EP1547707A2 - Verfahren und Vorrichtung zur Herstellung eines Formkörpers durch Verdichtung von Pulvermaterial - Google Patents

Verfahren und Vorrichtung zur Herstellung eines Formkörpers durch Verdichtung von Pulvermaterial Download PDF

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Publication number
EP1547707A2
EP1547707A2 EP04257374A EP04257374A EP1547707A2 EP 1547707 A2 EP1547707 A2 EP 1547707A2 EP 04257374 A EP04257374 A EP 04257374A EP 04257374 A EP04257374 A EP 04257374A EP 1547707 A2 EP1547707 A2 EP 1547707A2
Authority
EP
European Patent Office
Prior art keywords
tool
deformable
deformable tool
powder
article
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.)
Withdrawn
Application number
EP04257374A
Other languages
English (en)
French (fr)
Other versions
EP1547707A3 (de
Inventor
Wayne Eric Voice
Junfa Mei
Xinhua Wu
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.)
Rolls Royce PLC
Original Assignee
Rolls Royce PLC
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 Rolls Royce PLC filed Critical Rolls Royce PLC
Publication of EP1547707A2 publication Critical patent/EP1547707A2/de
Publication of EP1547707A3 publication Critical patent/EP1547707A3/de
Withdrawn legal-status Critical Current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
    • B22F3/1291—Solid insert eliminated after consolidation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B11/00—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/001—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a flexible element, e.g. diaphragm, urged by fluid pressure; Isostatic presses
    • 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

