EP0090118B1 - Keramikform und Verfahren zur Herstellung derselben - Google Patents

Keramikform und Verfahren zur Herstellung derselben Download PDF

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Publication number
EP0090118B1
EP0090118B1 EP82306346A EP82306346A EP0090118B1 EP 0090118 B1 EP0090118 B1 EP 0090118B1 EP 82306346 A EP82306346 A EP 82306346A EP 82306346 A EP82306346 A EP 82306346A EP 0090118 B1 EP0090118 B1 EP 0090118B1
Authority
EP
European Patent Office
Prior art keywords
mould
ceramic
article
mould cavity
cavity
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
EP82306346A
Other languages
English (en)
French (fr)
Other versions
EP0090118A1 (de
Inventor
Vijay Kumar Chandhok
Karl Simms Brosius
William Lee Mccollough
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.)
Crucible Materials Corp
Original Assignee
Crucible Materials Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Crucible Materials Corp filed Critical Crucible Materials Corp
Priority to AT82306346T priority Critical patent/ATE18364T1/de
Publication of EP0090118A1 publication Critical patent/EP0090118A1/de
Application granted granted Critical
Publication of EP0090118B1 publication Critical patent/EP0090118B1/de
Expired legal-status Critical Current

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Classifications

    • 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
    • B22F3/1275—Container manufacturing by coating a model and eliminating the model before consolidation
    • 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
    • B22F3/1216—Container composition
    • B22F3/1241—Container composition layered
    • 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
    • B22F3/1283—Container formed as an undeformable model eliminated after consolidation

