Fabrication of customized die inserts using closed-loop direct metal deposition (DMD)

Abstract

Techniques such as closed-loop direct metal deposition (CLDMD) and laser cladding are used to design and tailor tools and components for specific applications. Closed loop DMD in particular can achieve such changes on an existing tool with proper alloy matching (often referred as color matching in the die repair industry) and close dimensional tolerances. This process leads to cost and lead-time savings by reducing post processing cost and reconfiguring the original tool.

I claim:  
     
         1 . A method of enhancing a mold, die, or tool, comprising the steps of: 
 providing a mold, die or tool having a body with a working surface; and    modifying the body, the working surface, or both, directly from CAD data using a closed-loop, direct metal deposition process.    
     
     
         2 . The method of  claim 1 , wherein at least a portion of the working surface is modified to improve wear resistance.  
     
     
         3 . The method of  claim 1 , wherein at least a portion of the working surface is modified to improve resistance to dissolution during a die casting operation.  
     
     
         4 . The method of  claim 1 , wherein at least a portion of the working surface is modified to improve oxidation resistance.  
     
     
         5 . The method of  claim 1 , wherein at least a portion of the body is modified to incorporate cooling channels to improve thermal management.  
     
     
         6 . The method of  claim 1 , wherein at least a portion of the body is modified to incorporate conductive heat sinks or thermal barriers to improve thermal management.  
     
     
         7 . The method of  claim 1 , wherein at least a portion of the body or working surface is modified to produce a lightweight tool or component.  
     
     
         8 . The method of  claim 7 , wherein at least a portion of the body contains aluminum.  
     
     
         9 . The method of  claim 8 , wherein at least a portion of the body is cast aluminum-silicon.  
     
     
         10 . The method of  claim 8 , wherein at least a portion of the working surface is modified to produce a wear-resistant or high-temperature material.  
     
     
         11 . The method of  claim 10 , wherein at least a portion of the working surface is a metallurgically bonded molydenum alloy.  
     
     
         12 . The method of  claim 10 , further including a nickel alloy bond coat for improved service life for die casting of low melting point materials such as Zn alloys.  
     
     
         13 . The method of  claim 1 , further including a steel working surface.  
     
     
         14 . The method of  claim 1 , wherein the closed-loop DMD process is based upon a robotic implementation to process three-dimensional objects having a large mass and/or complexity.  
     
     
         15 . An enhancing a mold, die, or tool fabricated in accordance with the method of  claim 1 .  
     
     
         16 . An enhancing a mold, die, or tool fabricated in accordance with the method of  claim 2 .  
     
     
         17 . An enhancing a mold, die, or tool fabricated in accordance with the method of  claim 3 .  
     
     
         18 . An enhancing a mold, die, or tool fabricated in accordance with the method of  claim 4 .  
     
     
         19 . An enhancing a mold, die, or tool fabricated in accordance with the method of  claim 5 .  
     
     
         20 . An enhancing a mold, die, or tool fabricated in accordance with the method of  claim 6.