1. SPRAY METAL TOOLING
โข This process applies a zinc/aluminum alloy with an arc spray
to a pattern or model. The pattern or model can be a
stereolithography part or a model made from wood or metal.
โข Steel particles having a carbon content in the range of 0.01-
0.9% by weight are sprayed onto the spray forming pattern to
form a deposit on the spray forming pattern.
โข The deposit has a thickness of at least 0.5 inches and the
temperature of the steel particles increases as the thickness
of the steel deposit increases.
2. Spray Metal steps
โข Providing a master pattern
โข Melting the metal at the
gun
โข Spraying the liquid metal
onto the prepared
substrate by means of
compressed air
โข Molten particles are
projected onto the cleaned
substrate.
3. 3D Keltool
โข The word "Keltool" refers to the proprietary powder metal
sintering process, which involves penetrating a fused metal
part with copper alloy.
โข This process is based on metal sintering process.
โข This process converts RP master patterns into production tool
inserts with very good definition and surface finish.
โข 3D Keltool inserts are built of Sterlite of A6 composite tool
steel. The material properties allow the inserts using this
process to withstand more than 10lakh mould cycles.
โข The Keltool part (mold) is limited to 6 inches in all directions.
Therefore, any parts produced would be limited to about 4
inches in all directions.
4. 3D Keltool Process
โข Fabricating the master patterns of core and cavity.
โข Producing RTV silicon rubber mould from the pattern.
โข Filling the silicon rubber mould with metal mixtures to
produce green parts duplicating the masters.
โข Firing the green parts in a furnace to remove the plastic
binder and sintering the metal particles together.
โข Infiltrating the sintered parts (70% dense inserts) with copper
in the second furnace cycle to fill the 30% void space.
โข Finishing the core and cavity.