EP1649954A2 - Composant à basse porosité formée par métallurgie de poudres - Google Patents

Composant à basse porosité formée par métallurgie de poudres Download PDF

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Publication number
EP1649954A2
EP1649954A2 EP05255133A EP05255133A EP1649954A2 EP 1649954 A2 EP1649954 A2 EP 1649954A2 EP 05255133 A EP05255133 A EP 05255133A EP 05255133 A EP05255133 A EP 05255133A EP 1649954 A2 EP1649954 A2 EP 1649954A2
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EP
European Patent Office
Prior art keywords
component
powder
hot isostatic
heat treated
microstructure
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Withdrawn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
EP05255133A
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German (de)
English (en)
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EP1649954A3 (fr
Inventor
Gopal Das
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RTX Corp
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United Technologies Corp
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Publication date
Application filed by United Technologies Corp filed Critical United Technologies Corp
Publication of EP1649954A2 publication Critical patent/EP1649954A2/fr
Publication of EP1649954A3 publication Critical patent/EP1649954A3/fr
Withdrawn legal-status Critical Current

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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
    • B22F3/10—Sintering only
    • B22F3/11—Making porous 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
    • 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
    • B22F3/02—Compacting only
    • B22F3/04—Compacting only by applying fluid pressure, e.g. by cold isostatic pressing [CIP]
    • B22F3/045—Semi-isostatic pressure
    • 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

