CN105935774A - 用于制造物件的过程 - Google Patents
用于制造物件的过程 Download PDFInfo
- Publication number
- CN105935774A CN105935774A CN201610223630.4A CN201610223630A CN105935774A CN 105935774 A CN105935774 A CN 105935774A CN 201610223630 A CN201610223630 A CN 201610223630A CN 105935774 A CN105935774 A CN 105935774A
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- CN
- China
- Prior art keywords
- consolidation
- parts
- metal dust
- shell
- consolidation shell
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 57
- 238000007596 consolidation process Methods 0.000 claims abstract description 85
- 239000000843 powder Substances 0.000 claims abstract description 27
- 238000004519 manufacturing process Methods 0.000 claims abstract description 25
- 229910052751 metal Inorganic materials 0.000 claims description 59
- 239000002184 metal Substances 0.000 claims description 59
- 239000000463 material Substances 0.000 claims description 47
- 239000000428 dust Substances 0.000 claims description 40
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 39
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 19
- 229910052759 nickel Inorganic materials 0.000 claims description 19
- 229910045601 alloy Inorganic materials 0.000 claims description 17
- 239000000956 alloy Substances 0.000 claims description 17
- 229910017052 cobalt Inorganic materials 0.000 claims description 17
- 239000010941 cobalt Substances 0.000 claims description 17
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 17
- 239000000203 mixture Substances 0.000 claims description 16
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 14
- 229910052719 titanium Inorganic materials 0.000 claims description 14
- 239000010936 titanium Substances 0.000 claims description 14
- 238000003825 pressing Methods 0.000 claims description 4
- 125000003636 chemical group Chemical group 0.000 claims description 2
- 230000005611 electricity Effects 0.000 claims description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims 1
- 239000010931 gold Substances 0.000 claims 1
- 229910052737 gold Inorganic materials 0.000 claims 1
- 239000000654 additive Substances 0.000 abstract 1
- 230000000996 additive effect Effects 0.000 abstract 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 16
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 16
