Method of manufacturing dies and molds by melting-spray

Abstract

A method of manufacturing die and mold by melting-spray relates to a method of manufacturing die and mold used for plastic or metal shaping, in which there is no need for the operating procedure of replicating a melting-sprayed prototype from a prototype or from a rubber die which is reproduced from the prototype. The present invention includes the following steps: (1) directly manufacturing the melting-sprayed prototype; (2) forming a melting-spray layer on the surface of the melting-sprayed prototype; (3) reinforcing the melting-spray layer; and (4) removing the melting-sprayed prototype and then obtaining the die or mold. With this invention, the fast manufacturing speed, the low cost and the improved precision are obtained, and the existent operating procedure for manufacturing die and mold by melting-spray is shortened, thereby it is suitable for manufacturing die and mold used for plastic or metal shaping.

What is claimed is:  
     
         1 . A method of manufacturing die or mold by a melting-spray process, comprising: 
 directly manufacturing a melting-sprayed prototype;    forming a melting-spray layer on the surface of the melting-sprayed prototype;    reinforcing the melting-spray layer; and    removing the melting-sprayed prototype and then obtaining the die or mold.    
     
     
         2 . The method of manufacturing die or mold according to  claim 1 , characterized in that the melting-sprayed prototype is manufactured by removal-type machining,  
     
     
         3 . The method of manufacturing die or mold according to  claim 1 , characterized in that the melting-sprayed prototype is manufactured by material-accumulated shaping.  
     
     
         4 . A method of manufacturing die and mold according to  claim 1 , characterized in that the material of the melting-sprayed prototype is selected from the group consisting of metal, ceramic power, and a powder of mixed metal and ceramic.  
     
     
         5 . A method of manufacturing die and mold according to  claim 4 , characterized in that the material for forming the melting spray is selected from the group consisting of carbide alloy and wear resistant metal, and the material for reinforcing the melting spray layer comprises casting alloy.  
     
     
         6 . A method of manufacturing die and mold according to  claim 5 , wherein the ceramic power used in the melting-sprayed prototype is selected from the group comprising alumina and silicon dioxide, the material for forming the melting-spray layer is selected from the group comprising tungsten carbide alloy, stainless steel and nickel alloy, and the material for reinforcing is selected fro the group comprising bismuth alloy and zinc alloy.