Definitions

  • the present invention relates to a method of manufacturing an article by consolidating powder material, and in particular to a method of manufacturing an article by consolidating metal powder, ceramic powder or a mixture of metal powder and ceramic powder.
  • metal powder and/or ceramic powder is consolidated to form an article by placing the metal powder in a consumable/deformable tool.
  • the consumable/deformable tool is evacuated and then hot isostatically pressed such that the consumable/deformable tool deforms and compresses the metal powder and/or ceramic powder to a fully consolidated article.
  • this method of manufacturing articles requires sophisticated process/computer modelling to predict the shape of the tool required prior to hot isostatic pressing so that the hot isostatic pressing process deforms the tool, and hence the metal powder and/or ceramic powder, to near the net-shape of the article. Furthermore, because the tool is deformed during the hot isostatic pressing process the tool cannot be reused to produce further articles. Also, this method is dependent upon the control of the powder material and requires measurement of the powder flow and consolidation properties.
  • the present invention seeks to provide a novel method of manufacturing an article by consolidating powder material.
  • the present invention provides a method of manufacturing an article by consolidating powder material comprising the steps of:-
  • step (e) comprises heating to a temperature of 925°C and applying a pressure of 150MPa and maintaining for 2 hours.
  • the deformable tool is removed from the non-deformable tool.
  • the deformable tool is dissolved from the non-deformable tool.
  • the deformable tool is dissolved using an acid.
  • the deformable tool comprises a deformable vacuum bag.
  • the vacuum bag comprises a metal.
  • the metal comprises mild steel.
  • the non-deformable tool is removed from the article.
  • the non-deformable tool is removed by removing the tool parts.
  • the non-deformable tool comprises at least two tool parts.
  • the non-deformable tool comprises a non-deformable metal.
  • the metal comprises high strength steel.
  • the tool parts may be removed from the article and excess consolidated powder is removed from the end of the article, which was adjacent the opening.
  • the powder material comprises metal powder, ceramic powder or metal powder and ceramic powder.
  • the metal powder may be an alloy powder or an elemental powder.
  • the metal powder may be nickel alloy powder, titanium alloy powder, aluminium alloy powder, cobalt alloy powder or an iron alloy powder.
  • the article is a compressor blade, a compressor vane, a turbine blade, a turbine vane, a compressor disc, a turbine disc, a compressor blisk or a turbine blisk.
  • step (f) comprises hot isostatic pressing or isothermal pressing.
  • the present invention also provides an apparatus for manufacturing an article by consolidating powder material comprising a non-deformable tool and a deformable tool, the non-deformable tool comprising a plurality of tool parts, the non-deformable tool defining a first cavity having an open end, the first cavity corresponding in shape to that of the article, the non-deformable tool and deformable tool defining a second cavity interconnected with the first cavity.
  • the deformable tool comprises a deformable vacuum bag.
  • the vacuum bag comprises a metal.
  • the metal comprises mild steel.
  • the non-deformable tool comprises a non-deformable metal.
  • the metal comprises high strength steel.
  • An apparatus 10 for manufacturing an article by consolidating powder material comprises a non-deformable tool 12 and a deformable tool 14.
  • the non-deformable tool 12 comprises a plurality of tool parts 16 and 18 and the non-deformable tool 12 defines a first cavity 20, which has an open end 22.
  • the first cavity 20 corresponds in shape to that of an article to be manufactured.
  • the non-deformable tool 12 is arranged in the deformable tool 14 and the non-deformable tool 12 and deformable tool 14 define a second cavity 24 interconnected with the first cavity 20 via the opening 22.
  • the deformable tool 14 comprises a deformable vacuum bag, a thin walled deformable jacket and the vacuum bag comprises a metal, for example mild steel.
  • the vacuum bag may be formed by welding a number of metal parts together.
  • the non-deformable tool 12 comprises at least two tool parts 16 and 18 and the non-deformable tool 12 comprises a non-deformable metal, for example high strength steel, which does not adhere to the powder material after consolidation.
  • An article is manufactured by consolidating powder material by securing, welding, a pipe 28 to the deformable tool 14 such that the pipe 28 is interconnected with the second cavity 24.
  • the first cavity 20 and the second cavity 24 are filled with powder material 26, for example metal powder, ceramic powder or a mixture of metal powder and ceramic powder by supplying the powder material through the pipe 28.
  • the deformable tool 14 is evacuated using the pipe 28 and a vacuum pump (not shown).
  • the pipe 28 is then sealed, using one or more welds, to seal the deformable tool 14.
  • the apparatus 10 is then placed in a HIP vessel and heat and pressure are applied to the deformable tool 14 and the non-deformable tool 12 to consolidate the powder material 26 to form an article 30 in the first cavity 20 of the non-deformable tool 12.
  • the heat and pressure applied is preferably hot isostatic pressure.
  • the isostatic pressure on the deformable tool 12 is resisted at those positions where the deformable tool 14 is supported by the non-deformable tool 12.
  • the deformable tool 14 collapses, as shown in figure 2. This results in some of the powder material 26 in the second cavity 24 flowing, being extruded, through the opening 22 in the non-deformable tool 12 into the first cavity 20 in the non-deformable tool 12 to aid the consolidation of the powder material 26, as shown in figure 3.
  • the extrusion of the powder material 26 through the opening 22 reduces the size of potential defects in the article 30.
  • the apparatus 10 is removed from the HIP vessel and the deformable tool 14 is removed from the non-deformable tool 12.
  • the deformable tool 14 is removed from the non-deformable tool 12 by dissolving the deformable tool 14, for example using an acid, for example nitric acid.
  • the deformable tool may be removed by machining or it may be removed by a combination of machining and dissolving with acid.
  • the non-deformable tool 12 is then removed from the article 30.
  • the article 30 is a compressor blade.
  • the powder material may comprise a metal powder, a ceramic powder or a metal powder and a ceramic powder.
  • the metal powder may be an alloy powder or an elemental powder.
  • the metal powder may be nickel alloy powder, titanium alloy powder, aluminium alloy powder, cobalt alloy powder or an iron alloy powder.
  • the first cavity may define the shape of a compressor blade, a compressor vane, a turbine blade, a turbine vane, a compressor disc, a turbine disc, a compressor blisk or a turbine blisk.
  • the article may be a compressor blade, a compressor vane, a turbine blade, a turbine vane, a compressor disc, a turbine disc, a compressor blisk, a turbine blisk, a compressor bling or a turbine bling for a gas turbine engine.
  • a blisk is a disc having integral blades and a bling is a ring having integral blades.
  • the method may be used to manufacture other suitable articles.
  • titanium alloy for example a titanium alloy comprising 6wt% aluminium, 4wt% vanadium, powder the heating is to a temperature of 925°C, below the beta transus, and a pressure of 150MPa is applied for about 2 hours.
  • the particular temperature and pressure varies according to the specific alloy.
  • the temperature may be up to 1300°C, for example 1260°C.
  • the present invention effectively provides an apparatus comprising an open ended non-deformable hollow tool, defining an article shape first cavity, and a deformable hollow tool defining a second cavity with the non-deformable tool such that powder material in the second cavity is extruded into the first cavity due to isostatic pressure applied during consolidation.
  • the advantage of the present invention is that it eliminates the need for sophisticated process modelling techniques to determine the pre-consolidation shape of a deformable tool. Additionally, the non-deformable tool may be re-used to produce further articles.
  • powder flow and consolidation properties are not required. Also, it successfully consolidates powder material to a near net-shape article no matter how the powder material is packed in the tool and is therefore suitable for powder material with poor flowing characteristics, such as powder material produced by electrochemical/chemical or electro-de-oxidation powder production techniques.
  • the properties of the consolidated powder article are improved due to the relatively high degree of work applied by the powder extrusion during the hot isostatic pressing process. The extrusion of the powder material during the consolidation process breaks up potential defects in the powder material, by braking up the defects and spreading the remnants of the defects so as to reduce their size.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
EP04257374A 2003-12-24 2004-11-27 Verfahren und Vorrichtung zur Herstellung eines Formkörpers durch Verdichtung von Pulvermaterial Withdrawn EP1547707A3 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0330217 2003-12-24
GBGB0330217.1A GB0330217D0 (en) 2003-12-24 2003-12-24 An apparatus and a method of manufacturing an article by consolidating powder material

