EP0072175B1 - Method of producing a monolithic alloy component preform - Google Patents

Method of producing a monolithic alloy component preform Download PDF

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Publication number
EP0072175B1
EP0072175B1 EP82304080A EP82304080A EP0072175B1 EP 0072175 B1 EP0072175 B1 EP 0072175B1 EP 82304080 A EP82304080 A EP 82304080A EP 82304080 A EP82304080 A EP 82304080A EP 0072175 B1 EP0072175 B1 EP 0072175B1
Authority
EP
European Patent Office
Prior art keywords
preform
alloys
alloy
interface
powdered
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.)
Expired
Application number
EP82304080A
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German (de)
English (en)
French (fr)
Other versions
EP0072175A1 (en
Inventor
Rolf Jan Mowill
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MOWILL, JAN
Original Assignee
Individual
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Filing date
Publication date
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Publication of EP0072175A1 publication Critical patent/EP0072175A1/en
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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
    • 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

Definitions

  • This invention relates to a method of producing a multi-alloy component preform, in which a plurality of powdered alloys are introduced into an outer mold or can having an inner shape corresponding to the outer shape of the desired preform, the main bulk of each powdered alloy being substantially confined to a respective portion of the preform by providing a confining means substantially separating two different alloys and defining an interface therebetween, and consolidating the powdered alloys into a preform.
  • US-A-3510935 describes a process of manufacturing rod-shaped multilayer semi-finished material in which a block mold is filled with two or more different powders separated by removable partitions. That edge of each partition which is at the bottom during the charging of the powders is serrated, canted or roughened. When each partition is removed, an interlayer is formed with gradual transition between the two different powders which had been separated by the partition. The powders are then compacted and sintered in the block mold.
  • GB-A-530639 describes a process in which powdered iron or steel is placed in a mold the shape of which corresponds to a part to be made, those parts of the mold in which there are to be hard metal insets or added parts when the article is finished being left free.
  • the iron or steel powder is then covered with a thin plate, a metal foil or a wire fabric, and the remaining part of the mold which corresponds to the hard metal inset or added part is then filled with a mixture of the desired hard metal and an auxiliary metal.
  • Sintering is then carried out with the intermediate plate, foil or fabric combining with the separated metals to form a homogeneous body. Compression is effected before or during the sintering.
  • the different alloys and properties thereof are utilized in a single component by bringing the alloys together in powder form prior to powder consolidation.
  • Such consolidation may be hot isostatic pressing (HIP), consolidation at atmospheric pressure (CPA) etc.
  • a method of the type defined hereinbefore is characterised in that the confining means has a grid or screen structure to allow a controlled mixing of the powdered alloys through the perforations and a minimum separation of the alloys, eliminating the need for removing the confining means before consolidating the preform.
  • a method of the type defined hereinbefore is characterised in that the confining means defines an interface having a large number of protrusions and/or recesses from the general geometric shape of the confining means thereby providing an extended interface and that the material of the confining means is selected so as to provide desired alloy elements to one or both of the alloys adjacent the said interface, thus producing an interface alloy containing the material of the confining means.
  • a radial flow turbine wheel preform 10 is shown to consist of an inner hub portion of alloy B and an outer blade portion in alloy A bonded together into a monolithic component at an interface or rather an interface zone 11.
  • Fig. 3 the method of producing such a preform in the form of a cylindrical disc having concentric alloy portion is diagrammatically illustrated.
  • the preform is initially shaped by means of an outer mold or can 12 which the powdered alloys fill.
  • the outer can 12 is positioned in an enclosure 13 placed under vacuum or filled with inert gas to prevent oxidation of the powder particles as well known in the art.
  • a confining means in the form of a basket 14 is positioned concentrically within the outer can 12. The two concentric compartments on either side of the basket 14 are filled with the two alloys as indicated.
  • the interface-forming basket 14 may have a grid or screen structure, or it can be made from a perforated sheet, as a zig-zag wall with or without perforations, as a smooth wall etc.
  • the purpose of the basket is one or more of the following:
  • the controlled mixing of the powdered alloy particles to provide the interface zone can be obtained by allowing a controlled flow of one powder into the other through the basket 14, when in form of a grid, a screen or the like.
  • the filling operation may be controlled so that the rising powder level in one compartment precedes that in the other by a fixed or variable height (h) so that a powder flow from this one to the other compartment can take place above the level in the other compartment with the only restriction being offered by the grid itself.