- 229910052799 carbon Inorganic materials 0.000 description 16
- 229910052804 chromium Inorganic materials 0.000 description 16
- 239000011651 chromium Substances 0.000 description 16
- 239000002245 particle Substances 0.000 description 16
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 10
- 229910052710 silicon Inorganic materials 0.000 description 10
- 239000010703 silicon Substances 0.000 description 10
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 9
- 229910052782 aluminium Inorganic materials 0.000 description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 9
- 229910052796 boron Inorganic materials 0.000 description 9
- 238000005516 engineering process Methods 0.000 description 8
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 8
- 229910052721 tungsten Inorganic materials 0.000 description 8
- 239000010937 tungsten Substances 0.000 description 8
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 7
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 7
- 229910052750 molybdenum Inorganic materials 0.000 description 7
- 239000011733 molybdenum Substances 0.000 description 7
- 229910052758 niobium Inorganic materials 0.000 description 7
- 239000010955 niobium Substances 0.000 description 7
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 7
- 229910052726 zirconium Inorganic materials 0.000 description 7
- 229910052715 tantalum Inorganic materials 0.000 description 6
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 6
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 5
- 230000007797 corrosion Effects 0.000 description 5
- 238000005260 corrosion Methods 0.000 description 5
- 229910052717 sulfur Inorganic materials 0.000 description 5
- 239000011593 sulfur Substances 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- 238000003754 machining Methods 0.000 description 4
- 229910000906 Bronze Inorganic materials 0.000 description 3
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 3
- 239000010974 bronze Substances 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 229910052698 phosphorus Inorganic materials 0.000 description 3
- 239000011574 phosphorus Substances 0.000 description 3
- 229910052702 rhenium Inorganic materials 0.000 description 3
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000010419 fine particle Substances 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 229910052735 hafnium Inorganic materials 0.000 description 2