Publications (2)

Publication Number Publication Date
EP1547707A2 true EP1547707A2 (de) 2005-06-29
EP1547707A3 EP1547707A3 (de) 2006-11-02

Family

ID=31503318

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04257374A Withdrawn EP1547707A3 (de) 2003-12-24 2004-11-27 Verfahren und Vorrichtung zur Herstellung eines Formkörpers durch Verdichtung von Pulvermaterial

Country Status (4)

Country Link
US (1) US20050142023A1 (de)
EP (1) EP1547707A3 (de)
JP (1) JP2005187942A (de)
GB (1) GB0330217D0 (de)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2340905A1 (de) * 2009-12-16 2011-07-06 Rolls-Royce plc Verfahren zur Herstellung einer Komponente
EP2384838A1 (de) * 2010-05-06 2011-11-09 Rolls-Royce plc Formanordnung
US9346119B2 (en) 2010-09-14 2016-05-24 Rolls-Royce Plc Object forming assembly

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8992699B2 (en) * 2009-05-29 2015-03-31 General Electric Company Nickel-base superalloys and components formed thereof
US8992700B2 (en) * 2009-05-29 2015-03-31 General Electric Company Nickel-base superalloys and components formed thereof
US20100329876A1 (en) * 2009-06-30 2010-12-30 General Electric Company Nickel-base superalloys and components formed thereof
GB0916995D0 (en) * 2009-09-29 2009-11-11 Rolls Royce Plc A method of manufacturing a metal component from metal powder
GB2484691B (en) * 2010-10-20 2012-12-19 Rolls Royce Plc A mould assembly for a hot isostatic pressing process
CN102351495B (zh) * 2011-06-22 2013-02-20 青岛文创科技有限公司 具有防火和保温功能的吸音板及其加工方法
KR101666407B1 (ko) * 2014-12-23 2016-10-14 주식회사 포스코 용탕 분사용 노즐 제조방법
US10857596B1 (en) * 2018-09-11 2020-12-08 Honeywell International Inc. Method of producing an abrasive tip for a turbine blade
CN113664147B (zh) * 2021-08-02 2023-10-20 安徽应流航源动力科技有限公司 一种叶片蜡模喷蜡3d打印防变形工艺

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1557744A (en) * 1976-06-01 1979-12-12 Special Metals Corp Process and apparatus for producing aticles of complex shape
EP0036202A2 (de) * 1980-03-18 1981-09-23 Mtu Motoren- Und Turbinen-Union MàœNchen Gmbh Verfahren zur Herstellung von Turborotoren
EP0086417A2 (de) * 1982-02-13 1983-08-24 Mtu Motoren- Und Turbinen-Union MàœNchen Gmbh Kapsel für das heissisostatische Pressen von hochbeanspruchten und kompliziert geformten Werkstücken für Turbomaschinen

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA1002716A (en) * 1971-12-28 1977-01-04 Richard A. Alliegro Hot-pressing of shapes of non-uniform cross-sectional thickness
US3830607A (en) * 1973-01-05 1974-08-20 Gleason Works Apparatus for compacting material
US4142888A (en) * 1976-06-03 1979-03-06 Kelsey-Hayes Company Container for hot consolidating powder

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1557744A (en) * 1976-06-01 1979-12-12 Special Metals Corp Process and apparatus for producing aticles of complex shape
EP0036202A2 (de) * 1980-03-18 1981-09-23 Mtu Motoren- Und Turbinen-Union MàœNchen Gmbh Verfahren zur Herstellung von Turborotoren
EP0086417A2 (de) * 1982-02-13 1983-08-24 Mtu Motoren- Und Turbinen-Union MàœNchen Gmbh Kapsel für das heissisostatische Pressen von hochbeanspruchten und kompliziert geformten Werkstücken für Turbomaschinen

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2340905A1 (de) * 2009-12-16 2011-07-06 Rolls-Royce plc Verfahren zur Herstellung einer Komponente
US8758676B2 (en) 2009-12-16 2014-06-24 Rolls-Royce Plc Method of manufacturing a component
EP2384838A1 (de) * 2010-05-06 2011-11-09 Rolls-Royce plc Formanordnung
US8425817B2 (en) 2010-05-06 2013-04-23 Rolls-Royce Plc Mould assembly
US9346119B2 (en) 2010-09-14 2016-05-24 Rolls-Royce Plc Object forming assembly

Also Published As

Publication number Publication date
US20050142023A1 (en) 2005-06-30
JP2005187942A (ja) 2005-07-14
EP1547707A3 (de) 2006-11-02
GB0330217D0 (en) 2004-02-04

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