EP1779946B1 - Pressage isostatique à chaud supersolvus et laminage circulaire de formes creueses de poudres - Google Patents

Pressage isostatique à chaud supersolvus et laminage circulaire de formes creueses de poudres Download PDF

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Publication number
EP1779946B1
EP1779946B1 EP06255430A EP06255430A EP1779946B1 EP 1779946 B1 EP1779946 B1 EP 1779946B1 EP 06255430 A EP06255430 A EP 06255430A EP 06255430 A EP06255430 A EP 06255430A EP 1779946 B1 EP1779946 B1 EP 1779946B1
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Prior art keywords
annular
metallic
powder
ring rolling
temperature
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EP06255430A
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German (de)
English (en)
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EP1779946A1 (fr
Inventor
Jon Raymond Groh
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General Electric Co
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General Electric Co
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0433—Nickel- or cobalt-based alloys
    • 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
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • B22F5/106—Tube or ring forms
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/248—Thermal after-treatment
    • 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

Definitions

  • This invention relates to the fabrication of annular articles and, more particularly, to the fabrication of such annular articles from metal powders with minimal wasted material.
  • a number of important commercial articles have the shape of an annulus or annular band. Such articles are typically, but not necessarily, thin-walled cylinders with a large ratio of inner diameter-to-outer diameter (DI/DO) of greater than 0.75 but less than 1.0.
  • DI/DO inner diameter-to-outer diameter
  • the turbine blade retainers and the turbine cases are thin-walled cylinders having DI/DO of about 0.85 and 0.95, respectively.
  • this article is often made from a powder-metal, precipitation-strengthened nickel-base superalloy selected for use in severe operating conditions.
  • the nickel-base superalloy composition is melted and atomized to form a powder, and consolidated by a combination of hot isostatic pressing, hot compaction, and extrusion to form re-forge stock.
  • the powder is then worked by isothermal or hot-die forging into the form of a flat or contoured pancake.
  • the center section of the pancake is removed by trepanning, and the outer surface is machined to a generally cylindrical form. This preform is machined to the required ratio of inner diameter-to-outer diameter.
  • the removed center section and chips become revert material sent back to the melting operation.
  • a method of producing an annular article is known for instance from RU-C1-2 069 595 .
  • the present invention provides an approach for fabricating an annular metallic article from a powder starting material.
  • the microstructure of the final article is homogeneous, within the limits of the rolling process.
  • the final article does not have cast-in or working imperfections or cracking associated with production techniques using cast-and-wrought procedures.
  • the present approach is also highly economical in terms of the buy-to-fly cost ratio, because little, if any, material is removed by trepanning or machining of a center section.
  • a method for fabricating an annular metallic article comprises the steps of providing a can having an outer wall, an inner wall, and a fill volume between the outer wall and the inner wall, and loading a metallic powder into the fill volume.
  • the metallic powder is of a composition that has a precipitate solvus temperature, and a solidus temperature, which is greater than the precipitate solvus temperature.
  • the method further includes compacting the metallic powder at a temperature between the precipitate solvus temperature and the solidus temperature (i.e., greater than the precipitate solvus temperature and less than the solidus temperature) to form a compacted powder mass, and ring rolling the compacted powder mass to form the annular metallic article.
  • the step of compacting is preferably performed by hot isostatic pressing the can with the metallic powder therein.
  • the method includes no press forging; the method includes no extrusion; and the method includes no upset forging.
  • the compacted powder mass may be removed from the can after the step of compacting and before the step of ring rolling, but the ring rolling may instead be performed with the can in place.
  • the metallic powder is preferably made of a pre-alloyed nickel-base superalloy having a gamma prime ( ⁇ ') precipitate solvus temperature and a solidus temperature greater than the precipitate solvus temperature.
  • the step of compacting includes the step of compacting the metallic powder above the gamma prime precipitate solvus temperature and below the solidus temperature to produce a microstructure amenable to deformation by the ring rolling method.
  • Ring rolling may be performed in any operable manner, but is preferably performed at a temperature of below the precipitate solvus temperature to control grain size.
  • the final article may have an annular circular shape, so that it is cylindrically symmetric with its outer surface and its inner surface both substantially cylindrical.
  • the annular circular shape has a ratio of an inner diameter to an outer diameter (DI/DO) of greater than 0.75 and less than 1.0.
  • DI/DO inner diameter to an outer diameter
  • the approach is operable with smaller ratios of DI/DO, but its greatest economic benefits are realized when DI/DO is greater than 0.75 and less than 1.0.