Definitions

  • This invention relates to ceramic moulds and to a method of producing same.
  • the ceramic mould has an interior which conforms to the desired configuration of the article to be produced.
  • the cavity is filled with powdered metal, the mould is sealed, heated and then subjected to force sufficient to compact the powdered metal therein to form a dense article.
  • the preferred compacting method is to place the powder filled mould at elevated temperature in an autoclave for hot isostatic pressing by the use of a gas, such as helium.
  • One practice for producing moulds of this type involves making a wax pattern of the configuration of the article to be produced and then casting the ceramic around the pattern so that the interior of the ceramic conforms to the surface configuration of the pattern and thus the article to be produced. An opening is provided in the ceramic through which upon heating the wax may be melted to expose the cavity. Thereafter the cavity is filled with powdered metal and the powder is compacted in the conventional manner as by hot isostatic compacting.
  • a ceramic mould body having a mould cavity therein with the surface of the mould cavity conforming substantially to the configuration of the article to be produced.
  • the mould cavity is generally somewhat "oversize" with respect to the final article to allow for shrinkage during compacting.
  • An opening is provided for filling the cavity with powdered metal and thereafter sealing it prior to compacting.
  • the mould cavity has a continuous metal coating covering its surface. This prevents contact between the metal powder and the ceramic material of the mould and thus acts as a barrier to prevent contamination by impurities such as oxides from entering the powder during the heating and compacting cycle.
  • a preferred material for this coating is nickel or nickel-base alloys as they remain continuous during the high temperatures incident to hot compacting operations such as hot isostatic pressing.
  • the alloy powders are generally superalloys, such as nickel, iron or cobalt-base alloys, and titanium- base alloys for use in high temperature applications, such as jet engine components and the like.
  • the mould of the invention is also suitable for use with high speed steels and tool steels.
  • the mould is segmented into at least two selectively separated parts. When separated the interior can be coated with the metal and then the parts can be joined to form the integral mould.
  • a preferred method for applying the coating so that it is thin and continuous involves vapour deposition.
  • Figure 1 shows two identical mould segments in cross-section identified as 10 having a ceramic body portion 12 with a mould cavity 14 conforming to the configuration of the article to be produced, which in this case is a gearwheel.
  • the gear teeth 16 are defined in the interior surface of the body 12. This may be achieved by dipping a wax pattern conforming substantially to the shape of the gear wheel in a refractory slurry and then melting away the wax after drying the refractory material. Although this method is preferred, any other method may be used for producing the mould.
  • the interior surfaces of the mould cavity are coated with a metal 18, as shown in Figure 2, and the segments are joined and filled with powdered metal 20. The mould is then sealed and compacted such as by hot isostatic compacting.
  • a ceramic shell was internally coated with nickel using the chemical vapour deposition (CVD) process. This involved injecting nickel carbonyl gas into the heated shell, whereupon the nickel metal was deposited by thermal decomposition of the gas onto the surface of the shell cavity. A coating was produced with certain areas left bare. The coating thickness was of the order of 0.0254 to 0.254 mm (1 to 10 mils).
  • the shell was then processed in a normal manner to produce a powder metallurgy part, using a conventional nickel-base superalloy powder (Rene 95). The resulting compact was normal with an unusually bright surface appearance.
  • Metallographic examination revealed a nickel surface coating, a boundary layer of interdiffusion products, and the Rene 95 base metal (see Figure 4).
  • the Rene 95 powder particles are outlined by a contamination layer, a normal phenomenon with the conventional ceramic mould process (see Figure 5).
  • the nickel coating is thus seen to provide protection for contamination for the Rene 95 base metal from which the final compacted superalloy is to be made.
  • a ceramic shell was split and the interior of the shell conforming to the powder metallurgy article to be produced was coated with nickel by the ion deposition process wherein metal atoms are directly deposited on the target surface in a vacuum chamber.
  • the coating thickness was of the order of 0.00254 mm (.1 mils).
  • the shell was then processed in a normal manner to produce a powder metallurgy part, using titanium alloy powder. This included filling the shell with titanium alloy powder, evacuating, heating and hot-isostatic pressing to compact the powder to full density. The resulting compact had an unusually smooth surface appearance.
  • Metallographic examination revealed a surface diffusion-products layer of the order of 0.00254 mm (.1 mil) thick (see Figure 6).
  • a metal coating may be produced on the interior surfaces of a ceramic shell such as by electroplating the metal coating, which may be nickel, on a wax pattern shape and then providing a ceramic shell around this metal-coated wax pattern, as by dipping the assembly in a refractory slurry.
  • the metal coating which may be nickel
  • a wax pattern may be coated with nickel by first spraying the surface of the pattern with graphite to provide an electrically conductive base and then electroplating onto this conductive base a metal such as nickel.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Claims (10)