Definitions

  • the present invention relates generally to components prepared by powder metallurgy techniques. More specifically, the present invention relates to hot isostatic pressing such components after heat treating to eliminate, or at least minimize or shrink, any porosity therein.
  • Two-phase gamma-TiAl based intermetallic alloys have received considerable attention as potential materials for high-temperature aerospace and automotive applications, particularly as possible replacements for conventional nickel and titanium alloys in gas turbine engines.
  • Such alloys exhibit improved high temperature mechanical properties and improved oxidation resistance as compared to conventional high temperature titanium alloys.
  • Such alloys have good creep resistance and strength at elevated temperatures, and have a lower density than conventional nickel and titanium alloys.
  • Such alloys could be used to make lightweight gas turbine engine components, such as blades, vanes, disks, etc., where higher operating temperatures would allow increased efficiency to be achieved.
  • Powder metallurgy techniques can produce components having greater homogeneity than cast components, and higher strengthener content than conventionally wrought components. Therefore, it may be desirable to use powder metallurgy techniques to form such components.
  • the powder metallurgy techniques currently used to produce such components often create components having porosity therein that is too large or too numerous for many applications. Therefore, it would be desirable to have improved powder metallurgy techniques for producing such components. It would also be desirable to have methods for minimizing the porosity in such components, or at least reducing the porosity therein to an acceptable level. It would be further desirable to have powder metallurgy processing techniques that are useful for a variety of materials.
  • Embodiments of this invention comprise components and methods for forming such components, comprising: providing a powder; creating a preform from the powder; creating a component from the preform; heat treating the component to create a predetermined microstructure therein; and hot isostatic pressing the heat treated component to reduce any porosity therein.
  • Embodiments may further comprise machining the heat treated and hot isostatic pressed component to its final dimensions. Any porosity remaining in the heat treated and hot isostatic pressed component is generally less than about 0.005 (0.13 mm) in size.
  • This invention may be utilized to create gas turbine engine components such as, but not limited to, compressor disks, compressor blades, low pressure turbine blades, and tangential on board injectors.
  • Creating the preform from the powder may comprise hot isostatic pressing the powder at a temperature sufficient to densify the preform and consolidate the powder through bonding thereof.
  • this hot isostatic pressing may occur at about 925-1320°C and about 15-45 ksi (103-310 MPa) for about 2-10 hours in an argon atmosphere. More specifically, in embodiments, this hot isostatic pressing may occur at about 1260°C and about 25 ksi (172 MPa) for about 4 hours in an argon atmosphere.
  • the component may be created from the preform in numerous ways, such as via extrusion and/or isothermal forging, etc.
  • the component may be created from the preform at a temperature below the alpha transus temperature of the powder so that a near gamma microstructure exists in the preform.
  • Heat treating the component occurs at a time and temperature sufficient to create the desired microstructure in the component.
  • this heat treating may occur at a temperature above the alpha transus temperature of the powder, for example, at about 925-1370°C for about 2-10 hours, to create a lamellar microstructure in the component. More specifically, in embodiments, this heat treating may occur at about 1354°C for about 4 hours.
  • the component is hot isostatic pressed at a temperature low enough to prevent significant grain growth from occurring in the component.
  • this temperature may preserve a lamellar microstructure in the component, and be carried out at about 925-1320° C and about 15-45 ksi (103-310 MPa) for about 2-10 hours. More specifically, in embodiments, this hot isostatic pressing may be carried out at about 1232°C and about 25 ksi (172 MPa) for about 10 hours. After this hot isostatic pressing step, the component will have less or smaller porosity than existed in the component prior to this step.
  • the powder utilized in this invention may comprise any suitable material, including, but not limited to, gamma-TiAl, nickel aluminides, iron aluminides, titanium alloys, and superalloys.
  • the powder may comprise about 44-48 atomic percent aluminum, about 1-2 atomic percent niobium, about 1-2 atomic percent chromium, about 1-2 atomic percent molybdenum, about 0.1-0.2 atomic percent boron, and about 0.1-0.2 atomic percent carbon, the balance substantially titanium.
  • the powder may have an average particle size of about 70 ⁇ m.
  • FIGURES 1-8 For the purposes of promoting an understanding of the invention, reference will now be made to some embodiments of this invention as illustrated in FIGURES 1-8 and specific language used to describe the same.
  • the terminology used herein is for the purpose of description, not limitation. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for teaching one skilled in the art to variously employ the present invention.
  • This invention relates to improved powder metallurgy processed components that have little or no porosity therein.
  • Powder metallurgy techniques are used to make the components of this invention because such techniques provide microstructural and chemical homogeneities in the consolidated powder, and therefore, also in the final extruded and/or forged components produced therefrom.
  • This invention may be utilized with any material formed from a rapidly solidified powder produced by powder metallurgy in insoluble gas (i.e., argon or helium), and having thermally induced porosity therein in its consolidated and heat treated form.
  • insoluble gas i.e., argon or helium
  • Materials created from powders produced via powder metallurgy in argon or helium gas generally contain thermally induced porosity after heat treatment because argon and helium are both insoluble in metals, and when heat treated at elevated temperatures, these gases become mobile and precipitate as pores (i.e., as thermally induced porosity) in the material.
  • Embodiments of this invention comprise the general powder metallurgy technique 10 shown in Figure 1.
  • a powder may be provided 11.
  • a preform may be created 13 from the powder.
  • a component may be created 15 from the preform.
  • the component may be heat treated 17 to create a desired microstructure therein.
  • the component may be hot isostatic pressed 19 to minimize any porosity therein that is created during heat treatment.
  • the component can then be machined or otherwise formed into its final desired shape, form or dimensions.
  • the powders 11 utilized in this invention may comprise any rapidly solidified, insoluble gas produced powder, such as, but not limited to, gamma-TiAl powders, nickel aluminide powders, iron aluminide powders, titanium alloy powders, any other superalloy powders utilized to make gas turbine engine components, etc.
  • argon gas atomized gamma-TiAl powder may be desirable because it comprises a fine grain microstructure with virtually no chemical segregation.
  • gamma-TiAl components may be used instead of the superalloy components currently used in many gas turbine engine components.