  • the final article need not be cylindrically symmetric, and could have contoured cross-sectional shapes other than cylinders, such as for example, annular truncated cones.
  • a method for fabricating an annular metallic article comprises the steps of providing a can having a cylindrical outer wall, a cylindrical inner wall, and a fill volume between the outer wall and the inner wall, and loading a metallic powder into the fill volume.
  • the metallic powder is a pre-alloyed nickel-base superalloy having a gamma prime precipitate solvus temperature and a nickel-base superalloy solidus temperature above the gamma prime precipitate solvus temperature.
  • the method further includes compacting the metallic powder by hot isostatic pressing within the can at a temperature above the gamma prime precipitate solvus temperature to form a compacted powder mass, and ring rolling the compacted powder mass to form the metallic article having an annular circular shape. No press forging, no extrusion, and no upset forging are employed in the method. Other operable features described herein may be used with this embodiment.
  • the present approach fabricates an annular metallic article from powder metal.
  • the material is not cast and wrought, so that there is no cracking, casting segregation, or other imperfection resulting from casting and working operations.
  • the present approach allows the use of some highly alloyed metals that cannot be fabricated into annular articles by the conventional approach, because they are too strong to be fabricated by the conventional approach.
  • the metal powder is initially loaded into the annular fill volume of the can having an inner wall and an outer wall, and then the can with the metal powder is consolidated. The resulting annular powder compact is then ring rolled to the final form.
  • the use of the hollow-can (that is, hollow between its inner wall and its outer wall) approach results in relatively efficient utilization of the powder metal in the final ring-rolled annular article--the "buy-to-fly" ratio is closer to 1.0 than achieved by current methods.
  • This approach greatly reduces or avoids entirely the need to remove and scrap metal from the central portion of a conventional forging as in prior approaches. The result is that the metallurgical and mechanical performances of the final annular article, and its cost, are improved over that achieved by prior approaches.
  • the present approach is to be contrasted with conventional ring rolling, in which the ring-rolling stock is prepared by casting and upset forging.
  • the working of the reforge stock to a ring by conventional ring rolling would cause cracking in the nickel-base superalloy, which normally has a high flow stress and limited ductility. Cracking during conventional upset, punch, and ring rolling may be reduced by changing the alloying content of the nickel-base superalloy to increase the ductility and achieve the malleability required for the ring-rolled article, but the result is reduced material performance in service. Textures and other characteristics of the rolled material may be retained into the final article in the conventional ring-rolling approach, resulting in anisotropic properties.
  • Figures 1 and 2 depict an annular metallic article 20.
  • the annular metallic article 20 has an outer surface 22, an inner surface 24, an interior volume 26 within the inner surface 24, an axis 28 extending through the interior volume 26, and solid metal in an annular volume 30 between the outer surface 22 and the inner surface 24.
  • the annular metallic article 20 may be cylindrical with the axis 28 as a cylindrical axis so that the annular metallic article 20 is circular in cross section as illustrated in Figure 2 , or it may be noncircular in cross section. Where the annular metallic article 20 is cylindrical with a circular cross section as shown in Figure 2 , the annular metallic article 20 may be described as having an outer diameter DO of the outer surface 22 and an inner diameter DI of the inner surface 24. It is preferred, but not necessary, that the ratio DI/DO be greater than 0.75 and less than 1.0, which is termed herein a "thin-walled" annular article.
  • Figure 3 depicts a method for fabricating the annular metallic article 20.
  • the method includes providing a can 60, step 40.
  • the can is desirably made of a metal such as 300-series stainless steel.
  • the can 60 illustrated in Figure 4 , has an outer wall 62, an inner wall 64, an annular fill volume 66 between the outer wall 62 and the inner wall 64, an open top 68 to the fill volume 66, and preferably a solid bottom 70 to the fill volume 66.
  • the annular fill volume 66 of the can 60 is initially empty and hollow, but is subsequently filled with powder, as shown. Desirably, an open central space 72 extends through the volume bounded by the inner wall 64.
  • a metallic powder 74 is loaded into the fill volume 66 of the can 60, step 42.
  • the metallic powder 74 is of a nickel-base superalloy composition that has a gamma prime precipitate solvus temperature and a solidus temperature that is greater than the gamma prime precipitate solvus temperature. That is, there is a gamma prime phase that is present below the precipitate solvus temperature, and that phase dissolves into the metallic matrix when the temperature is raised into the range above the precipitate solvus temperature and below the solidus temperature of the metal powder to improve malleability.
  • the metallic powder 74 may be pre-alloyed or not pre-alloyed, but pre-alloyed is preferred because subsequent processing is typically not at a sufficiently high temperature and for a sufficiently long time to achieve substantially complete homogeneity, if the powder is not furnished in the pre-alloyed form.
