EP1607157A2 - Verfahren zur Verfestigung von Pulver - Google Patents

Verfahren zur Verfestigung von Pulver Download PDF

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Publication number
EP1607157A2
EP1607157A2 EP05253052A EP05253052A EP1607157A2 EP 1607157 A2 EP1607157 A2 EP 1607157A2 EP 05253052 A EP05253052 A EP 05253052A EP 05253052 A EP05253052 A EP 05253052A EP 1607157 A2 EP1607157 A2 EP 1607157A2
Authority
EP
European Patent Office
Prior art keywords
container
powder
die
preforms
placing
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Withdrawn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
EP05253052A
Other languages
English (en)
French (fr)
Other versions
EP1607157A3 (de
Inventor
Daniel Clark
Justin Burrows
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 EP1607157A2 publication Critical patent/EP1607157A2/de
Publication of EP1607157A3 publication Critical patent/EP1607157A3/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Withdrawn legal-status Critical Current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
    • B22F3/14—Both compacting and sintering simultaneously
    • 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
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • 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
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the present invention relates to a method of consolidating a powder to produce a component, join components or coat a component.
  • a method of consolidating a powder to produce new components, join components or coat components suitable for aerospace applications relates to a method of consolidating a powder to produce new components, join components or coat components suitable for aerospace applications.
  • Aerospace components require the use of high strength, high temperature resistant alloys, which are notoriously difficult to process. As it is not possible to weld or use other fabrication techniques on these alloys, components are machined from billets. Machining the components from billets is time consuming, expensive and wasteful.
  • Powder metallurgy has been used to produce billets of these high performance alloys from which components having complex geometries are machined.
  • Current powder processing routes for these alloys require expensive and wasteful processes, such as extrusion, to eliminate traces of prior particle grain boundaries and produce low specification components.
  • the present invention seeks to provide a powder processing route which overcomes the problems of prior particle grain boundaries and provides a low cost manufacturing route for components from these high specification alloys.
  • a method of consolidating a powder comprises the steps of filling an electrically conductive container with powder, evacuating air out of the filled container and sealing the filled container after evacuation, placing the sealed container in a die and applying a force sufficient to consolidate the powder whilst simultaneously applying a electric pulse and an ultrasound pulse thereto, removing the container from the die and removing the container from the consolidated powder.
  • a method of consolidating a powder to join preforms comprising the steps of placing at least two preforms in abutting relationship in an electrically conductive container, coating the abutting surfaces of the preforms with powder, evacuating any air out of the container and sealing the container after evacuation, placing the sealed container in a die and applying a force sufficient to consolidate the powder and join the preforms whilst simultaneously applying an electric pulse and an ultrasound pulse to the container, removing the container from the die and removing the container from the joined preforms.
  • a method of consolidating a powder comprises the steps of placing a preform in an electrically conductive container, coating the surfaces of the preform with powder, evacuating any air out of the container and sealing the container after evacuation, placing the sealed container in a die and applying a force sufficient to consolidate a coating of the powder onto the preform whilst simultaneously applying an electric pulse and an ultrasound pulse to the container, removing the container from the die and removing the container from the coated preform.
  • the powder coating may have a different composition to the preforms and the composition of each of the preforms may be different.
  • the electric and ultrasound pulses are applied during consolidation to disrupt the grain boundaries and assist in the fragmentation of any oxides.
  • a high amplitude, high frequency electrical pulse is applied to the container.
  • the electrical pulse heats the surface of the powder, increasing the plasticity at the surface.
  • Electrical energy in the range of 1-20KHz is applied with a frequency of the order of 20KHz.
  • the force used to compress the powder may be a mechanically induced shock wave in the range of 5-20 GPa.
  • the shock wave assists in the disruption of the grain boundaries and helps destroy any oxides.
  • the ultrasound pulse is of the order of 20KHz, and is applied simultaneously with the shock wave to further disrupt the grain boundaries and to assist in the fragmentation of oxides.
  • the container is vibrated as it is filled with the powder.
  • the powder may be a nickel alloy and the container may be made from nickel, mild steel or stainless steel.
  • the consolidated powder may then be sintered or hot isostatically pressed.