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 239000012255 powdered metal Substances 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 238000000149 argon plasma sintering Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000004320 controlled atmosphere Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 208000020442 loss of weight Diseases 0.000 description 1
- 229910001105 martensitic stainless steel Inorganic materials 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052756 noble gas Inorganic materials 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- -1 pottery Substances 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 238000012163 sequencing technique Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/14—Both compacting and sintering simultaneously
- B22F3/15—Hot isostatic pressing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/1208—Containers or coating used therefor
- B22F3/1258—Container manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/22—Blade-to-blade connections, e.g. for damping vibrations
- F01D5/225—Blade-to-blade connections, e.g. for damping vibrations by shrouding
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D9/00—Stators
- F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/26—Rotors specially for elastic fluids
- F04D29/32—Rotors specially for elastic fluids for axial flow pumps
- F04D29/321—Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
- F04D29/324—Blades
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/40—Casings; Connections of working fluid
- F04D29/52—Casings; Connections of working fluid for axial pumps
- F04D29/54—Fluid-guiding means, e.g. diffusers
- F04D29/541—Specially adapted for elastic fluid pumps
- F04D29/542—Bladed diffusers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
- B22F2005/103—Cavity made by removal of insert
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2220/00—Application
- F05D2220/30—Application in turbines
- F05D2220/32—Application in turbines in gas turbines
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2240/00—Components
- F05D2240/35—Combustors or associated equipment
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2260/00—Function
- F05D2260/20—Heat transfer, e.g. cooling