  • the metallic powder 74 is a nickel-base superalloy composition.
  • nickel-base means that the composition has more nickel than any other element.
  • the nickel-base superalloy is defined as a nickel-base alloy strengthened by the precipitation of gamma prime or a related phase.
  • ReneTM 88DT having a nominal composition, in weight percent, of about 13 percent cobalt, about 16 percent chromium, about 4 percent molybdenum, about 3.7 percent titanium, about 2.1 percent aluminum, about 4 percent tungsten, about 0.75 percent niobium, about 0.015 percent boron, about 0.03 percent zirconium, about 0.05 percent carbon, up to about 0.5 percent iron, balance nickel and minor impurity elements; and ReneTM 95, having a nominal composition, in weight percent, of about 13 percent chromium, about 8 percent cobalt, about 3.5 percent molybdenum, about 3.5 percent tungsten, about 3.5 percent niobium, about 2.5 percent titanium, about 3.5 percent aluminum, about 0.01 percent boron, about 0.05 percent zirconium, about 0.06 percent carbon, balance nickel and incidental impurities.
  • Each of these nickel-base superalloys has a gamma-prime precipitate solvus temperature (less than the solidus temperature), above which the gamma-prime phase dissolves into the gamma matrix, and below which the gamma-prime phase is thermodynamically stable.
  • These alloys are of particular interest in fabricating annular metallic articles 20 such as turbine blade retainers and turbine cases because they offer improved mechanical performance to the articles but are of too high a strength and too low a malleability to be fabricated by the conventional casting and upset forging approach.
  • the present approach allows annular metallic articles 20 of such materials to be fabricated of such materials.
  • the metallic powder 74 is compacted at a temperature above the precipitate solvus temperature and below the solidus temperature of the metallic powder 74 to form a compacted powder mass with sufficient malleability to work by methods such as ring rolling, step 44.
  • the fill volume 66 having the metal powder therein is sealed (and optionally evacuated), as by welding an annular top plate over the open top 68.
  • the compacting is preferably performed by hot isostatic pressing (HIP) the metallic powder 74 within the can 60, thereby using the can as the containment vessel for the hot isostatic pressing.
  • HIP hot isostatic pressing
  • Other operable compacting techniques such as extrusion or upset forging may be used but are less preferred because they tend to impart a preferred orientation to the compacted powder mass.
  • the compacting step 44 increases the relative density of the mass of metallic powder 74 and also causes the individual particles to bond together and become cohesive. Because of the form of the can 60 and the annular fill volume 66, the compacted powder mass is annular in shape. A central portion of the compacted powder mass is therefore not trepanned or otherwise removed, avoiding the need for this costly processing step found in conventional approaches.
  • the compacted powder mass may optionally be removed from the can 60 at this point, step 46. Alternatively, the next step may be performed with the compacted powder mass still within the can 60. If the compacted powder mass is removed from the can 60, the removal is preferably accomplished by machining the can 60 from the exterior of the compacted powder mass.
  • the compacted powder mass is ring rolled to form the annular metallic article 20, step 48.
  • Ring rolling is a known rolling technology for other applications, but has not been used in the present manner.
  • Figure 5 schematically depicts the compacted powder mass 76 being processed by a ring-rolling apparatus 78.
  • the ring rolling step 48 starts with the annular compacted powder mass 76 resulting from step 44 (or from step 46, if used), and continuously reduces a thickness T of the annular compacted powder mass 76 as each portion passes between the ring rolls, until the desired thickness is reached.
  • the annular compacted powder mass 76 is cylindrical
  • the final annular metallic article 20 is typically cylindrical or nearly cylindrical, and can be straightened to a cylindrical form if desired.
  • the ring rolling is preferably performed at a ring-rolling temperature below the gamma prime precipitate solvus temperature to control grain growth and grain structure of the material during the ring rolling.
  • the ring-rolled annular metallic article 20 may be removed from the remnants of the can 60, step 50. (That is, either step 46 or step 50 is normally performed, but not both steps.) This removal is preferably accomplished by machining the remnants of the can 60 from the ring-rolled annular metallic article 20. Alternatively, for some applications it may be desired to leave the remnants of the metallic can 60 in place, and neither step 46 nor step 50 is performed. Subsequent optional heat treatment processes, step 52, such as solution heat treating and precipitation ageing may be performed with the can intact or after removal of the can.
  • the article may optionally be final processed, step 54, such as by final machining and/or coating.
  • step 54 such as by final machining and/or coating.
  • the order of steps 50, 52, and 54, when performed, may be interchanged as necessary or desired.
  • Annular article 70 Solid bottom 22 Outer surface 72 Central space 24 Inner surface 74 Metallic powder 26 Interior volume 76 Compacted powder 28 Axis 78 Ring-rolling apparatus 30 Annular volume 80 32 82 34 84 36 86 38 88 40 90 42 92 44 94 46 96 48 Figure 3 98 50 100 52 102 54 104 56 106 58 108 60 Hollow can 110 62 Outer wall 112 64 Inner wall 114 66 Fill volume 116 68 Open top 118