  • h the specific gravity of the two powders as well as other factors which will influence the behaviour of the flow of powder into the other compartment will have to be taken into account.
  • the height h and/or the restriction offered by the grid can be controlled to vary the amount of mixing of one alloy into the other and/ or the thickness of the resulting interface zone. Variation of the latter can be used to compensate for interface zone slimming during subsequent forging of the preform.
  • the controlled transfer of portions of one powdered alloy into the adjacent layer of the other powdered alloy can also be achieved in other ways, for instance by rotating the inner basket 14 or even rotating the basket as well as the outer can 12 using the centrifugal force to provide said controlled transfer. Shaking would be a further alternative. Instead of transferring powder particles, merely one or more elements of one alloy may be transferred across the interface to form an interface zone, and this may be accomplished by diffusion when the basket 14 has been removed prior to or during the consolidation step or possible further metallurgical treatment.
  • a zig-zag type basket as shown in Fig. 4 would provide a considerable interface zone by diffusion alone.
  • the basket 14 may be removed by decomposing or melting the material in the basket whereupon the molten or decomposed material is extracted and/or evaporated.
  • the material may also be incorporated in one or both of the alloys A or B or in the interface alloy.
  • Both the basket 14 and the outer can 12 may have different shapes in order to give the best final outer shape and interface configuration as illustrated in Fig. 5 for the basket 14.
  • the powder preform After the powder preform has been consolidated, for example by hot isostatic pressing, it may be subjected to superplastic or hot die forging in which the material will flow into its near net shape. The turbine wheel blank would then be ready for heat treatment and final machining. Hot isostatic pressing may be used to shape the preform to final near net shape instead of merely for consolidation purposes.
  • the method described will provide a sound monolithic structure without the many uncertain aspects connected with diffusion bonding of solid parts.
  • the interface alloy will provide a compliance zone between the two alloys which for example could have a coefficient of expansion between those of the alloys A and B after the powder preform has been consolidated.
  • a pressing and/or forging operation can follow which will give final dimensions prior to machining, as shown as an example in Fig. 6, in which the interface is indicated at 11 before forging and at 15 after forging.
  • the outer contour of the preform is indicated at 16 and that of the final turbine wheel at 17.
  • the line 16' indicates the contour between the blade and the hub portion of the turbine wheel.
  • Trial and error methods will have to be used to determine the interface configuration 11 in the preform 10 which will result in the desired interface configuration 15 in the final component.
  • the interface alloy now has properties which lies between those of A and B. Thus, there is no sharp "bonding line" between the two alloys.
  • a preform according to the invention can consist of more than two alloys and more than one basket 14.
  • a basket can be pre-loaded with powder prior to inserting the basket into the outer can. This is illustrated in Fig. 7, in which a basket 14' preloaded with powdered alloy B and a basket 14" preloaded with powdered alloy C may be placed into the outer can 12, whereupon a powdered alloy A may be introduced to fill the remaining space between the two baskets.
  • the baskets would have an internal air tight seal 18 of a material which would easily be decomposed and may be extracted or absorbed into the powder on either side of the basket when exposed to the operation temperature of the consolidation process or to other influences.
  • material C could be an alloy which is resistant to corrosion and abrasion at high temperature, whereas the requirement for high ultimate tensile strength is less than for the alloys A and B.
  • the alloy B would be the alloy of the highest tensile strength.
  • the properties of alloy A would fall between those of alloys B and C.
  • the method of the invention has the potential of giving turbines the ability to operate at very high temperatures and tip-speeds without incurring risk of failure by inadequate and unreliable bonding.
  • the method offers numerous interface geometry choices for the optimization of the structural properties of the finished turbines.
  • alloy should be taken to refer to any solid, structural composition composed of two or more chemical elements of which at least one is a metal, providing this composition lends itself to powder metallurgy processing methods including consolidation steps.
  • alloy not only mixtures of elemental metals, but also compositions such as metal carbides and ceramic materials are comprised by the term "alloy" as used in the present Specification.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Medicines Containing Antibodies Or Antigens For Use As Internal Diagnostic Agents (AREA)
EP82304080A 1981-08-07 1982-08-02 Method of producing a monolithic alloy component preform Expired EP0072175B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO812680 1981-08-07
NO812680A NO150668C (no) 1981-08-07 1981-08-07 Fremgangsmaate til fremstilling av et monolittisk maskindelemne med partier av forskjellig legeringssammensetning ved pulvermetallurgi

