DESC:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)

TITLE OF THE INVENTION

“A MOLD AND A METHOD FOR MAKING A COMPONENT”

APPLICANTS:
Name Nationality Address
Mahindra & Mahindra Limited Indian Mahindra Research Valley, Mahindra World, City Plot No. 41/1, Anjur P.O. Chengalpattu, KancheepuramDist, Tamilnadu.- 603204

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:-

TECHNICAL FIELD
[001] The embodiments herein generally relate to composites, and more particularly but not exclusively to manufacturing of metal matrix composites.

BACKGROUND
[001] Generally, a composite is a material that is made up of two or more materials such that the properties of the composite are superior than the individual materials used for making it. The metal matrix components generally include a metal as the matrix and particles of oxides, carbides or nitrides as the reinforcement. Components made from metal matrix components tend to have a higher wear resistance than the components made from conventional metals and therefore usage of metal matrix components for various industrial applications is on rise.
[002] Conventionally in components that undergo friction, when the layer of the functional surface that is exposed to friction wears out, the entire component is replaced. Thus the current product lifecycle is less and replacement of the part incurs additional cost. Hence, selective functional areas of components are transformed into composite through different techniques like lasers surface alloying, plasma surface alloying or friction surfacing techniques. All these techniques used for making the selective functional areas transformation involve complex equipment and process, which ultimately ends up with the increase in the product cost. On the other hand manufacturing of components that are completely made of metal matrix composites involve less complex process but incurs high cost.
[003] Therefore, there exists a need for a simple and a cost effective method for manufacturing a component having a functional layer made of metal matrix composite.

OBJECTS
[004] The principle object of an embodiment of this invention is to provide a simple and a cost effective method for manufacturing a component having a functional layer made of metal matrix composite.
[005] Another object of an embodiment of this invention is to provide a mold/die for manufacturing a component having a functional layer made of metal matrix composite.
[006] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[007] The embodiments of this invention are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[008] FIG. 1 depicts a schematic of a mold according to an embodiment of the invention as disclosed herein;
[009] FIG. 2 depicts a cross-sectional view of the mold according to an embodiment of the invention as disclosed herein;
[0010] FIG. 3 depicts a cross-sectional view of the mold having the first metal with hard particles according to an embodiment of the invention as disclosed herein;
[0011] FIG. 4 depicts a cross-sectional view of the mold having the first metal with hard particles and the second metal according to an embodiment of the invention as disclosed herein; and
[0012] FIG. 5 depicts a cross section view of the component according to an embodiment of the invention as disclosed herein.

DETAILED DESCRIPTION
[0013] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0014] The embodiments herein achieve a simple and a cost effective method for manufacturing a component having a functional layer made of metal matrix composite. Further, embodiments herein achieve a mold/die for manufacturing a component having a functional layer made of metal matrix composite. Referring now to the drawings, and more particularly to FIGS. 1 through 5, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0015] FIG. 1 depicts a schematic of a mold according to an embodiment of the invention as disclosed herein. FIG. 2 depicts a cross-sectional view of the mold according to an embodiment of the invention as disclosed herein. In an embodiment the mold 100 includes an heating means 102 and a cavity 104.
[0016] FIG. 5 depicts a cross section view of the component according to an embodiment of the invention as disclosed herein. In an embodiment the heating means 102 is used for controlling the temperature of a metal forming the matrix of the metal matrix composite used for making the functional layer 202 of the component 200. The heating means 102 is provided below the cavity 104 of the mold 100. In an embodiment the heating means 102 is an electric coil. However, it is also within the scope of the invention to provide a gas based heater, oil, coal etc as the heating means 102 without otherwise deterring the intended function of the heating means 102 as can be deduced from the description.
[0017] In an embodiment the cavity 104 is used for manufacturing the component 200. The cavity 104 of the mold 100 is designed according to size and shape of the component 200. In an embodiment the mold 100 can be made from green sand, resin or metal.
[0018] FIG. 3 depicts a cross-sectional view of the mold having the first metal with hard particles according to an embodiment of the invention as disclosed herein. FIG. 4 depicts a cross-sectional view of the mold having the first metal with hard particles and the second metal according to an embodiment of the invention as disclosed herein. The component 200 is made as follows. In an embodiment, a first metal A and a second metal B are heated to a molten state. Thereafter, the first metal A in the molten state is incorporated/mixed with hard particles H (not shown) and the first metal A in molten state mixed with hard particles H is poured into the cavity 104 of the mold 100. The first metal A forms the matrix of the metal matrix composite used for making the functional layer 202 of the component 200 and the hard particles H forms the reinforcement of the metal matrix composite used for making the functional layer 202 of the component 200. The heating means 102 in the mold 100 prevents the immediate solidification of the first metal A and keeps the first metal A in a semi molten state. Thereafter the second metal B in the molten state is poured into the cavity 104 of the mold 100. The second metal B bonds with the first metal A and forms the remaining layer of the component 200. Thereafter, the mold 100 is cooled and the component 200 is removed from the mold 100. In an embodiment the melting point of the first metal A is lower than the melting point of the second metal B. In an embodiment the first metal A used is cast-iron or aluminum or copper or bronze. In an embodiment the second metal B used is zinc or aluminum or copper. However, it is also within the scope of the invention to provide any other metals as first metal A and second metal B. In an embodiment the hard particles used is SiC or BN or Si3N4 or TiN or TiC or VC or NbC or WC or Al2O3 or TiO2 or Cr2O3 or SiO2. However, it is also within the scope of the invention to provide any other hard particles H.
[0019] A method 300 for manufacturing a component having a functional layer made of metal matrix composite includes, providing a mold with a heating means and a cavity 302, heating a first metal to a molten state 304, heating a second metal to a molten state 306, mixing the first metal with a plurality of hard particles 308, pouring the first metal mixed with plurality of hard particles into the cavity of the mold 310, controlling the temperature of the first metal poured into the cavity of the mold using the heating means 312, pouring the second metal into the cavity of the mold 314 and cooling the mold 316.
[0020] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