1. Form (10) für die Herstellung von pulvermetallurgischen Artikeln (22), die einen Keramikformkörper (12) mit einem inneren Hohlraum (14) aufweist, dessen Oberfläche der äußeren Form des herzustellenden Artikels entspricht und der mit einem Metallpulver (20) ausfüllbar ist, aus dem durch Verpressen der Artikel geformt wird, dadurch gekennzeichnet, daß der Hohlraum (14) der Form eine lückenlose Metallbeschichtung (18) aufweist, die die Hohlraumoberfläche bedeckt.
2. Form nach Anspruch 1, dadurch gekennzeichnet, daß die Metallbeschichtung (18) aus Nickel ist.
3. Form nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß der Keramikformkörper (12) in zumindest zwei einzelne separate Teile aufgeteilt ist.
4. Form nach Anspruch 1, 2, oder 3, dadurch gekennzeichnet, daß die Form einen Keramikkern innerhalb des Hohlraums (14) der Form aufweist, und daß der Keramikkern eine lückenlose Metallbeschichtung aufweist.
5. Verfahren zur Herstellung einer Form (10) für die Verwendung bei der Herstellung eines pulvermetallurgischen Artikels (22), wobei ein Keramikformkörper (12) mit einem inneren Hohlraum (14) hergestellt wird, dessen Oberfläche der äußeren Form des Artikels (22) entspricht und in den Metallpulver zur Verpressung und Formung des Artikels (22) einfüllbar ist, dadurch gekennzeichnet, daß in einem weiteren Verfahrensschritt eine lückenlose Metallbeschichtung (18) auf die Oberfläche des Hohlraumes (14) aufgebracht wird.
6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, daß der Keramikformkörper (12) aus zumindest zwei separaten Segmenten (10) hergestellt wird und daß die Segmente zur Bildung des Hohlraumes (14) zusammengefügt werden.
7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, daß die Segmente (10) jeweils einen Oberflächenteil aufweisen, aus dem der Hohlraum (14) gebildet wird, wenn die Segmente (10) zusammengefügt sind, und daß eine lückenlose Metallbeschichtung (18) auf diesen Oberflächenteil aufgebracht wird, bevor diese Segmente (10) zur Bildung des Hohlraumes (14) zusammengefügt werden.
8. Verfahren nach Anspruch 5, 6 oder 7, dadurch gekennzeichnet, daß die Metallbeschichtung (18) Nickel enthält.
9. Verfahren nach einem der vorhergehenden Ansprüche 5 bis 8, dadurch gekennzeichnet, daß die Beschichtung (18) mit Hilfe chemischer Gasphasenabscheidung aufgebracht wird.
10. Verfahren nach einem der vorhergehenden Ansprüche 5 bis 9, dadurch gekennzeichnet, daß innerhalb des Hohlraums der Form ein Keramikkern mit einer lückenlosen Metallbeschichtung vergesehen wird.
EP82306346A 1982-03-26 1982-11-30 Keramikform und Verfahren zur Herstellung derselben Expired EP0090118B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT82306346T ATE18364T1 (de) 1982-03-26 1982-11-30 Keramikform und verfahren zur herstellung derselben.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US36234182A 1982-03-26 1982-03-26
US362341 1982-03-26

Publications (2)

Publication Number Publication Date
EP0090118A1 EP0090118A1 (de) 1983-10-05
EP0090118B1 true EP0090118B1 (de) 1986-03-05

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP82306346A Expired EP0090118B1 (de) 1982-03-26 1982-11-30 Keramikform und Verfahren zur Herstellung derselben

Country Status (4)

Country Link
EP (1) EP0090118B1 (de)
AT (1) ATE18364T1 (de)
CA (1) CA1203659A (de)
DE (1) DE3269719D1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10223371A1 (de) * 2002-05-25 2003-12-04 Peter Amborn Werkzeugform zur Herstellung von metallischen Formteilen durch Gieß-, Heiß-, Warm o. Kaltumformung sowie ein Verfahren zur Herstellung einer derartigen Werkzeugform

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4772450A (en) * 1984-07-25 1988-09-20 Trw Inc. Methods of forming powdered metal articles
US5985207A (en) * 1995-11-16 1999-11-16 Vawter; Paul D. Method for manufacturing powder metallurgical tooling
US6939508B2 (en) * 2002-10-24 2005-09-06 The Boeing Company Method of manufacturing net-shaped bimetallic parts
GB0623048D0 (en) * 2006-11-18 2006-12-27 Bentley Motors Ltd Improvements in or relating to ceramic tooling
US11229950B2 (en) 2017-04-21 2022-01-25 Raytheon Technologies Corporation Systems, devices and methods for spark plasma sintering

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL121210C (de) * 1961-05-01
FR2002321A1 (de) * 1968-02-21 1969-10-17 Inst Odlewnictwa

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10223371A1 (de) * 2002-05-25 2003-12-04 Peter Amborn Werkzeugform zur Herstellung von metallischen Formteilen durch Gieß-, Heiß-, Warm o. Kaltumformung sowie ein Verfahren zur Herstellung einer derartigen Werkzeugform

Also Published As

Publication number Publication date
EP0090118A1 (de) 1983-10-05
ATE18364T1 (de) 1986-03-15
CA1203659A (en) 1986-04-29
DE3269719D1 (en) 1986-04-10

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