  • gamma titanium aluminides and derivations thereof (i.e., gamma-TiAl, ⁇ -TiAl, etc.) are those compositions that are capable of forming the two-phase ( ⁇ + ⁇ 2 ) microstructure found generally centered around about 44-48 atomic percent aluminum in the binary titanium-aluminum phase diagram. Alloying additions of X, where X may include, but is not limited to, chromium, niobium, molybdenum, boron, and/or carbon, etc., may be provided in embodiments of this invention to modify and/or improve the properties of the alloy for a given application.
  • the preform may be formed 13 from the powder in any suitable manner, such as, for example, by hot isostatic pressing, hot die compaction, etc.
  • the powder may be canned and hot isostatic pressed at a temperature sufficient to densify the preform and consolidate the powder through bonding thereof. Hot isostatic pressing the powder in this manner allows the powder grains to connect metallically and/or to sinter together.
  • the preform should have a near gamma microstructure if the hot isostatic pressing is performed below the alpha transus temperature (T ⁇ ) of the powder.
  • the component can be created 15 therefrom in any suitable manner, such as, for example, by forging, extrusion, and/or by a combination of extrusion and then forging, etc.
  • the preform may be isothermally forged to create a desired component, such as a disk.
  • the extrusion and/or isothermal forging are typically carried out at a temperature in the ( ⁇ + ⁇ ) phase field of the Ti-Al phase diagram, which is well below T ⁇ for this material. Therefore, gamma-TiAl components should have a near gamma microstructure after they are formed.
  • the extrusion and/or isothermal forging may be carried out at temperatures as high as about 1023°C or higher.
  • the component can be heat treated 17 to create the desired microstructure therein. Since fully lamellar microstructures are strong and crack resistant, they are desirable in many applications.
  • a crack resistant lamellar microstructure can be achieved in gamma-TiAl components by heat treating the component at a temperature above the T ⁇ of the component alloy. In other embodiments (i.e., nickel aluminides, iron aluminides, other titanium alloys and other superalloys), heat treating at temperatures of about 1000-1200°C for about 2-4 hours may be used to create a desirable microstructure in the components.
  • Such elevated temperature heat treatment often leaves behind cavities in the component, which can be confirmed in various manners, such as, for example, by ultrasonic scanning, x-ray radiography, serial sectioning, etc.
  • porosity may be thermally induced porosity that is created by the argon or other insoluble gas that is entrapped in the powder, which agglomerates in the form of cavities/pores during heat treatment. This is an undesirable condition known as thermally induced porosity. Regardless of the mechanism of formation, this porosity may be much larger than acceptable for many components.
  • the porosity may be associated with grain boundaries, which may reduce the low cycle fatigue properties of the final component by serving as preferential sites for crack initiation. Therefore, this porosity must be eliminated, or at least be reduced to an acceptable level, in order for powder metallurgy techniques to be acceptably utilized for forming many components.
  • hot isostatic pressing 19 the component after heat treating 17 may eliminate the porosity therein, or at least reduce the porosity therein to an acceptable level.
  • Hot isostatic pressing can eliminate internal voids and microporosity in a component through a combination of plastic deformation, creep and diffusion, thereby producing a denser component.
  • This hot isostatic pressing step should have minimal effect on the microstructure, other than decreasing the amount or size of porosity therein.
  • a simple calculation may be done to show whether or not the compressive creep strain that is developed during this hot isostatic pressing step is enough to heal the porosity therein sufficiently to make the component acceptable for use for a given application.
  • ultrasonic inspection may be utilized to verify that any porosity remaining in the component is acceptable.
  • the component Once the component is heat treated and hot isostatic pressed, it may be machined or otherwise formed to its desired final dimensions, if necessary.
  • the fully lamellar microstructure of the gamma-TiAl components should be maintained if this additional processing step is carried out at a temperature below the T ⁇ of the component alloy.
  • the powder metallurgy processing techniques of this invention may be utilized to make a variety of components, such as, for example, gas turbine engine components (i.e., compressor disks, compressor blades, low pressure turbine blades, tangential on board injectors, etc.) or any other components that may be exposed to high mechanical loads at high temperatures.
  • gas turbine engine components i.e., compressor disks, compressor blades, low pressure turbine blades, tangential on board injectors, etc.
  • any other components that may be exposed to high mechanical loads at high temperatures.
  • An exemplary non-limiting sample gamma-TiAl disk was made and evaluated to verify this invention.
  • This sample was prepared utilizing argon gas atomized gamma-TiAl powder 11 having a nominal composition, in atomic percent, of Ti-46Al-3.7(Nb,Cr,Mo)-0.4(B,C) and having an average particle size of about 70 ⁇ m.
  • a preform was created 13 by canning and hot isostatic pressing this powder at about 1260°C and about 25 ksi (172 MPa) for about 4 hours in an argon atmosphere.
  • the preform was isothermally forged 15 into a disk in a two-step operation in the ( ⁇ + ⁇ ) phase field at about 1177°C using about an 85% reduction.
  • the disk had a near gamma microstructure, as shown in Figure 2.
  • the disk was then heat treated 17 at about 1354°C for about 4 hours under vacuum to create a fully lamellar microstructure comprising alternating platelets of ⁇ -TiAl phase and ⁇ 2 -Ti 3 Al with an average lamellar grain size of about 250 ⁇ m, as shown in Figure 3.
  • gamma-TiAl having a duplex microstructure provides better elongation and strength properties
  • gamma-TiAl having a lamellar microstructure provides better creep resistance, toughness, and crack resistance.
  • Ultrasonic scans and serial sectioning indicated that a small amount of cavities/pores 50, 55 existed in this heat treated disk, as shown in Figure 4. As shown in Figures 5 (a) and (b), ultrasonic scans confirmed the presence of this porosity 50, 55.
  • This porosity 50, 55 which had diameters of about 0.013" (0.33 mm) and 0.019" (0.48 mm) respectively, was much larger than acceptable for many components, such as for rotating compressor disks used in gas turbine engines.
  • this invention provides improved powder metallurgy processing techniques for producing components having little or no porosity therein.
  • these techniques can be used with a variety of materials to produce components that have good mechanical properties at elevated temperatures. These techniques may be utilized to make gas turbine engine components and other components that are subjected to high mechanical loads at high temperatures. Many other embodiments and advantages will be apparent to those skilled in the relevant art.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Powder Metallurgy (AREA)
EP05255133A 2004-10-20 2005-08-19 Composant à basse porosité formée par métallurgie de poudres Withdrawn EP1649954A3 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/969,160 US20060083653A1 (en) 2004-10-20 2004-10-20 Low porosity powder metallurgy produced components

