The KelTool™ method is a cutting-edge technology for the rapid production of high-performance metal molds. The process combines advanced materials and precise manufacturing steps to produce durable and high-quality molds that meet industrial standards. The primary base material used in this method is a dual-phase mixed powder, which typically consists of WC powder (tungsten carbide) and A6 tool steel powder. This combination of materials results in molds with excellent hardness, wear resistance, and thermal conductivity. Below, we explore the key process features of the KelTool™ method, focusing on its material composition, advantages, and potential limitations.

Key Features of the KelTool™ Method

1. Dual-Phase Mixed Powders for Enhanced Performance

The KelTool™ method utilizes a dual-phase mixed powder as the core material. This powder is composed of finely ground WC particles (tungsten carbide) with an average particle size of 1-4 μm and A6 tool steel powder with an average particle size of 20-38 μm. The combination of these powders provides numerous benefits over single-phase powders. Here are the key advantages:

• High Density: The ratio of fine and coarse particle sizes is greater than 7, leading to a significantly higher density in the final mold material.
• Improved Filling: The fine WC particles help fill the gaps between the larger A6 tool steel particles, ensuring a more compact and uniform structure.
• Reduced Binder Density: With less binder material required, the amount of binder that needs to be removed during the sintering process is reduced, which also decreases the risk of defects during mold production.
• Smaller Shrinkage Rate: The KelTool™ method achieves a relatively low average shrinkage rate during sintering, contributing to better dimensional accuracy and overall precision of the mold.
• Optimized Material Properties: The fine WC particles reduce surface roughness and improve wear resistance, while the larger A6 tool steel particles provide excellent toughness, creating a balanced material that performs well under various operating conditions.

2. Advantages of the KelTool™ Method

The KelTool™ method offers several notable advantages in mold manufacturing:

• Durable Steel Mold Material: The final molds produced through the KelTool™ method consist of a composition of 70% A6 tool steel powder and 30% copper. The A6 tool steel provides excellent wear resistance and low distortion, while tungsten carbide (WC) contributes to hardness and durability. The copper material improves the strength and thermal conductivity of the mold, making it suitable for high-performance applications.
• Hardness and Durability: The molds produced using the KelTool™ method have a hardness of 30-34 HRC in their initial state, which increases to 46-50 HRC after heat treatment. These molds are capable of lasting for over one million cycles, providing excellent longevity and making them ideal for large-scale production runs.
• Simplicity and Speed: One of the key benefits of the KelTool™ method is its simple and fast production process. Once the initial design and rapid prototyping are completed, the sintering and copper infiltration processes can be carried out in a continuous sequence, saving time and reducing manufacturing costs.
• Cost Efficiency: With precise temperature control, the sintering and copper infiltration steps can be carried out seamlessly. This minimizes costs, reduces cycle times, and prevents distortion or shrinkage issues that may arise from temperature fluctuations.

3. Disadvantages of the KelTool™ Method

While the KelTool™ method offers numerous advantages, there are also some limitations to consider:

• Fine Material Granularity: The method requires the use of fine powder materials, and the binder’s adhesion, flowability, and curing properties need to meet strict specifications. This can add complexity to the material selection and preparation process.
• Insufficient Strength in Master Molds: The master mold (negative mold) used in the KelTool™ method may not have the same strength and hardness as the final mold, leading to lower precision in the produced mold. The master mold must be carefully designed and manufactured to ensure a high-quality final product.
• Longer Production Cycle: The production cycle for molds using the KelTool™ method can be longer than some other methods, with an average lead time of 4 weeks. Creating core components typically takes 8-10 days, and the maximum mold size is generally limited to 152mm x 203mm x 101mm. This can be a drawback when tight production timelines are required.

Conclusion

The KelTool™ method offers a rapid, cost-effective, and efficient approach to manufacturing high-performance steel molds. By utilizing dual-phase mixed powders such as WC and A6 tool steel, this process produces durable molds with excellent hardness, wear resistance, and thermal conductivity. The method is especially beneficial for industries requiring high-quality molds for large-scale production runs, offering excellent mold life and dimensional accuracy.

Despite its many advantages, the KelTool™ method does come with certain challenges, including the need for fine-grained materials and the longer production cycle. However, the benefits of the method, particularly in terms of speed, cost, and mold durability, make it a valuable tool in modern manufacturing, especially for industries that require precise and reliable molds for high-volume production.