  • Figure 1 shows apparatus suitable for consolidating a powder in accordance with present invention.
  • Figure 2 shows apparatus suitable for joining preforms of consolidated powder.
  • Figure 3 shows apparatus suitable for consolidating a powder coating onto a preform.
  • a nickel alloy powder 10 is encapsulated in a container 12.
  • the container 12 is made from a ductile material, which is electrically conductive and which will not contaminate the powder by diffusion.
  • the container 12 is made from pure nickel, mild steel or stainless steel sheet. Electrically insulting connectors 14 are provided on either end of the container 12.
  • the container 12 is vibrated to pack the powder 10 down.
  • a vacuum pump (not shown) is attached to a tube 16 on the container 12 and is used to evacuate the gas atmosphere surrounding the powder 10. Once the gas has been evacuated from the container 12 the tube 16 is crimped and welded shut.
  • the sealed container 12 is then placed into a die 20 having two electrically insulated connectors 22.
  • the electrical connecters 22 are attached to a source of electrical energy, such as a capacitor bank (not shown).
  • the die 20 is closed and motor-driven hydraulic actuators (not shown) apply a force in the direction of arrows A to the die 20.
  • the shock wave applies a force, in the range of 5-20 GPa. The force necessary will depend upon the type of powder and the size of the component. For a nickel alloy powder a shock wave of the order of 10 GPa is applied for a few tenths of a microsecond to effect full consolidation.
  • the capacitor bank simultaneously delivers a high amplitude, high frequency pulse of electrical energy to the connectors 22 on the die 20.
  • a 1-20KJ pulse of electrical energy is delivered at a frequency of approximately 20KHz and an amplitude as high as the frequency switch system will allow.
  • the electrical energy is transmitted to the connectors 14 on the container 12.
  • the electric energy is transmitted through the powder 10 for of the order of 10 milliseconds.
  • the electrical pulse has a waveform and amplitude that are tailored to disrupt grain boundaries and oxides.
  • the electrical pulse is applied for of the order of 10 milliseconds such that it heats the surface of the powder 10 to increase the plasticity but does not allow substantial heat conduction into the powder 10, which could cause micro structural alteration.
  • An ultrasound pulse of the order of 20kHz is also superimposed onto the shock wave to further disrupt the grain boundaries and to assist in the fragmentation of any oxides.
  • the container 12 is removed from the die 20.
  • the preform is then removed from the container 12, either by machining or by electrolysis.
  • Boron nitride could be used as a release agent to assist in the removal of the preform from the container.
  • preforms 10a, 10b and 10c are placed in the container 12. Mechanical compaction is aided by coating the abutting surfaces 11 of the preforms 10a, 10b, and 10c with powder 10.
  • the powder coated onto abutting faces 11 of the preforms 10a, 10b and 10c may be of a different composition. This is particularly beneficial when the preforms 10a, 10b and 10c are formed from powders of dissimilar materials, which cannot be joined by conventional techniques such as welding.
  • the container 12 is evacuated, sealed and placed into the die 20.
  • a shock wave is generated in the hydrostatic medium 18 whilst an electrical pulse and ultrasound pulse is applied simultaneously to the container 12 to join the preforms 10a, 10b and 10c together.
  • the ultrasound pulse has a frequency of the order of 20kHz and is superimposed onto the shock wave to further disrupt the grain boundaries and to assist in the fragmentation of any oxides.
  • the container 12 is then removed from the die 20 and from the joined preforms.
  • the method can also be used to apply a powder coating to a preform.
  • a preform 10d is placed in the container 12.
  • Powder 10 is placed around the surfaces of the perform 10d.
  • the powder coating 10 may be of a different composition to the perform 10d.
  • the container 12 is evacuated, sealed and placed into the die 20.
  • a shock wave is generated in the hydrostatic medium 18 whilst an electrical pulse and ultrasound pulse is applied simultaneously to the container 12.
  • the container 12 is then removed from the die 20 and from the coated preform 10d.
  • the process described simultaneously compacts and disrupts grain boundaries and oxides in the powder 10. As the heat is not conducted into the powder 10 this comparatively cold processing route allows fine-grained preforms of consolidated powder to be produced. A fine grain structure is required to produce tough, fatigue resistant components. The process thus enables the use of low cost manufacturing route to produce high specification preforms of material from powder, join dissimilar performs together or apply powder coatings to the preforms.
  • the consolidated preforms may be further processed depending on the material properties required for a particular application.
  • the preforms of consolidated powder may be subsequently sintered or hot isotropically pressed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Powder Metallurgy (AREA)
  • Physical Or Chemical Processes And Apparatus (AREA)
EP05253052A 2004-06-16 2005-05-18 Verfahren zur Verfestigung von Pulver Withdrawn EP1607157A3 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0413392 2004-06-16
GBGB0413392.2A GB0413392D0 (en) 2004-06-16 2004-06-16 A method of consolidating a power

