Michigan Technological University
Contact: Jim Lutzke; [email protected]
NEW MANUFACTURING APPROACH BOOSTS PERFORMANCE, LOWERS COSTS
HOUGHTON, MI≠A researcher in Michigan Technological Universityπs Institute of Materials Processing has developed a new manufacturing approach that combines casting, forging, powder metallurgy, bonding and coating in one process to produce high performance components at lower cost for a variety of industries.
Called CastCon, the process begins with a sand mold formed with a pattern and made from a selected sand and binder mixture. A powdered material is fed into the cavity of the sand mold either dry or wet. The powdered material, metal or ceramic powder, is then heated and isostatically pressed with a high pressure source. The sand mold acts as a pressure transmitting medium, uniformly consolidating the powdered material within the mold.
According to its developer, Dr. Scott (Xiaodi) Huang, major advantages of the CastCon process over current methods include:
1) excellent shape forming capability inherited from the vast use of sand molding techniques in the metal casting industry;
2) good mechanical properties equivalent to forged parts resulting from zero porosity and fine microstructure;
3) great flexibility of prooducing a wide variety of metallic, intermetallic, ceramic and composite components facilitated by using various powdered materials and their mixtures;
4) the capability of producing macro composites by bonding different powders, or a powder to a solid, or a solid to a solid;
5) a unique powder coating method for improving abrasive and corrosion resistance; and
6) a production process suitable for both single piece and high volume productions.
Huang says his process allows manufacturers to produce a small quantity of parts using low cost sand molds. By comparison, if the part were produced by forging, the costs for tooling designed to produce a small quantity would be prohibitive. With the new process, parts can be made at near net shape, which translates into significant savings on machining costs.
≥We can achieve still greater savings by using a softer, less expensive core material for a part and covering it with a very hard outer metal or ceramic sheath , which will withstand wear for a much longer period than traditional materials,≤ says Huang. ≥For example, the parts for armored tank treads wear out very quickly and are very costly to replace. CastCon allows us to use a less expensive material for the core of the tread and a harder, more durable outer material to achieve longer wear.≤
Huang says the CastCon process can be used to produce a variety of parts, ranging from surgical implants to gear parts, vehicle brakes, machine parts, drill bits, train wheels and rails, advanced cutting tools, permanent molds, die inserts, forging dies, turbines, and aircraft components. He says opportunities currently exist to implement this advanced manufacturing process in rapid prototyping using molds produced in stereo lithography or in a production application.
For more information on CastCon, contact Kip Paxton at 906-487-1826; e-mail: [email protected].
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