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Forging (AREA)

Claims (10)

  1. Procédé de fabrication d'un article métallique annulaire (20), comprenant les étapes de préparation d'une boîte (60) présentant une paroi externe (62), une paroi interne (64), et un volume de remplissage (66) entre la paroi externe (62) et la paroi interne (64) ;
    chargement d'une poudre métallique (74) dans le volume de remplissage (66), dans lequel la poudre métallique (74) est d'une composition qui présente une certaine température de solvus de précipité et une température de solidus supérieure à la température de solvus de précipité ;
    compactage de la poudre métallique (74) à une température comprise entre la température de solvus de précipité et la température de solidus afin de former une masse de poudre compacte (76) ; et
    laminage annulaire de la masse de poudre compactée (76) afin de former l'article métallique annulaire (20).
  2. Procédé selon la revendication 1, dans lequel l'étape de chargement comporte l'étape de
    production de la poudre métallique (74) réalisée à partir d'un super alliage à base de nickel préalablement allié présentant une certaine température de solvus de précipité gamma prime.
  3. Procédé selon la revendication 1, dans lequel l'étape de chargement comporte l'étape de
    production de la poudre métallique (74) réalisée à partir d'un super alliage à base de nickel préalablement allié présentant une certaine température de solvus de précipité gamma prime, et l'étape de compactage comporte l'étape de
    compactage de la poudre métallique (74) au-dessus de la température de solvus de précipité gamma prime.
  4. Procédé selon la revendication 1, dans lequel l'étape de chargement comporte l'étape de
    production d'une composition de poudre métallique présentant une résistance trop élevée et une malléabilité trop faible pour être façonnée en un article métallique annulaire (20) par moulage et forgeage par refoulement.
  5. Procédé selon la revendication 1, dans lequel l'étape de compactage comporte l'étape de
    pressage isostatique à chaud de la boîte (60) avec la poudre métallique (74) à l'intérieur.
  6. Procédé selon la revendication 1, dans lequel le procédé ne comporte pas d'estampage à chaud, ni d'extrusion, et ni de forgeage par refoulement.
  7. Procédé selon la revendication 1, dans lequel l'étape de laminage annulaire comporte l'étape de
    laminage annulaire de la masse de poudre compactée (76) à une température inférieure à la température de solvus de précipité.
  8. Procédé selon la revendication 1, dans lequel l'étape de laminage annulaire comprend l'étape de
    laminage annulaire de la masse de poudre compactée (76) en une forme circulaire annulaire.
  9. Procédé selon la revendication 1, dans lequel l'étape de laminage annulaire comprend l'étape de
    laminage annulaire de la masse de poudre compactée (76) en une forme circulaire annulaire présentant un rapport d'un diamètre interne sur un diamètre externe supérieur à 0,75 et inférieur à 1,0.
  10. Procédé selon la revendication 1, comportant une étape supplémentaire, après l'étape de laminage annulaire, de traitement thermique de l'article métallique annulaire (20).
EP06255430A 2005-10-26 2006-10-23 Pressage isostatique à chaud supersolvus et laminage circulaire de formes creueses de poudres Active EP1779946B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/258,663 US20070092394A1 (en) 2005-10-26 2005-10-26 Supersolvus hot isostatic pressing and ring rolling of hollow powder forms