Publications (2)

Publication Number Publication Date
EP0072175A1 EP0072175A1 (en) 1983-02-16
EP0072175B1 true EP0072175B1 (en) 1986-01-08

Family

ID=19886182

Family Applications (1)

Application Number Title Priority Date Filing Date
EP82304080A Expired EP0072175B1 (en) 1981-08-07 1982-08-02 Method of producing a monolithic alloy component preform

Country Status (4)

Country Link
EP (1) EP0072175B1 (no)
JP (1) JPS5842703A (no)
DE (1) DE3268398D1 (no)
NO (1) NO150668C (no)

Families Citing this family (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4602952A (en) * 1985-04-23 1986-07-29 Cameron Iron Works, Inc. Process for making a composite powder metallurgical billet
US4721598A (en) * 1987-02-06 1988-01-26 The Timken Company Powder metal composite and method of its manufacture
GB2233000A (en) * 1989-05-25 1991-01-02 Gkn Technology Ltd Connecting rod
SE503422C2 (sv) * 1994-01-19 1996-06-10 Soederfors Powder Ab Sätt vid framställning av en sammansatt produkt av rostfria stål
US5762843A (en) * 1994-12-23 1998-06-09 Kennametal Inc. Method of making composite cermet articles
US5541006A (en) * 1994-12-23 1996-07-30 Kennametal Inc. Method of making composite cermet articles and the articles
US6183687B1 (en) 1995-08-11 2001-02-06 Kennametal Inc. Hard composite and method of making the same
US5623723A (en) * 1995-08-11 1997-04-22 Greenfield; Mark S. Hard composite and method of making the same
JP2000080407A (ja) * 1998-09-03 2000-03-21 Ykk Corp 成形品の製造方法
US6908688B1 (en) 2000-08-04 2005-06-21 Kennametal Inc. Graded composite hardmetals
US7967924B2 (en) * 2005-05-17 2011-06-28 General Electric Company Method for making a compositionally graded gas turbine disk
GB0920697D0 (en) * 2009-11-26 2010-01-13 Rolls Royce Plc Method of manufacturing a multiple composition component
US9475118B2 (en) * 2012-05-01 2016-10-25 United Technologies Corporation Metal powder casting
GB2523583C (en) * 2014-02-28 2019-12-25 Castings Tech International Limited Forming a composite component
DE102014006371A1 (de) * 2014-05-05 2015-11-05 Gkn Sinter Metals Engineering Gmbh Wasserstoffspeicher-Herstellvorrichtung nebst Verfahren hierzu und Wasserstoffspeicher
CN115070043A (zh) * 2021-03-10 2022-09-20 中国航发商用航空发动机有限责任公司 一种gh4065a和gh4169同种、异种材料多级转子组件及其制备方法

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB530639A (en) * 1938-06-16 1940-12-17 Meutsch Voigtlaender & Co Process for the production of articles provided with coatings or insets of hard metal
GB1149769A (en) * 1966-01-03 1969-04-23 Eugen Durrwachter Process and apparatus for the manufacture of multilayer blocks
US3862286A (en) * 1972-10-10 1975-01-21 Aluminum Co Of America Method of fabricating compacted powdered metal extrusion billets

Also Published As

Publication number Publication date
DE3268398D1 (en) 1986-02-20
NO150668B (no) 1984-08-20
EP0072175A1 (en) 1983-02-16
JPS5842703A (ja) 1983-03-12
NO150668C (no) 1984-11-28
NO812680L (no) 1983-02-08

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