Method for producing highly mechanically demanded pieces and specially tools from low cost ceramics or polymers

Abstract

The present invention is directed to a method for the production of highly demanded pieces at low cost. The method is especially well suited for deep drawing dies, but also any other type of tooling. It is also very well suited for machine components of big dimensions and with high mechanical solicitations, like rotors and cages in wind mills and other big machines. The pieces or tools are cast with a low cost ceramic, like a high resistance concrete (with special mention to HPC or UHPC) or a low water admixture castable or any other low cost high mechanical resistance material (low cost ceramics or high resistance polymers are especially suited). Once cast, the working surface of the die or piece is coated with a metal, an intermetallic or a high performance ceramic. Projection or deposition techniques are used to obtain the high value working surface.

1 . Piece or tool, wherein the base material is a concrete or low water admixture castable, with a mechanical resistance higher than 200 MPa. 
     
     
         2 . Piece or tool according to  claim 1 , wherein the base material is a concrete or low water admixture castable, with a mechanical resistance higher than 250 MPa. 
     
     
         3 . Piece or tool according to  claim 1 , wherein the material is at least partially coated with a metal, an inter-metallic compound or a technical ceramic. 
     
     
         4 . Piece or tool according to  claim 3 , wherein the coating includes a thermal projection coating. 
     
     
         5 . Piece or tool according to  claim 1 , wherein a portion of the arid of the high or ultrahigh resistance concrete (HPC or UHPC) is at least partly replaced by metallic particles. 
     
     
         6 . Piece or tool according to  claim 1 , wherein a portion of the cement of the high or ultrahigh resistance concrete (HPC or UHPC) is replaced by metallic nanopowders. 
     
     
         7 . Piece or tool according to  claim 1 , wherein the base material is internally armoured with metallic parts. 
     
     
         8 . Piece or tool according to  claim 1 , wherein the piece or tool is hopped by means of a compression ring to improve tensile stress resistance of the resulting part. 
     
     
         9 . Piece or tool according to  claim 1 , further comprising tubes superficially or subsuperficially placed in the base material, conferring a cooling/heating functionality to the piece or tool when a fluid is circulated through the tubes. 
     
     
         10 . Piece or tool according to  claim 1 , which is a tool for the forming of plastics, sheet forming or alloy die casting. 
     
     
         11 . Piece according to  claim 1 , which is a structural component, machine bench or other component.