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Publication Number Publication Date
EP1649954A2 true EP1649954A2 (fr) 2006-04-26
EP1649954A3 EP1649954A3 (fr) 2006-10-11

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EP05255133A Withdrawn EP1649954A3 (fr) 2004-10-20 2005-08-19 Composant à basse porosité formée par métallurgie de poudres

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US (1) US20060083653A1 (fr)
EP (1) EP1649954A3 (fr)
JP (1) JP2006118038A (fr)
KR (1) KR20060053133A (fr)
RU (1) RU2005125788A (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2692464A3 (fr) * 2012-08-01 2017-05-10 Honeywell International Inc. Composants d'aluminure de titane et procédés de fabrication desdits composants à partir d'articles formés par un processus de consolidation
EP3067435B1 (fr) 2015-03-09 2017-07-26 LEISTRITZ Turbinentechnik GmbH Procede de production d'un composant tres resistant en alliage d'aluminure de titane alpha+gamma pour machines a piston et turbines a gaz, en particulier groupes motopropulseurs
CN108380893A (zh) * 2018-03-28 2018-08-10 西北工业大学 TiAl系金属间化合物圆环热等静压扩散连接方法

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KR100757258B1 (ko) * 2006-10-31 2007-09-10 한국전력공사 고온등압압축-열처리 일괄공정에 의한 가스터빈용 니켈계초합금 부품의 제조방법 및 그 부품
IT1399883B1 (it) 2010-05-18 2013-05-09 Nuova Pignone S R L Girante incamiciata con materiale funzionale graduato e metodo
EP2570674A1 (fr) * 2011-09-15 2013-03-20 Sandvik Intellectual Property AB Aube de rotor résistant à l'érosion consistant en un stratifié métallique
KR101312317B1 (ko) * 2011-11-16 2013-09-27 국방과학연구소 이종 특성을 가진 부재들을 포함하는 일체형 부품 및 그 제조 방법
US10309232B2 (en) * 2012-02-29 2019-06-04 United Technologies Corporation Gas turbine engine with stage dependent material selection for blades and disk
CN102776413B (zh) * 2012-07-27 2013-12-25 中国航空工业集团公司北京航空材料研究院 一种新型钛基高温合金的制备方法
US20150377073A1 (en) * 2013-03-15 2015-12-31 United Technologies Corporation Titanium aluminide turbine exhaust structure
ES2728527T3 (es) * 2014-09-01 2019-10-25 MTU Aero Engines AG Procedimiento de fabricación de componentes de TiAl
JP6792837B2 (ja) * 2016-02-17 2020-12-02 国立大学法人大阪大学 チタン‐アルミニウム合金
CN106244853B (zh) * 2016-08-30 2018-04-06 南京赛达机械制造有限公司 一种防水蚀钛合金汽轮机叶片
CN113664199A (zh) * 2021-08-20 2021-11-19 西安欧中材料科技有限公司 航空发动机涡轮叶片热等静压近净成型方法

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2692464A3 (fr) * 2012-08-01 2017-05-10 Honeywell International Inc. Composants d'aluminure de titane et procédés de fabrication desdits composants à partir d'articles formés par un processus de consolidation
EP3702069A1 (fr) * 2012-08-01 2020-09-02 Honeywell International Inc. Composants d'aluminure de titane à partir d'articles formés par un processus de consolidation
EP3067435B1 (fr) 2015-03-09 2017-07-26 LEISTRITZ Turbinentechnik GmbH Procede de production d'un composant tres resistant en alliage d'aluminure de titane alpha+gamma pour machines a piston et turbines a gaz, en particulier groupes motopropulseurs
US10196725B2 (en) 2015-03-09 2019-02-05 LEISTRITZ Turbinentechnik GmbH Method for the production of a highly stressable component from an α+γ-titanium aluminide alloy for reciprocating-piston engines and gas turbines, especially aircraft engines
EP3067435B2 (fr) † 2015-03-09 2021-11-24 LEISTRITZ Turbinentechnik GmbH Procede de production d'un composant tres resistant en alliage d'aluminure de titane alpha+gamma pour machines a piston et turbines a gaz, en particulier groupes motopropulseurs
CN108380893A (zh) * 2018-03-28 2018-08-10 西北工业大学 TiAl系金属间化合物圆环热等静压扩散连接方法

Also Published As

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US20060083653A1 (en) 2006-04-20
EP1649954A3 (fr) 2006-10-11
JP2006118038A (ja) 2006-05-11
RU2005125788A (ru) 2007-02-20
KR20060053133A (ko) 2006-05-19

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