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

摘要

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 arc 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. Optionally localized fusion treatments (IR, laser, HDIR or any other localized energy source) are applied to obtain full density on the surface. Also welding, laser deposition or any other deposition by melting can be applied (often on top of a deposited or projected intermediate layer). Different layers can be applied, and trough proper masking a specific surface functionality can be attained. Rolls, jaws, bearing supports, machine benches and other structural parts and any other highly solicited part can be obtained at low cost by means of the present invention.