Multiple smooth elements bonded to a ground; novel tools and methods for surface improvement of metals and other materials

Abstract

The Present Invention introduces novel methods and tools for improving the surfaces of metals and other flowable materials with smooth-surfaced tools, such as fibers and spheroids bonded to a ground. The new tools deform and compress rather than remove material, thereby increasing surface hardness, density, reflectivity, electrical conductivity, impermeability and corrosion resistance. Benefits include economies in production and maintenance, an improved work environment, and reduced costs for energy, stock materials and precious metal reclamation.

1 . A method of reducing asperities on the surface of a workpiece comprising the steps of:
 providing a tool comprising a plurality of smooth-surfaced members of a material harder than the material of the surface of the intended workpiece, and a substantially rigid backing member, said smooth-surfaced members being affixed to said backing member;   urging said tool against the asperities in said surface such that said smooth-surfaced members exert high local pressure on said asperities, while simultaneously moving said tool with respect to said surface;   whereby said asperities are reduced by plastic deformation of the material of the workpiece, and without removal of the material of the workpiece.   
     
     
         2 . (canceled) 
     
     
         3 . The method of  claim 1 , wherein said smooth-surfaced members are spheroids. 
     
     
         4 . The method of  claim 3 , wherein the material of said spheroids is selected from the group comprising metals, glass, carbides, and ceramics. 
     
     
         5 . The method of  claim 1 , wherein said smooth-surfaced members are fibers. 
     
     
         6 . The method of  claim 5 , wherein the materials of said fibers are selected from the group comprising metal, glass and carbon fibers. 
     
     
         7 . The method of  claim 5 , wherein said fibers are provided in the form of woven cloth, nonwoven batts, wire, or screen. 
     
     
         8 . (canceled) 
     
     
         9 . The method of  claim 1 , wherein said backing member comprises a layer of a material selected from the group comprising paper, mesh, woven and non-woven fabric, resin impregnated fabric, felt, polymer film and foam, polishing cloth and metal. 
     
     
         10 . The method of  claim 1 , wherein said backing member comprises a layer of a material selected from the group comprising films, belts, discs, cylinders, wheels, and flap wheels; non-woven pads; foam-backed cloth; and metal wools. 
     
     
         11 . The method of  claim 1 , wherein the pressure at which the smooth-surfaced members urged against the surface to be treated is increased to the point that material of the surface is removed by adhesion to the smooth-surfaced members. 
     
     
         12 . The method of  claim 1 , wherein said backing member is provided in the form of a contoured wheel. 
     
     
         13 . The method of  claim 1 , wherein said backing member is provided in the form of a contoured disk. 
     
     
         14 . The method of  claim 1 , wherein said backing member is provided in the form of a burr. 
     
     
         15 . The method of  claim 1 , wherein said backing member is provided in the form of a pipe conditioning tool. 
     
     
         16 . (canceled) 
     
     
         17 . The method of  claim 1 , wherein said backing member comprises a layer of acrylic foam. 
     
     
         18 . The method of  claim 1 , wherein the relative motion of the tool with respect to the workpiece is provided by affixing said backing member to a reciprocating tool.