Methods of filling a die cavity with multiple materials for powder metal compaction

Abstract

A method of making powder metal compacted parts of multiple dissimilar materials. A die insert is provided having a pattern of cavities corresponding in shape to the shape of a die cavity. The pattern of cavities are filled with two or more dissimilar powder metals which are subsequently pressed within the die cavity to form a compacted powder metal part having at least two discrete regions of dissimilar material.

What is claimed is:  
     
         1 . A method of making a powder metal compacted part of multiple dissimilar materials, the method comprising: 
 providing a die insert having a pattern of cavities, the pattern having a shape corresponding to a shape of a die cavity in a die;    filling at least two different cavities of the die insert with at least two respective dissimilar powder metals;    separating the powder metals from the die insert so as to position the powder metals in their filled pattern in the die cavity;    pressing the powders in the die cavity to form a compacted powder metal part having at least two discrete regions of dissimilar material.    
     
     
         2 . The method of  claim 1 , wherein the die insert is provided on a top surface of the die over a lower punch positioned in an ejection position, and the separating occurs by lowering the lower punch to draw the powder metals from the die insert into the die cavity formed by lowering the punch.  
     
     
         3 . The method of  claim 1 , wherein the die insert is placed in the die cavity prior to the filling, and the separating occurs by lifting the die insert out of the die cavity.  
     
     
         4 . The method of  claim 1 , wherein each of the at least two powder metals are filled concurrently.  
     
     
         5 . The method of  claim 1 , wherein each of the at least two powder metals are filled sequentially with each powder metal being pressed after each filling step.  
     
     
         6 . The method of  claim 1 , wherein the insert is vibrated to facilitate separation of the powder metals from the die insert.  
     
     
         7 . The method of  claim 1 , wherein a lubing agent is applied to interior surfaces of the insert cavities prior to filling to facilitate separation of the powder metals from the die insert.  
     
     
         8 . The method of  claim 1 , wherein the die insert is heated to facilitate one or both of separation of the powder metals from the die insert and compaction of the powders in the die cavity.  
     
     
         9 . The method of  claim 1 , wherein the pressing comprises uniaxially pressing the powders in the die cavity.  
     
     
         10 . The method of  claim 1 , wherein the pressing comprises pre-heating the powders and pre-heating the die.  
     
     
         11 . The method of  claim 1 , further comprising sintering the compacted powder metals.  
     
     
         12 . A method of making a powder metal compacted part of multiple dissimilar materials, the method comprising: 
 providing a die insert having a pattern of cavities, the pattern having a shape corresponding to a shape of a die cavity in a die;    filling one or more first cavities of the die insert with a first powder metal;    pressing the first powder metal in the die insert to compact the first powder metal;    repeating the steps of filling and pressing, each time with a different powder metal, until the desired number of powder metals have been filled;    separating the powder metals from the die insert so as to position the powder metals in their filled pattern in the die cavity;    pressing the powders in the die cavity to form a compacted powder metal part having at least two discrete regions of dissimilar material.    
     
     
         13 . The method of  claim 11  wherein the die insert is provided on a top surface of the die over a lower punch positioned in an ejection position, and the separating occurs by lowering the lower punch to draw the powder metals from the die insert into the die cavity formed by lowering the punch.  
     
     
         14 . The method of  claim 12 , wherein the die insert is placed in the die cavity prior to the filling, and the separating occurs by lifting the die insert out of the die cavity.  
     
     
         15 . The method of  claim 12 , wherein the insert is vibrated to facilitate separation of the powder metals from the die insert.  
     
     
         16 . The method of  claim 12 , wherein a lubing agent is applied to interior surfaces of the insert cavities prior to filling to facilitate separation of the powder metals from the die insert.  
     
     
         17 . The method of  claim 12 , wherein the die insert is heated to facilitate one or both of separation of the powder metals from the die insert and compaction of the powders in the die cavity.  
     
     
         18 . The method of  claim 12 , wherein the pressing comprises uniaxially pressing the powders in the die cavity.  
     
     
         19 . The method of  claim 12 , wherein the pressing, comprises pre-heating the powders and pre-heating the die.  
     
     
         20 . The method of  claim 12 , further comprising sintering the compacted powder metals.  
     
     
         21 . A method of making a powder metal compacted part of multiple dissimilar materials, the method comprising: 
 placing a die insert in a die cavity, the die insert having a pattern of cavities;    filling at least two different cavities of the die insert with at least two respective dissimilar powder metals;    lifting the die insert out of the die cavity; and    pressing the powders in the die cavity to form a compacted powder metal part having at least two discrete regions of dissimilar material.    
     
     
         22 . The method of  claim 21 , wherein each of the at least two powder metals are filled concurrently.  
     
     
         23 . The method of  claim 21 , wherein each of the at least two powder metals are filled sequentially with each powder metal being pressed after each filling step.  
     
     
         24 . The method of  claim 21 , wherein the insert is vibrated to facilitate separation of the powder metals from the die insert.  
     
     
         25 . The method of  claim 21 , wherein a lubing agent is applied to interior surfaces of the insert cavities prior to filling to facilitate separation of the powder metals from the die insert.  
     
     
         26 . The method of  claim 21  wherein the die insert is heated to facilitate one or both of separation of the powder metals from the die insert and compaction of the powders in the die cavity.  
     
     
         27 . The method of  claim 21 , wherein the pressing comprises uniaxially pressing the powders in the die cavity.  
     
     
         28 . The method of  claim 21 , wherein the pressing comprises pre-heating the powders and pre-heating the die.  
     
     
         29 . The method of  claim 21 , further comprising sintering the compacted ponder metals.  
     
     
         30 . A method of making a powder metal compacted part of dissimilar materials, the method comprising: 
 providing a die having a lower punch positioned in an ejection position;    providing a die insert on a top surface of the die over the lower punch, the die insert having a pattern of cavities with a shape corresponding to a shape of a die cavity formed when the lower punch is in a non-ejection position;    filling at least two different cavities of the die insert with at least two respective dissimilar powder metals;    lowering the lower punch of the die from the ejection position to the non-ejection position to draw the powder metals from the die insert into the die cavity in their filled pattern;    pressing the powder metals in the die cavity to form a compacted powder metal part having at least two discrete regions of dissimilar material.    
     
     
         31 . The method of  claim 30 , wherein each of the at least two powder metals are filled concurrently.  
     
     
         32 . The method of  claim 30 , wherein each of the at least two powder metals are filled sequentially with each powder metal being, pressed after each filling step.  
     
     
         33 . The method of  claim 30 , wherein the insert is vibrated to facilitate separation of the powder metals from the die insert.  
     
     
         34 . The method of  claim 30 , wherein a lubing agent is applied to interior surfaces of the insert cavities prior to filling to facilitate separation of the powder metals from the die insert.  
     
     
         35 . The method of  claim 30 , wherein the die insert is heated to facilitate one or both of separation of the powder metals from the die insert and compaction of the powders in the die cavity.  
     
     
         36 . The method of  claim 30 , wherein the pressing comprises uniaxially pressing the powders in the die cavity.  
     
     
         37 . The method of  claim 30 . wherein the pressing, comprises pre-heating the powders and pre-heating the die.  
     
     
         38 . The method of  claim 30 , further comprising sintering the compacted powder metals.