Ford Motor Company Limited

Ford Global Technolgoies, LLC

Other

Allen Roche

Richard L Allor

Samir Samir

David Robert Collins

Chijoke Mgbokwere

Mark Thomas Lusk

John Michael Nicholson

Joseph A Szuba

Grigoriy Grinberg

Richard Michael Jordan

Sankaran Subramaniam

Patrick Grant

David Warren Worthey

Piers Newbery

Jonathan Betts

A method for generating a variable flow of melted material is disclosed. The method includes providing first and second members having a potential energy difference between them. One or more members is extended at a first average extension rate for a first period while producing an electrical arc. One or more members is extended at a second average extension rate for a second period while producing an electrical arc. One or more members is extended at a third average extension rate for a third period while producing an electrical arc. A transport medium is flowed across one or more members during one or more of the extending steps.

Method for producing a variable flow of melted material and articles therefrom

A method and arrangement for implementing post-heat treatment after spray forming is ended to achieve stress control in the manufacture of a spray formed metallic tool involves providing a spray-formed metallic tool by applying a spray-forming material on a mold substrate and causing substantially homogenous metallic phase transformations of the spray forming material within the spray-formed metallic tool to a substantially homogenous distribution of commingled metallic phases consisting, for example, of predetermined proportions of at least a bainite phase and a martinsite phase.

Method and arrangement implementing heat treatment after the execution of sprayform techniques

The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.

Spray formed articles made of boron steel

Method and apparatus for controlling stresses in a spray form process makes use of one dimensional modeling in which characteristics of a geometrical point are quantified by iterative detection, such as taking a surface temperature reading using a pyrometer. This temperature information is used in a one dimensional simulation to predict characteristics for a column from the point down through a spray-formed article to an interface with a substrate. The modeling technique can used with a plurality of geometrical points to model the whole article, and the one dimensional simulation can be integrated with robotic spray-forming controls to minimize residual stress in the spray-formed article.

Method and arrangement for controlling stresses based on one-dimensional modeling in sprayform techniques

Method and apparatus for controlling a spray-forming process incorporating time, temperature, and transformation dependent stress relief techniques involves the manipulation of both temperature and time for strategic phase changes that result in a specific and planned volumetric increase. This manipulation is made based on controlling ongoing spray parameters to spray-form an article having a mixed-phase and interspersed makeup of metallic phases that minimizes residual stress in the article.

Method and arrangement for affecting time, temperature and transformation dependent stress relief in sprayform techniques

A method for implementing post-heat treatment during spray forming to achieve stress control in the manufacture of a spray formed metallic tool involves applying a metallic spray-forming material onto a mold substrate and causing substantially homogenous metallic phase transformations from the austenite phase, for example, via manipulation of either or both of the substrate temperature and the spray forming cell environment temperature.

Method and arrangement for implementing heat treatment during the execution of spray-form techniques

Spray formed articles made of boron steel and method for making the same

A method for implementing pre-heat treatment before spray forming begins to achieve stress control in the manufacture of a spray formed metallic article involves preheating either or both of a spray forming cell environment and a mold substrate, initiating application of the metallic spray forming material onto the mold substrate, and causing substantially homogenous initial metallic phase transformations from the austenite phase via a predetermined relationship between the initial application temperature of the spray-forming material and the initial temperature of either or both of the preheated cell environment and the preheated mold substrate.

Method and arrangement for heat treatment before the execution of sprayform techniques

One method of the present invention relates to a method for enhancing adhesion of spraying metal to a ceramic model. The method is comprised of providing the ceramic model having a spray surface, and modifying at least a portion of the spray surface if the ceramic model to enhance adhesion of spray metal to the spray surface.

Method for enhancing adhesion of metal particles to ceramic models

One method of the present invention includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle and lowering the temperature of the slurry to freeze the slurry and form a freeze-cast substrate while controlling temperature gradients within the mold unit to minimize distortion in the freeze-cast substrate. Another method includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle, placing insulation material around at least a portion of the casting receptacle to minimize distortion in the freeze-cast substrate by controlling temperature gradients within the mold unit, and lowering the temperature of the slurry to freeze the slurry to form a freeze-cast substrate.

Method for producing a freeze-cast substrate

One method of the present invention relates to a method for spray forming metal deposits. The method is comprised of providing a ceramic substrate having a spraying pattern for receiving sprayed metal particles, spraying metal particles onto the spraying pattern to form a metal deposit on the spraying pattern for at least a first spray period, controlling the spraying step during the first spray period so that the temperature of the deposited metal particles increases at an average rate of less than or equal to about 15&deg; per minute. The first spray period can be defined as lasting until the temperature of the deposited metal particles is at or about a steady state temperature. The steady state temperature is preferably in the range of about 330&deg; C. to about 370&deg; C.

Method for spray forming metal deposits

The present invention discloses a method of correcting the shape of a spray-formed article which has a concave bowing relative to the working surface of the article. Specifically, deviations of such articles from a desired predetermined shape are corrected by applying sufficient heat to a non-working surface to permanently remove at least a partial amount of the concave bowing while leaving the working surface substantially unmarred. This process is repeated iteratively until the article achieves the predetermined shape.

Method and arrangement for changing the shape of thin-shell articles manufactured by spray-form techniques

A process for producing a metallic tool, mould, die or other body of significant thickness or a coating, the process comprising directing a spray ( ) comprising molten metallic droplets carried by a propelling gas toward an object surface ( ) of a substrate or pattern ( ) so as to build up a metallic deposit or coating comprising the mould, tool, die, body or coating on the object surface ( ) of the substrate or pattern ( ), wherein at one or more predetermined stages during spraying droplets of a relatively large mean size are sprayed and at one or more other stages droplets or a relatively smaller mean size are sprayed.

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Saline, MI, United States of America

Allen Roche