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/50—Intrinsic material properties or characteristics
- F05D2300/502—Thermal properties
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
本发明涉及用于制造物件的过程。具体而言,提供了一种制造物件的过程(100)以及形成的物件。该过程(100)包括制造近终形部件(121)。该方法(100)包括通过增材制造形成固结壳(101)。固结壳(101)限定具有与部件(121)对应的几何形状的内部空间。提供金属粉末至内部空间。从内部空间去除气体(113)。使金属粉末在足够的热和压力下在固结壳(101)中固结以形成近终形部件(121)。
Description
技术领域
本发明针对用于制造物件的过程以及由该过程形成的物件。更具体地,本发明针对用于形成具有精细颗粒结构的高温部件的方法。
背景技术
涡轮系统被不断地改进以增加效率和降低成本。用于增加涡轮系统效率的一种方法包括增加涡轮系统的操作温度。为了增加涡轮系统的操作温度,各个部件必须构造为经得起增加的温度。
过去,与涡轮系统一起使用的高温物件通过常规锻造技术形成。常规锻造技术可能昂贵,只能由少数设施执行,可能导致不可用的废料,且可能容易开裂、氧化和/或被外物污染。另外,高温合金在锻造过程期间容易开裂,这影响过程产量和最终的部件成本。
用于形成高温部件的另一种已知方法是铸造成近终形。然而,近终形铸造技术产生粗颗粒、不均匀的微观结构以及孔隙缺陷,这影响了机械特性和部件性能。
已知的粉末冶金过程通常产生需要过量的机加工和耗费的粗制形状。这种粉末冶金部件需要大量的二次机加工,导致过多的材料浪费。
相比于现有技术显示出一种或多种改进的方法和物件将是本领域中期望的。
发明内容
在一个实施例中,制造物件的过程包括制造近终形部件。该过程包括通过增材制造形成固结壳。固结壳限定具有与部件对应的几何形状的内部空间。提供金属粉末至内部空间。从内部空间去除气体。使金属粉末在足够的热和压力下在固结壳中固结以形成近终形部件。
在另一个实施例中,固结壳包括具有与部件对应的几何形状的内部空间。固结壳还包括从内部空间延伸的管道。金属粉末存在于内部空间中。
在另一个实施例中,部件包括通过增材制造形成的固结壳。固结壳限定具有与部件对应的几何形状的内部空间。内部空间至少部分地填充有固结粉末。
技术方案1.一种制造近终形部件的过程,所述过程包括:
通过增材制造形成固结壳,所述固结壳限定具有与部件对应的几何形状的内部空间;
提供金属粉末至所述内部空间;
从所述内部空间去除气体;以及
使所述金属粉末在足够的热和压力下在所述固结壳中固结以形成所述近终形部件。
技术方案2.根据技术方案1所述的过程,其中,所述固结包括热等静压。
技术方案3.根据技术方案1所述的过程,其中,所述金属粉末包括选自由镍、钴、钛、铁、其合金以及其组合组成的组的金属。
技术方案4.根据技术方案1所述的过程,其中,与所述部件对应的所述几何形状包括在固结后形成所述近终形部件的几何形状。
技术方案5.根据技术方案1所述的过程,其中,所述过程还包括去除所述固结壳。
技术方案6.根据技术方案5所述的过程,其中,去除所述固结壳包括选自由机械去除、电学去除或化学去除组成的组的去除过程。
技术方案7.根据技术方案1所述的过程,其中,所述固结壳包括第二可去除材料以在所述部件中形成通道。
技术方案8.根据技术方案1所述的过程,其中,所述近终形部件是压缩机叶片。
技术方案9.根据技术方案1所述的过程,其中,提供金属粉末至所述内部空间包括提供第一金属粉末和第二金属粉末。
技术方案10.根据技术方案9所述的过程,其中,所述第一金属粉末和所述第二金属粉末具有不同的成分。
技术方案11.根据技术方案9所述的过程,其中,所述第一金属粉末和所述第二金属粉末具有不同的特性。
技术方案12.根据技术方案1所述的过程,其中,所述固结壳在所述部件上形成涂层材料。
技术方案13.一种固结壳,包括:
具有与部件对应的几何形状的内部空间;以及
从所述内部空间延伸的管道;
其中金属粉末存在于所述内部空间中。
技术方案14.根据技术方案13所述的固结壳,其中,所述部件是压缩机叶片。
技术方案15.根据技术方案13所述的固结壳,其中,所述金属粉末是选自由镍、钴、钛、铁、其合金以及其组合组成的组的金属。
技术方案16.根据技术方案13所述的固结壳,其中,所述金属粉末包括第一金属粉末和第二金属粉末。
技术方案17.一种部件,包括:
通过增材制造形成的固结壳,所述固结壳限定具有与所述部件对应的几何形状的内部空间,所述内部空间至少部分地填充有固结粉末。
技术方案18.根据技术方案17所述的部件,其中,所述部件选自由涡轮轮叶、压缩机叶片、压缩机导叶、翼型件节段、喷嘴、护罩以及燃烧部件组成的组。
技术方案19.根据技术方案17所述的部件,其中,所述部件是压缩机叶片。
技术方案20.根据技术方案17所述的部件,其中,所述固结壳在所述部件上形成涂层。
本发明的其他特征和优点从下面结合附图更详细的描述将变得显而易见,附图通过示例的方式示出本发明的原理。
附图说明
图1是根据本发明的实施例的用于制造的过程和物件的示意图。
图2是根据本发明的实施例的部件的透视图。
图3是根据本发明的实施例的图2的部件沿方向3-3的截面图。
图4是根据本发明的实施例的图2的部件沿方向3-3的截面图。
