Formation, repair and modification of lay up tools

Abstract

A composite lay up tool comprising a metal faceplate ( 12 ) on a support member ( 13 ), wherein the faceplate has been formed by cold-gas dynamic spraying of particles of the metal onto a substrate and wherein the support member is compatible with the faceplate and comprises a casting of a ceramic composition. A process for forming the tool is disclosed. In one aspect, a castable ceramic composition comprises a binder and an aggregate component mixable with water to form a slurry ready for casting, wherein the aggregate component is one of or a mixture of fused silica and a particulate metal alloy, and the binder and aggregate component are present in the proportions 10-50 wt % and 90-50 wt % based on the dry weight of the composition. Also disclosed is a process for producing a faceplate for a lay up tool, which process comprises cold-gas dynamic spraying of particles of a nickel-iron alloy onto a substrate to form a faceplate of the nickel-iron alloy on the substrate, the faceplate being of a thickness in the range 2 to 10 mm. Further disclosed is a process for depositing a metal on a faceplate of a lay up tool in which the faceplate is formed of a nickel-iron alloy, which process comprises preparing an area of a surface of the faceplate to effect cleaning and conditioning of the area to accept and adhere to cold-gas dynamic sprayed particles, and cold-gas dynamic spraying particles of the metal onto the cleaned and conditioned area, wherein the metal is a nickel-iron alloy selected to be compatible with the faceplate.

1 . A composite lay up tool comprising a metal faceplate on a support member, wherein the faceplate has been formed by cold-gas dynamic spraying of particles of the metal onto a substrate and wherein the support member is compatible with the faceplate and comprises a casting of a ceramic composition. 
     
     
         2 . A composite lay up tool according to  claim 1  wherein the support member has a thermal expansion coefficient that differs from that of the faceplate by no greater than +15% in at least a selected temperature range. 
     
     
         3 . A composite lay up tool according to  claim 2  wherein the selected temperature range is 150-250° C. 
     
     
         4 . A composite lay up tool according to  claim 1 , wherein the ceramic composition comprises a binder and an aggregate component and the aggregate component is one of, or a mixture of, fused silica and a particulate metal alloy. 
     
     
         5 . A composite lay up tool according to  claim 4  wherein the binder and the aggregate component are present in the proportions by weight 10-50% and 90-50% respectively, based on the dry weight of the composition. 
     
     
         6 . A composite lay up tool according to  claim 1  wherein the metal of the faceplate is a nickel-iron alloy. 
     
     
         7 . A composite lay up tool according to  claim 6  wherein the metal of the faceplate is Invar 36. 
     
     
         8 . A composite lay up tool according to  claim 6  wherein the ceramic composition includes an aggregate component comprising or particulate form of the same nickel-iron alloy. 
     
     
         9 . A composite lay up tool according to  claim 1  wherein the faceplate and the support member are connected by a plurality of anchors. 
     
     
         10 . A composite lay up tool according to  claim 9  wherein the faceplate and the support member are spaced apart by a predetermined gap. 
     
     
         11 . A process for producing a composite lay up tool that comprises a metal faceplate on a support member compatible with the faceplate, which process comprises forming the metal faceplate by cold-gas dynamic spraying of particles of the metal onto a substrate and forming the support member by casting of a ceramic composition. 
     
     
         12 . A process according to  claim 11  wherein the metal and the ceramic composition are selected so that the support member has a thermal expansion coefficient that differs from that of the faceplate by no greater than +15% in at least a selected temperature range. 
     
     
         13 . A process according to  claim 12  wherein the selected temperature range is 150-250° C. 
     
     
         14 . A process according to  claim 11 , wherein the ceramic composition comprises a binder and an aggregate component and the aggregate component is one of, or a mixture of, fused silica and a particulate metal alloy. 
     
     
         15 . A process according to  claim 4  wherein the binder and the aggregate component are present in the proportions by weight 10-50% and 90-50% respectively, based on the dry weight of the composition. 
     
     
         16 . A process according to any  claim 11  wherein the metal of the faceplate is a nickel-iron alloy. 
     
     
         17 . A process according to  claim 16  wherein the metal of the faceplate is Invar 36. 
     
     
         18 . A process according to  claim 16  wherein the ceramic composition includes an aggregate component comprising a particulate form of the same nickel-iron alloy. 
     
     
         19 . A process according to  claim 11  including positioning a plurality of anchors to correct the faceplate and the support member. 
     
     
         20 . A process according to  claim 11  wherein the substrate is the support member. 
     
     
         21 . A process according to  claim 11  wherein the formed faceplate is mounted to the support member after its formation on the substrate, and the substrate is thereafter removed. 
     
     
         22 - 45 . (canceled)