Publications (2)

Publication Number Publication Date
EP1779946A1 EP1779946A1 (fr) 2007-05-02
EP1779946B1 true EP1779946B1 (fr) 2009-05-13

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DE (1) DE602006006775D1 (fr)

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NO329945B1 (no) 2008-10-10 2010-12-27 Tool Tech As Fremgangsmate for fremstilling av en syrefast, somlos trykkbeholder
RU2483835C1 (ru) * 2012-01-19 2013-06-10 Открытое акционерное общество "Всероссийский Институт Легких сплавов" (ОАО ВИЛС) Способ получения деталей газотурбинных двигателей с длительным ресурсом эксплуатации из порошковых никелевых сплавов
FR2996476B1 (fr) * 2012-10-05 2015-02-13 Snecma Procede de fabrication d'une piece couverte d'un revetement abradable
FR2996474B1 (fr) * 2012-10-05 2014-12-12 Snecma Procede pour l'integration de materiau abradable dans un logement par compression isostatique
CN103551573B (zh) * 2013-10-22 2015-06-17 中国科学院金属研究所 可避免原始颗粒边界相析出的高温合金粉末热等静压工艺
CN106111992B (zh) * 2016-06-23 2018-09-18 航天材料及工艺研究所 一种热等静压粉末冶金薄壁构件的壁厚均匀性控制工装及方法
US20200122233A1 (en) * 2018-10-19 2020-04-23 United Technologies Corporation Powder metallurgy method using a four-wall cylindrical canister

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US3533782A (en) * 1967-01-13 1970-10-13 Schloemann Ag Production of shaped pieces,strips or sections from metal particles
US3982904A (en) * 1973-06-27 1976-09-28 Viking Metallurgical Corporation Metal rings made by the method of particle ring-rolling
GB1557744A (en) * 1976-06-01 1979-12-12 Special Metals Corp Process and apparatus for producing aticles of complex shape
US4212669A (en) * 1978-08-03 1980-07-15 Howmet Turbine Components Corporation Method for the production of precision shapes
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US4405295A (en) * 1982-03-01 1983-09-20 Amsted Industries Incorporated Method of manufacturing complex metallic plate
RU2069595C1 (ru) * 1993-03-01 1996-11-27 Акционерное общество "Кулебакский металлургический завод" Способ изготовления раскатных кольцевых заготовок
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JP2004042235A (ja) * 2002-07-15 2004-02-12 Mitsubishi Heavy Ind Ltd 環状工作物製造装置及び環状工作物製造方法

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DE602006006775D1 (de) 2009-06-25
EP1779946A1 (fr) 2007-05-02
US20070092394A1 (en) 2007-04-26

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