在任何可能之处,将在附图各处使用相同的参考标号以表示相同的部分。
具体实施方式
提供了物件和用于制造物件的过程。例如,本公开内容的实施例相比于不包括本文公开的一个或多个特征的概念,减少了制造浪费,缩短了循环时间,允许形成具有均匀且精细颗粒微观结构的部件、形成具有高温操作的部件、具有较高压缩机比率和效率的涡轮操作、形成近终形部件、灵活的设计,例如,用于部件冷却/流体加热/轻量设计,包括复杂的几何形状。在一个实施例中,部件和固结壳可以由相同的粉末材料形成,这减少或消除了不同的金属反应区,或者它们的组合。在一个实施例中,本公开内容是一种模块化过程并按期望允许用作用于燃气涡轮部件的自动化/机器人化制造单元。在一个实施例中,在压紧作用下发生的收缩率的调整允许形成具有最低限度或无机加工的近终形部件。在该实施例中,外壳由部件的所需合金制成。
如图1中所示,在过程100中的步骤200中,固结壳101通过增材制造过程形成。增材制造技术形成具有内部空间的固结壳,内部空间具有对应于部件近终形结构的几何形状。如本文中所用,“近终形”表示在增材制造之后,部件121形成得非常接近部件121的最终形状,不需要大量的传统的机械修整技术,诸如切削加工或打磨。增材制造技术从用于增材制造技术的任何适合材料形成固结壳101。在一个实施例中,增材制造技术包括但不限于本领域的普通技术人员已知的直接金属激光熔化(DMLM)、直接金属激光烧结(DMLS)、选择性激光烧结(SLS)、选择性激光熔化(SLM)、电子束熔化(EBM)、熔化层积成型(FDM),或它们的组合。
在一个实施例中,增材制造方法是DMLS。如图1中所示,DMLS包括能量源103,诸如激光器,它朝具有粉末金属106的平台107引导高能射束105,粉末金属被烧结以形成实体。能量源103和高能射束105根据计算模型或程序化路径而移动和引导,以形成具有受控几何形状的实体部件。如图1中所示,所形成的受控几何形状是固结壳101。
在另一个实施例中,增材制造方法是DMLM,且包括将材料的第一层分布至指定区域,将第一层选择性地激光熔化,在第一层上分布材料的至少一个附加层,且选择性地激光熔化该至少一个附加层中的每一层。在该实施例中,第一层和该至少一个附加层的选择性激光熔化形成固结壳101。在另一个实施例中,材料是粉化粉末。在另一个实施例中,DMLM在惰性气体的气氛中执行。在一个实施例中,FDM包括给喷嘴供应材料,加热喷嘴,通过喷嘴挤出材料。当材料穿过喷嘴时,喷嘴的加热熔化材料。在材料通过喷嘴挤出后,材料硬化,形成固结壳101。适合用于增材制造的材料包括但不限于,金属、陶瓷、合金、超级合金、钢、不锈钢、工具钢、镍、钴、铬、钛、铝、或它们的组合。在一个实施例中,部件的固结壳101由具有有利特性的材料制成,比如耐腐蚀性和抗氧化性。例如,固结壳101由已知的耐腐蚀和/或抗氧化成分制成,以赋予耐腐蚀性和/或抗氧化性。同样地,在另一个实施例中,如果需要耐腐蚀性,使用耐腐蚀壳形成固结壳101。
在另一个实施例中,固结壳101限定包括由第二金属或合金(诸如能通过物理或化学手段去除的金属或合金)形成的内部空间或内壁的部件几何形状。例如,第二可去除材料(诸如金属或合金)是活泼材料,诸如镁或铝。活泼材料是相比于不活泼材料(诸如镍基材料)具有较大活性的材料。在该实施例中,活泼材料能从部件滤去或蚀去,从而产生例如用于流体流(气体或液体)、加热或冷却或者用于减重空间的通道。
固结壳101包括限定内部空间的壁,该内部空间具有与部件121对应的几何形状。固结壳101形成为包括内部空间,该内部空间具有与所需部件的几何形状对应的几何形状。在一个实施例中,内部空间包括与近终形部件相同的几何形状或通过加工改变而形成近终形部件。例如,固结壳几何形状和尺寸将包括内部空间,其为固结期间可能发生的三维收缩的原因。与所需部件的几何形状对应的几何形状是在固结后形成部件121的所需几何形状的几何形状。在另一个实施例中,与所需部件对应的几何形状包括其中固结壳101去除后的表面。在一个实施例中,多个固结壳101接合在一起,例如通过焊接,从而允许同时处理多个部件。
由增材制造过程形成的固结壳101包括从固结壳101的内部空间延伸且通往外部空间的管道102或类似结构。管道102形成为具有几何形状并在允许利用粉末填充固结壳101且允许气体排出的位置中形成。管道102在具有减少或消除对固结后的部件121的几何形状的影响的几何形状的位置中形成。
一旦固结壳101形成,将金属粉末111提供给固结壳101(步骤201)。在另一个实施例中,在通过增材制造过程形成固结壳101期间可将金属粉末111引入固结壳101。固结壳101至少部分地填充有来自金属粉末源109的金属粉末111。在一个实施例中,金属粉末111是精细颗粒粉末。合适的精细颗粒粉末允许在固结后形成精细颗粒高强度合金。金属粉末的合适的颗粒尺寸是例如筛目大小,可以在大约-80目到+325目之间,或者从大约-140目到+270目。如果粉末颗粒太小,粉末流入固结壳101内的流动性被抑制。如果粉末颗粒太大,粉末的堆积密度减小,且所获得的部件121的颗粒尺寸可能不是期望的。在一个实施例中,金属粉末111是选自由镍、钴、钛、铁、其合金以及它们的组合组成的组的金属。在一个实施例中,固结壳101填充有单一成分的金属粉末111。在一个实施例中,固结壳101的一部分至少部分地填充有第一成分的金属粉末111,且固结壳101的其余部分填充有第二成分的金属粉末111,其中第一成分和第二成分具有不同的特性。在另一个实施例中,第一成分和第二成分在颗粒尺寸上不同。在一个实施例中,金属粉末111的特性与部件121的区段的特性匹配。在一个实施例中,金属粉末111的特性与固结壳101的特性相同或基本相同。例如,金属粉末111的粉末颗粒尺寸被调整为适用于部件121。在一个实施例中,金属粉末的颗粒尺寸选择为给部件121提供所需的特性。例如,选择的粉末颗粒尺寸提供作为特殊的固定的或旋转的燃气涡轮部件使用必需的机械特性和耐热特性。根据应用所需要的机械特性,合适的颗粒尺寸的示例包括比ASTM 15更精细、或者从大约ASTM 2到ASTM 15、或者比ASTM 3更精细、或者比ASTM 5更精细、或者比ASTM 8更精细、或者从大约ASTM 8到大约ASTM12的平均颗粒尺寸。本公开内容对ASTM颗粒尺寸的参考符合美国测试与材料协会建立的标准尺度。