Publications (2)

Publication Number Publication Date
EP1607157A2 true EP1607157A2 (de) 2005-12-21
EP1607157A3 EP1607157A3 (de) 2009-07-15

Family

ID=32749956

Family Applications (1)

Application Number Title Priority Date Filing Date
EP05253052A Withdrawn EP1607157A3 (de) 2004-06-16 2005-05-18 Verfahren zur Verfestigung von Pulver

Country Status (3)

Country Link
US (1) US20050281702A1 (de)
EP (1) EP1607157A3 (de)
GB (1) GB0413392D0 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010013544A1 (de) * 2010-03-26 2011-09-29 Roland Gschwinder Verfahren und Vorrichtung zur Herstellung eines Erzeugnisses durch Urformen aus flüssigem, breiigem, pastenförmigem, pulverigem, körnigem, festem Material und/oder dessen Kompositionszuständen

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11338367B2 (en) 2018-06-08 2022-05-24 Hewlett-Packard Development Company, L.P. Metal powder compactors
WO2021178588A1 (en) * 2020-03-04 2021-09-10 The Regents Of The University Of California Isostatic pressure spark plasma sintering (ip-sps) net shaping of components using nanostructured materials

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3508209A (en) * 1966-03-31 1970-04-21 Ibm Monolithic integrated memory array structure including fabrication and package therefor
US3656946A (en) * 1967-03-03 1972-04-18 Lockheed Aircraft Corp Electrical sintering under liquid pressure
US20020025272A1 (en) * 2000-07-12 2002-02-28 Witherspoon F. Douglas Dynamic consolidation of powders using a pulsed energy source

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE417580B (sv) * 1979-02-27 1981-03-30 Asea Ab Forfarande for framstellning av emnen fran pulver genom hogt allsidigt tryck
US4702884A (en) * 1986-07-03 1987-10-27 The United States Of America As Represented By The Secretary Of The Navy Glass-lined pipes
US4704252A (en) * 1986-11-03 1987-11-03 Tocco, Inc. Isostatic hot forming of powder metal material
US5348694A (en) * 1988-12-20 1994-09-20 Superior Graphite Co. Method for electroconsolidation of a preformed particulate workpiece
US5246638A (en) * 1988-12-20 1993-09-21 Superior Graphite Co. Process and apparatus for electroconsolidation
US4938673A (en) * 1989-01-17 1990-07-03 Adrian Donald J Isostatic pressing with microwave heating and method for same
US5134260A (en) * 1990-06-27 1992-07-28 Carnegie-Mellon University Method and apparatus for inductively heating powders or powder compacts for consolidation
US6432554B1 (en) * 1992-02-10 2002-08-13 Iap Research, Inc. Apparatus and method for making an electrical component
US5689797A (en) * 1992-02-10 1997-11-18 Iap Research, Inc. Structure and method for compaction of powder-like materials
US6273963B1 (en) * 1992-02-10 2001-08-14 Iap Research, Inc. Structure and method for compaction of powder-like materials
US20030001299A1 (en) * 2001-06-29 2003-01-02 Nachappa Gopalsami Method and apparatus for ultrasonic temperature monitoring

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3508209A (en) * 1966-03-31 1970-04-21 Ibm Monolithic integrated memory array structure including fabrication and package therefor
US3656946A (en) * 1967-03-03 1972-04-18 Lockheed Aircraft Corp Electrical sintering under liquid pressure
US20020025272A1 (en) * 2000-07-12 2002-02-28 Witherspoon F. Douglas Dynamic consolidation of powders using a pulsed energy source

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010013544A1 (de) * 2010-03-26 2011-09-29 Roland Gschwinder Verfahren und Vorrichtung zur Herstellung eines Erzeugnisses durch Urformen aus flüssigem, breiigem, pastenförmigem, pulverigem, körnigem, festem Material und/oder dessen Kompositionszuständen

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Publication number Publication date
US20050281702A1 (en) 2005-12-22
GB0413392D0 (en) 2004-07-21
EP1607157A3 (de) 2009-07-15

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