release agents. This raises safety and health issues and can also result in a build up of release agents on the surface of the mould cavity. This must be periodically removed when the build up becomes too great by sandblasting. Eventually, wear of the cavity surface, particularly at the edges together with cracking requires the mould to be taken out of production and either repaired or scrapped. Conventionally, cast iron can be repaired using a manual oxyacetylene powder spray fuse process. The repair material is a nickel based fusible powder with excellent wetting and fusion properties and with a hardness similar to cast iron so that the mould can be accurately machined after being "patched" without the machinery tools "digging in" to the surface. An object of the present invention is to provide a mould and a coating for a mould which has improved thermal properties to resist cracking and improved wear properties so as to provide an increased useful life; improved release properties which reduce frequency of swabbing; and superior surface finish of the cavity to improve the surface quality and engraving details of the glass container product. The problems are solved by the teaching according to the independent claims. Particular developments are given in the dependent claims. Within the frame of the invention are all combinations of at least two of the descriptive elements and technical features disclosed in the claims and/or in the description. In accordance with a first aspect of the invention, the invention provides a mould for use in producing glass articles, the mould including at least one mould surface defining a cavity which is adapted to receive molten glass, and in which the mould surface is provided with a coating over substantially the whole of the surface, the coating comprising an alloy. The mould consists of segments preferably of two partial sections or half bodies and each half body has a hollow space or a mould-in area which completes the hollow space of the other half body to form a mould cavity. Providing an alloy coating over the whole cavity surface has been found to enable the life of the mould to be increased considerably, compared with an uncoated mould. By the whole cavity surface, we mean substantially the whole area of the surface which, in use, contacts the hot glass. Coatings in accordance with the invention have also been found, in some cases, to produce glass containers with improved surface finish and engraved details. Coatings produced in accordance with the invention have also required less swabbing than uncoated moulds, and in many cases the gains have been considerable. Preferably, the coating has a Rockwell C hardness in the range HRC35 to HRC50. This is significantly harder than cast iron, and so increases the wear resistance of the mould. The alloy coating may comprise an alloy of cobalt and nickel. Providing cobalt enhances the high temperature properties of the alloy as well as offering excellent coating performance during rapid temperature cycling between temperatures of 300°C and 800°C. Cobalt may be substituted — whole or partially -- by chromium. The provision of nickel in the alloy ensures that the alloy fuses to the mould body at a temperature of less than 1090°C in vacuum and may also enhance the release properties of the mould. The alloy may also include silicon and boron. The selection of differing amounts of these elements enhances the fusion properties of the alloy and influences the hardness of the coating. The alloy coating may also include tungsten, chromium, carbon, iron and other elements. The selection of differing amounts of one or more of these elements enables the hardness of the alloy to be maintained within the stated range whilst permitting variations in the content of nickel and cobalt. This allows the performance of the alloy to be accurately matched with requirements of the glass container product. In a most preferred arrangement, the coating is fused ~ metallurgically bonded — to the mould. A metallurgical bond ensures that the coating will not detach from the substrate and also that good heat transfer is provided from the glass through the coating into the mould. The coating may be fused to the mould by using a two-stage process in which a powder containing the constituent elements of the alloy coating is initially provided. The powder may comprise a specially formulated alloy powder in which each particle essentially comprises the elements of the final alloy coating. Alternatively, it may comprise one or more different powders which may be mixed together. For example, one powder may comprise a nickel alloy whilst the other comprises a cobalt alloy. This creates the flexibility for powder blends based on commercially available grades. Modifying the proportion of nickel and cobalt allows the fusion temperatures to be tailored to match the properties and characteristics of the base material. In a first stage