用于金属粉末111的其他材料包括,例如按重量比的成分:约10%镍、约29%铬、约7%钨、约1%铁、约0.25%碳、约0.01%硼,以及余量钴(例如,FSX414);约0.015%硼、约0.05%到约0.15%碳、约20%到约24%铬、约3%铁、约0.02%到约0.12%镧、约1.25%锰、约20%到约24%镍、约0.2%到约0.5%硅、约13%到约15%钨、以及余量钴(例如,188);约22.5%到约24.25%铬、可达约0.3%钛(例如,约0.15%到约0.3%钛)、约6.5%到约7.5%钨、约9%到约11%镍、约3%到约4%钽、可达约0.65%碳(例如,约0.55%到约0.65%碳)、可达约0.55%锆(例如,约0.45%到约0.55%锆),以及余量钴(例如,Mar-M-509);约0.05%碳、约20%镍、约20%铬、约0.1%锆、约7.5%钽,以及余量钴(例如,Mar-M-918);约6.6%到约7.0%铬、约11.45%到约12.05%钴、约5.94%到约6.30%铝、约0.02%钛、约4.70%到约5.10%钨、约1.3%到约1.7%钼、约2.6%到约3.0%铼、约6.20%到约6.50%钽、约1.3%到约1.7%铪、约0.10%到约0.14%碳、约0.0035%锰、约0.03%锆、约0.01%到约0.02%硼、约0.2%铁、约0.06%硅、约0.1%钾、约0.004%硫、约0.1%铌,以及余量镍(例如,René142);约13.70%到约14.30%铬、约9%到约10%钴、约3.2%铝、约4.8%到约5.20%钛、约3.7%到约4.3%钨、约0.1%铼、可达约4.3%铼和钨的组合、约0.5%钽、约0.1%铪、约0.15%到约0.19%碳、约0.15%钯、约0.3%铂、约0.01%镁、约0.02%到约0.1%锆、约0.01%到约0.02%硼、约0.35%铁、约0.1%硅、约0.1%锰、约0.015%磷、约0.0075%硫、约0.1%铌,以及余量镍(例如,René80);约0.08到约0.12%碳、约22.2%到约22.8%铬、约0.10%锰、约0.25%硅、约18.5%到约19.5%钴、约1.8%到约2.2%钨、约2.3%钛、约1.2%铝、约1.0%钽、约0.8%铌、约0.05%锆、约0.008%硼,以及余量镍(例如,可从通用电气公司获取的);约20%到约24%铬、约10%到约15%钴、约8%到约10%钼、约0.8%到约1.5%铝、约0.05%到约0.15%碳、约3.0%铁、约1.0%锰、约0.015%硅、约0.015%硫、约0.6%钛、约0.5%铜、约0.006%硼,以及余量镍(例如,617);约5%铁、约20%到约23%铬、可达约0.5%硅、约8%到约10%钼、可达约0.5%锰、可达约0.1%碳、以及余量镍(例如,625);约50%到约55%镍和钴的组合、约17%到约21%铬、约4.75%到约5.50%铌和钽的组合、约0.08%碳、约0.35%锰、约0.35%硅、约0.015%磷、约0.015%硫、约1.0%钴、约0.35%到0.80%铝、约2.80%到约3.30%钼、约0.65%到约1.15%钛、约0.001%到约0.006%硼、约0.15%铜,以及余量铁(例如,718);马氏体不锈钢,其具有按重量比的标称成分:15.5%铬、6.3%镍、1.5%铜、0.37%铌(可达0.4%的铌)、0.05%碳,以及余量铁(例如,可从通用电气公司获取的GTD-450);约0.15%碳、约1.00%锰、约0.50%硅、约11.5%到约13.0%之间的铬、约0.04%磷、约0.03%硫,以及余量铁(例如,403Cb);约0.15%碳、约0.60%锰、约0.40%硅、约0.50%镍、约10.8%铬、约0.85%钼、约0.22%钒、约0.39%铌,以及余量铁(例如,403Cb+);约20%铬、约10%钴、约8.5%钼、可达约2.5%钛、约1.5%铝、可达约1.5%铁、可达约0.3%锰、可达约0.15%硅、约0.06%碳、约0.005%硼,以及余量镍(282);约18%铬、约14.8%钴、约3.0%钼、约1.25%钨、约5%钛、约2.5%铝、约0.035%碳、约0.033硼、约0.03锆,以及余量镍(例如,720)。″INCONEL″是由西弗吉尼亚州亨廷顿的Huntington AlloysCorporation生产的合金的联邦注册商标。″HAYNES″是由印第安那州科科莫的Haynes International,Inc.生产的合金的联邦注册商标。″UDINIET″是由纽约州哈特福德的Special Metals Corporation生产的合金的联邦注册商标。