CLAIMS
We claim
1. A mold for manufacturing a component, said mold comprising:
at least one cavity; and
a heating means adapted to control the temperature of a metal defining the matrix of a metal matrix composite used for making a functional layer of the component,
wherein
said heating means is provided below said cavity.
2. The mold as claimed in claim 1, wherein said heating means is at least one of a electric coil, gas based heater, oil and coal.
3. The mold as claimed in claim 1 is made from at least one of green sand, resin and metal.
4. A method for manufacturing a component having a functional layer made of metal matrix composite, said method comprising:
providing a mold with a heating means and a cavity;
heating a first metal to a molten state;
heating a second metal to a molten state;
mixing the first metal with a plurality of hard particles;
pouring the first metal mixed with plurality of hard particles into the cavity of the mold;
controlling the temperature of the first metal poured into the cavity of the mold using the heating means of the mold; and
pouring the second metal into the cavity of the mold,
wherein
the first metal defines a matrix for the metal matrix composite and the plurality of hard particles defines a reinforcement for the metal matrix composite.
5. The method as claimed in claim 4, further comprising the step of cooling the mold.

Dated this 29th September 2015

Signature:
Name: Kalyan Chakravarthy

ABSTRACT
A mold and a method for making a component includes, at least one cavity and a heating means. The heating means is used to control the temperature of a metal defining the matrix of a metal matrix composite used for making a functional layer of the component. The heating means is provided below the cavity.
Fig. 1
,CLAIMS:CLAIMS
We claim
1. A mold for manufacturing a component, said mold comprising:
at least one cavity; and
a heating means adapted to control the temperature of a metal defining the matrix of a metal matrix composite used for making a functional layer of the component,
wherein
said heating means is provided below said cavity.
2. The mold as claimed in claim 1, wherein said heating means is at least one of a electric coil, gas based heater, oil and coal.
3. The mold as claimed in claim 1 is made from at least one of green sand, resin and metal.
4. A method for manufacturing a component having a functional layer made of metal matrix composite, said method comprising:
providing a mold with a heating means and a cavity;
heating a first metal to a molten state;
heating a second metal to a molten state;
mixing the first metal with a plurality of hard particles;
pouring the first metal mixed with plurality of hard particles into the cavity of the mold;
controlling the temperature of the first metal poured into the cavity of the mold using the heating means of the mold; and
pouring the second metal into the cavity of the mold,
wherein
the first metal defines a matrix for the metal matrix composite and the plurality of hard particles defines a reinforcement for the metal matrix composite.
5. The method as claimed in claim 4, further comprising the step of cooling the mold.

Dated this 29th September 2015

Signature:
Name: Kalyan Chakravarthy