of the process, the powder may be applied to the cavity surface of the mould by thermal spraying. This may either be using oxyacteylene spraying or high velocity oxy fuel spraying. Of course, the skilled man will readily appreciate that other techniques are suitable, such as laser powder coating, plasma transferred arc or other welding techniques. In a second stage of the process, the sprayed mould may be raised to an elevated temperature under vacuum in a furnace. The temperature should be raised to such a point that the coating fuses to the mould to form a metallurgical bond and to create a uniform, densified fine coating with no interconnected porosity. Of course, the coating could be fused by alternate techniques such as flame, induction, arc or laser heating processes. Vacuum furnace fusion is the favoured method due to its degree of control of temperature at critical times in the process, resulting in a coating which provides excellent wear and thermal shock protection, and ensures efficient heat transfer from the mould body. The coating of the mould may be an alloy comprising between 40% and 75% nickel and between 7% and 3 1 % cobalt by weight. Preferably, it comprises between 41 % and 54% nickel and between 20% and 31 % cobalt, especially suitable for original coatings, and between 60% and 75% nickel and between 7% and 20% cobalt for repair material. In accordance with a second aspect of the invention, the invention provides a coating for a mould for use in producing a blown glass container, the mould coating being an alloy comprising between 40% and 75% nickel and between 7% and 31 % cobalt (by weight), the balance of the alloy comprising other elements and/or unavoidable impurities. For an original coating, the alloy preferably comprises between 40% and 60%) nickel and between 15% and 35% cobalt. For a repair coating it preferably comprises between 60% and 75% nickel and between 7% and 20% cobalt. It should be noted that repair material can be successfully applied to base metal as a coating. For original coating, alloys preferably comprise between 41 % and 54% nickel and between 20% and 3 1% cobalt. Alloys with these narrower ranges of constituents have been found especially beneficial as original coatings. For repair coatings, alloys preferably comprise between 60% and 71 % nickel and between 10% and 18% cobalt. Alloys with these narrower ranges of constituents have been found especially beneficial as repair coatings. By providing a coating containing both nickel and cobalt in significant proportions, a considerable increase in the life of the mould can be achieved over a conventional uncoated or repaired mould. The coating offers excellent performance in temperatures between 300 ° C and 800 " C during rapid cycling of temperature. It also provides the benefits of reduced swabbing and improved surface quality of the glass container product. The coating may also include the elements tungsten, molybdenum, chromium, carbon iron, boron and silicon. Tungsten may be substituted, in whole or partially, by molybdenum. Cobalt may be substituted, in whole or partially, by chromium. Other elements, manganese, copper and/or phosphorus may also be added. It may have a Rockwell C hardness of substantially between 35 HRC and 50 HRC. Preferably, the coating initially comprises a powder. The powder may be specially formulated and manufactured or may be prepared by thoroughly mixing two or more commonly available powders. For example, a suitable powder may be produced by mixing a cobalt powder available under the name EMP 1 170 available from Castolin with a nickel powder available under the name PE 8040 from Castolin. Other cobalt powders are available under the name CO 451 from Osprey Metals Ltd., Red Jacket Works, Midlands Road, Neath, West Glamorgan, SAl l INS, England, nickel powders under the name MHA#40 available from Mitsubishi Materials Corporation. The ratio of nickel to cobalt in the coating may be selected such that the coating will fuse to a substrate at a temperature of between 1010°C and 1090°C. This powder may therefore be initially thermally sprayed onto the base mould (for example using an oxyacetylene or high velocity oxy fuel spray gun) and then heated to a temperature of 1045°C to 1085°C, preferably 1050°C to 1080°C, — depending on vacuum — to fuse it to the mould. This produces a metallurgical bond that ensures the coating will not detach from the substrate and improves heat transfer from coating to mould. An advantage of the use of a nickel/cobalt coating over, for example, a nickel coating is that the cobalt increases the high temperature properties of the coating. A mainly cobalt coating would, however, have a fusion point above 1 100°C which is too high for use with cast iron moulds. The presence of a nickel - based alloy lowers fusion temperature. For initial coating, and optionally repair, the balance of the coating may comprise substantially 5% to 20%, but preferably 9% to 1 7%), chromium; 0. 