然后,气体113从固结壳101排出(步骤203)。气体113的去除或固结壳101的排空可以经由真空设备115通过管道102抽真空来实现。在一个实施例中,真空设备115包括具有足够小的筛目大小的筛网或过滤器,以防止粉末在固结壳101的排空期间逸出。
在从固结壳101去除气体后,使用任何合适的手段将管道102密封。例如,在一个实施例中,通过使管道102机械地卷曲将固结壳101密封。在一个实施例中,管道102被机械地卷曲、加热、在卷曲端上TIG焊接。
包括金属粉末111的固结壳101在一段时间内且在足以使固结壳101中的金属和/或合金粉末压实的温度和压力下经历固结的步骤。用于固结的时间、温度和压力条件将必然根据合金成分和包括其熔点、粉末类型、颗粒尺寸以及堆积密度在内的粉末特性而改变。如图1中所示,在步骤204中,将固结壳101提供至高压密闭容器117。高压密闭容器117提供受控的气氛119,以使金属粉末111在固结壳101中固结。在一个实施例中,固结通过热等静压(HIP)完成。HIP包括在高压密闭容器117中的惰性气氛中同时施加的热和压力。在一个实施例中,固结的条件包括在大约45ksi到大约60ksi的压力下加热到大约2600到大约3000°F。在另一个实施例中,理想的是对固结壳101和金属粉末111施加压力,随后是单独的加热步骤,以将粉末颗粒烧结。相反地,对于一些合金而言,在烧结或部分地烧结金属粉末111后,再施加压力以压实金属粉末111也是所期望的。
固结产生了近终形几何形状的部件121(步骤205)。在一个实施例中,将部件121机加工以去除管道102。在一个实施例中,将固结壳101从部件121去除。在一个实施例中,固结壳101的去除例如通过使用已知的机械材料去除方法的机加工而机械地完成。在一个实施例中,固结壳101的去除使用已知的材料去除方法而化学地或电学地完成。部件121包括精细颗粒结构。例如,部件121的微观结构包括提供例如作为特殊的固定或旋转燃气涡轮部件使用必需的期望的机械或耐热特性的微观结构。例如,部件121包括比ASTM 15更精细、或者从大约ASTM 2到ADTM 15、或者比ASTM 3更精细、或者比ASTM 5更精细、或者比ASTM 8更精细、或者从大约ASTM 8到大约ASTM 12的颗粒尺寸。
在一个实施例中,方法100是自动化的。在一个实施例中,图1中所示的步骤在没有手动处理的情况下执行。例如,在一个实施例中,方法100的步骤由自动化设备在单个抽空的容器或气氛中执行。自动化过程减少或消除由大气污染物或手动处理导致污染的风险。例如,抽空的容器或气氛中的金属粉末111减少暴露至污染物,并将导致部件121中的颗粒污染的风险减少。
图2示出了根据本发明的实施例的部件121。部件121是具有与操作中的部件的几何形状相同或基本相同的几何形状的近终形部件。图2中所示的部件121是涡轮轮叶、压缩机叶片或压缩机导叶。其他合适的部件121包括翼型件节段、喷嘴、护罩、燃烧部件、和/或任何其他合适的高温涡轮部件。根据一个实施例,图3示出了显示沿图2的方向3-3的截面图的实施例。在该实施例中,部件121包括固结部101。图4示出了一个实施例,其显示了备选实施例的沿图2的方向3-3的截面图,其中固结壳101已经被去除。合适的去除方法包括机械去除或其他机加工过程。
尽管已经参考一个或多个实施例描述了本发明,但本领域技术人员应当理解,在不脱离本发明范围的情况下可以做出各种改变且对于其元件可替代等同物。另外,在不脱离其实质范围的情况下,可以做出很多修改以适应根据本发明的教导的特殊情况或材料。因此,意在使本发明不限于如用于实现本发明所构思的最佳模式而公开的特定实施例,而是本发明将包括落入所附权利要求的范围内的所有实施例。另外,在详细描述部分中标出的所有数值应当被理解为明确地标出了精确值和近似值。
Claims (10)
1.一种制造近终形部件(121)的过程(100),所述过程(100)包括:
通过增材制造形成固结壳(101),所述固结壳(101)限定具有与部件(121)对应的几何形状的内部空间;
提供金属粉末至所述内部空间;
从所述内部空间去除气体(113);以及
使所述金属粉末在足够的热和压力下在所述固结壳(101)中固结以形成所述近终形部件(121)。
2.根据权利要求1所述的过程(100),其特征在于,所述固结包括热等静压。
3.根据权利要求1所述的过程(100),其特征在于,所述金属粉末包括选自由镍、钴、钛、铁、其合金以及其组合组成的组的金属。
4.根据权利要求1所述的过程(100),其特征在于,与所述部件(121)对应的所述几何形状包括在固结后形成所述近终形部件(121)的几何形状。
5.根据权利要求1所述的过程(100),其特征在于,所述过程还包括去除所述固结壳(101)。
6.根据权利要求5所述的过程(100),其特征在于,去除所述固结壳(101)包括选自由机械去除、电学去除或化学去除组成的组的去除过程(100)。
7.根据权利要求1所述的过程(100),其特征在于,所述固结壳(101)包括第二可去除材料以在所述部件(121)中形成通道。
8.根据权利要求1所述的过程(100),其特征在于,所述近终形部件(121)是压缩机叶片。
9.根据权利要求1所述的过程(100),其特征在于,提供金属粉末至所述内部空间包括提供第一金属粉末和第二金属粉末。
10.根据权利要求9所述的过程(100),其特征在于,所述第一金属粉末和所述第二金属粉末具有不同的成分。
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