Method for producing powder metal tooling, mold cavity member

Abstract

A method of producing a mold cavity insert using powder metals includes the steps of providing a master die having a pattern with a shape that defines a mold cavity, applying powder metal in the master die, and compacting the powder metal within the master die with a press assembly to form a compacted part. The method further includes the steps of removing the compacted part from the master die, placing the compacted part in a furnace, and heating the compacted part in the furnace to an elevated temperature to cure the part and provide a mold cavity insert that may be employed in a mold.

1 . A method of producing a mold cavity member, comprising the steps of: 
 providing a master die having a pattern with a shape that defines a mold cavity;    applying powder metal in the master die;    compacting the powder metal within the master die with a press assembly to form a compacted part;    removing the compacted part from the master die;    placing the compacted part in a furnace; and    heating the compacted part in the furnace to an elevated temperature to cure the part and provide a mold cavity member.    
     
     
         2 . The method as defined in  claim 1 , wherein the step of compacting the powder metal comprises compressing the powder metal within the cavity of the master die between a first hob and a second hob.  
     
     
         3 . The method as defined in  claim 2 , wherein the step of compacting the powder metal comprises forcibly moving the first hob towards the second stationary hob.  
     
     
         4 . The method as defined in  claim 1 , wherein the step of heating the compacted part comprises heating the compacted part in a hipping furnace at a pressure in excess of 15,000 psi.  
     
     
         5 . The method as defined in  claim 1 , wherein the step of heating the compacted part comprises heating the compacted part in a vacuum furnace.  
     
     
         6 . The method as defined in  claim 1 , wherein the step of heating the compacted part comprises heating the part in the furnace at a temperature of at least 2,080° F.  
     
     
         7 . The method as defined in  claim 1  further comprising the step of heating at least one of the master die and the press assembly.  
     
     
         8 . The method as defined in  claim 7 , wherein the at least one of the master die and press assembly is heated to a temperature of at least 175° F.  
     
     
         9 . The method as defined in  claim 1 , wherein the mold cavity member comprises a mold cavity insert.  
     
     
         10 . The method as defined in  claim 9  further comprising the step of placing the mold cavity insert in a mold.  
     
     
         11 . A method of producing a mold cavity member, comprising the steps of: 
 providing a master die having a pattern with a shape that defines a mold cavity;    applying powder metal in the master die;    heating at least one of the master die and a press assembly;    compacting the powder metal within the master die with the press assembly having a first hob and a second hob to form a compacted part, wherein the powder metal is compressed within the cavity of the die between the first hob and the second hob;    removing the compacted part from the master die;    placing the compacted part in a furnace; and    heating the compacted part in the furnace to an elevated temperature to cure the part and provide a mold cavity member.    
     
     
         12 . The method as defined in  claim 11 , wherein the step of compacting the powder metal comprises forcibly moving the first hob toward the second stationary hob.  
     
     
         13 . The method as defined in  claim 1   1 , wherein the step of heating the compacted part comprises heating the compacted part in a hipping furnace at a pressure in excess of 15,000 psi.  
     
     
         14 . The method as defined in  claim 11 , wherein the step of heating the compacted part comprises heating the compacted part in a vacuum furnace.  
     
     
         15 . The method as defined in  claim 11 , wherein the step of heating the compacted part comprises heating the part in the furnace at a temperature of at least 2,080° F.  
     
     
         16 . The method as defined in  claim 11 , wherein the at least one of the master die and press assembly is heated to a temperature of at least 175° F.  
     
     
         17 . The method as defined in  claim 11 , wherein the tooling member comprises a mold cavity insert.  
     
     
         18 . The method as defined in  claim 17  further comprising the step of placing the mold cavity insert in a mold.