1 % to 1 %, but preferably 0.2% to 0.8%, carbon; 2.5% to 6.5%, but preferably 3.0% to 4.5%, tungsten; 1 .5% to 4%, but preferably 3.0 to 3.3 %, iron; 1 to 5.5%, but preferably 2.5%o to 3.7%, silicon and 0.5% to 3.5%, but preferably 1 .2% to 2.1 %, boron. It may also include manganese, copper and phosphorus. The finished coating after final machining — where required — may have a thickness of between 0.2mm and 1 .5mm although 0.5mm to 0.8mm is preferred. Thus, a 0.5mm coating provides excellent levels of thermal protection and good heat transfer capabilities. In accordance with a third aspect of the invention, the invention comprises a mould for use in producing blown glass articles, the mould having an inner coating in accordance with the second aspect of the invention. The coating may be fused to the mould, which in a most advantageous arrangement comprises a cast iron body. The body may be in two or more pieces which when fitted together define a cavity into which a glass gob can be blown or pressed. The coating may be restricted to those mould surfaces which are in contact with glass being processed. Coating may also be applied to seams, edges, interlocks and other areas of the mould and glass processing system to protect against thermal shock, wear, mechanical and other damage. More advantages, characteristics and details of the invention and inherent to the same may be derived from the following description of only one illustrative and preferred embodiment along with the accompanying drawings, in which Fig. 1 shows a rough mould in accordance with the invention for use in the production of blown glass articles. The mould 10 illustrated in Fig. 1 comprises two half bodies 12, 12 a which when placed together define a cavity into which a glass article — in the mould shown a bottle -- can be blown. Each mould half body 12, 12 a is moulded and machined in cast iron. The inside of each half body 12, 12 a is scooped, contains a cavity or a hollow space 14 and is given a smooth surface which corresponds to the shape of one half of the finished article to be produced in the mould 10. The outer form of each mould body 12, 12 a has an outer surface 1 8 which is irregular in sectional view and which is chosen to co-operate with a holder -- not shown -- which presses the bodies 12, 12 a together during moulding as the glass is introduced. The smooth inner surface of each cavity 14 of the mould halfs 12, 12 a is covered with an alloy coating 16. The coating 16 comprises approximately 49%o nickel, 26%) cobalt, 13.5% chromium, 0.48%) carbon, 3.5% tungsten, 2.3%) iron, 3%> silicon and 1.1% boron by weight. To apply the coating 16, two different alloys in powdered form are initially thoroughly mixed. One powder is substantially a cobalt based alloy -- for example EMP 1 170 from Castolin. — , the other a nickel alloy such as PE 8040 from Castolin. After mixing together, the powdered alloy is applied to the face of the mould 10 using a thermal lance or an oxyacetylene spray gun. The roughly applied coating 16 is then heated in a furnace to its fusion point of around 1060 ° C, whereafter it is left to cool. The coating 16 is then machined to form the finished mould. Operational experience has shown that coated moulds 10 enjoy consderably increased life, require reduced swabbing rates and produce a glass container product with significantly enhanced surface finish. The contents of nickel and cobalt together in the coating ensure compatibility with both high termperature operation and base material requirements. The addition of cobalt enables the coating to withstand high temperatures, and the remaining nickel ensures that the alloy can be fused to the mould 10 at a sufficiently low temperature to preserve the cast irons properties. The inclusion of hardening elements such as carbon, chromium, silicon, boron and tungsten protects the cavity surface and in particular the edges of the cavity 14 from wear during operation and cleaning. In the event of wear of the mould and the coating, a repair may be made by fusing a patch of new coating alloy over the damaged area. In this case, a batch of alloy may be used which has a lower fusion temperature than the original (damaged) coating. This ensures that the repair coating can be heated to the fusion point without overheating the original coating. Thus, a repair material having a fusion temperature of between, say, 1030°C and 1060°C is preferred. An obvious advantage of this approach is that it obviates the need to remove the original damaged coating. A suitable combination of original and repair material can be provided with an original coating having between 40%) and 60%> nickel, 15%> and 35%) cobalt, and a repair material having between 60%> and 70%) nickel and 7% to 20% cobalt. The invention leads to improved release properties with reduced swabbing, to an improved surface finishing and an extended mould life.

Claims: CLAIMS 1. An improved mould (10) for use in the production of glass containers such as bottles, jars and the like, the mould including at least one mould surface defining a cavity (14) which is adapted to receive molten glass, and in which the mould surface is provided with a coating (16) over substantially the whole of the surface, the coating comprising an alloy. 2. Mould according to claim 1 which consists of segments or partial sections with mould-in areas, which together form a mould cavity, preferably of two half bodies ( 12, 12 a ) with a hollow space (14) in each segment or half body. 3. Mould according to claim 1 or 2, wherein the coating (16) is metallurgically bonded to the mould (10). 4. Mould according to one of the claims 1 to 3, wherein the coating (16) comprises an alloy of cobalt and/or nickel. 5. Mould according to claim 4, wherein the alloy includes silicon and/or boron. 6. Mould according to claim 4 or 5, wherein the alloy coating ( 16) includes tungsten, chromium, carbon, iron and/or other elements. 7. Mould according to one of the claims 1 to 6, wherein the coating (16) has a Rockwell C hardness in the range HRC35 to HRC50. 8. Mould according to one of the claims 1 to 7, wherein the coating ( 16) has a fusion range of 1040°C to 1090°C. 9. Mould according to one of the claims 1 to 8, wherein the finished coating (16) has a thickness of between 0.2 mm and 1.5 mm, preferably 0.3 mm to 0.8 mm. 10. Mould according to one of the claims 1 to 9, wherein the alloy coating (16) for the mould ( 10) for use in producing a blown glass article, comprises an alloy weight of between 40%) and 75% nickel and between 7% and 3 1 % cobalt, the balance of the alloy comprising preferably other elements and/or unavoidable impurities. 1 1. Mould according to claims 10, wherein an original coating comprises 15%> to 35%> cobalt and 40%> to 60% nickel by weight, preferably 20% to 31% cobalt and 41 % to 54% nickel. 12. Mould according to claim 10 or 1 1 , wherein for use as a repairing coating the coating comprises between 60% and 75% nickel and 7%> to 20%) cobalt by weight. 13. Mould according to at least one of the claims 1 to 12, wherein the coating (16) comprises substantially 5%> to 20%) chromium by weight, 0.1 to 1 % carbon, 2.5%o to 6.5% tungsten, 1.5% to 4%o iron, 1 .0% to 5.5% silicon and 0.5% to 3.5% boron. 14. Mould according to claim 13, wherein the coating ( 16) comprises by weight 9%> to 17% chromium, 0.2% to 0.8% carbon, 3.0%) to 4.5% tungsten, 3.0% to 3.3% iron, 2.0% to 4.5%, preferably 2.5% to 3.1%, silicon and 1 .2% to 2.5%, preferably 1.2% to 2.1 %, boron. 15. Mould according to claim 13 or 14, wherein the coating (16) includes manganese and/or copper. 16. Mould according to one of the claims 13 to 15, wherein the coating (16) includes phosphorus. 17. Mould according to at least one of the claims 1 to 16, wherein the cavity surface of the mould (10) is coated. 18. Mould according to at least one of the claims 1 to 17, wherein the cavity surface and areas of the mould with no glass contact, e.g. mould hangers and interlocks, are coated. 19. Process for producing a mould according to one of the foregoing claims, wherein the coating is fused to the mould by using a two- stage process in which a powder containing the constituent elements of the alloy coating is initially provided, the powder comprises a specially formulated alloy powder in which each particle essentially comprises the elements of the final alloy coating or the coating comprises one or more different powders which may be mixed together. 20. Process according to claim 19, wherein one powder comprises a nickel alloy whilst the other powder comprises a cobalt alloy. 21 . Process according to claim 19 or 20, wherein in a first stage the powder is applied to the cavity surface of the mould by thermal spraying, preferably oxyactecylene spraying or high velocity oxy fuel spraying. 22. Process according to claim 21 , wherein the powder is applied to the cavity surface and areas of the mould with no glass contact, e.g. mould hangers and interlocks. 23. Process according to one of the claims 19 to 22, wherein the sprayed mould is raised to an elevated temperature under vacuum in a furnace or alternative fusion purposes. 24. Process according to claim 23, wherein the mould is heated to a temperature of 1045°C to 1085°C, preferably 1050°C to 1080°C.

Inventors: SUTHERLAND NEIL, SUTHERLAND, NEIL
Applicants: CASTOLIN EUTECTIC INTERNAT S A, SUTHERLAND NEIL, CASTOLIN EUTECTIC INTERNATIONAL S.A., SUTHERLAND, NEIL
Application year: 2000
Main classification: C03B40
IPC codes: C03B9, C03B40, C23C4