EP2217395A1 - Net or near net shape powder metallurgy process - Google Patents
Net or near net shape powder metallurgy processInfo
- Publication number
- EP2217395A1 EP2217395A1 EP08852655A EP08852655A EP2217395A1 EP 2217395 A1 EP2217395 A1 EP 2217395A1 EP 08852655 A EP08852655 A EP 08852655A EP 08852655 A EP08852655 A EP 08852655A EP 2217395 A1 EP2217395 A1 EP 2217395A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- former
- coating
- component
- boron nitride
- carbon
- 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.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 39
- 238000004663 powder metallurgy Methods 0.000 title description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 52
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 29
- 238000000576 coating method Methods 0.000 claims abstract description 26
- 238000009792 diffusion process Methods 0.000 claims abstract description 26
- 239000011248 coating agent Substances 0.000 claims abstract description 24
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 23
- 239000010439 graphite Substances 0.000 claims abstract description 23
- 239000000843 powder Substances 0.000 claims abstract description 23
- 229910052582 BN Inorganic materials 0.000 claims abstract description 20
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims abstract description 20
- 238000001513 hot isostatic pressing Methods 0.000 claims abstract description 12
- 229910052751 metal Inorganic materials 0.000 claims abstract description 12
- 239000002184 metal Substances 0.000 claims abstract description 12
- 238000005507 spraying Methods 0.000 claims abstract description 8
- 238000001816 cooling Methods 0.000 claims abstract description 5
- 238000003826 uniaxial pressing Methods 0.000 claims abstract description 3
- 239000002002 slurry Substances 0.000 claims abstract 9
- 230000008602 contraction Effects 0.000 claims abstract 2
- 239000000463 material Substances 0.000 claims description 16
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 16
- 229910045601 alloy Inorganic materials 0.000 claims description 14
- 239000000956 alloy Substances 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 3
- 238000003825 pressing Methods 0.000 claims 2
- 239000010410 layer Substances 0.000 description 9
- 238000007596 consolidation process Methods 0.000 description 8
- 229910052759 nickel Inorganic materials 0.000 description 7
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000007900 aqueous suspension Substances 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 3
- 229910052804 chromium Inorganic materials 0.000 description 3
- 239000011651 chromium Substances 0.000 description 3
- 238000003754 machining Methods 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000012255 powdered metal Substances 0.000 description 3
- 230000004888 barrier function Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 125000004432 carbon atom Chemical group C* 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- 229910000990 Ni alloy Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000009694 cold isostatic pressing Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000011156 metal matrix composite Substances 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 230000000930 thermomechanical effect Effects 0.000 description 1
- 238000012876 topography Methods 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
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
- B22F3/15—Hot isostatic pressing
-
- 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
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
Definitions
- This invention relates to a net or near net shape powder metallurgy process.
- the invention relates particularly, but not exclusively, to the provision of an atomic diffusion filter between a graphite former, used to derive the finished net or near net shape form used in the manufacture of near net shape powder metallurgy components.
- a known manufacturing method used for producing components and materials utilises the consolidation of metal powders by Hot Isostatic Pressing.
- a pre-consolidation of the metal powders may or may not be used utilising Cold Isostatic Pressing.
- metal powder is placed in a containment and a vacuum is applied within the containment, and the containment is sealed. This then may or may not be partially consolidated in a cold form by subjecting the containment to a cold Isostatic process (CIPing) . The contained powder is then subjected to Hot Isostatic Pressing (HIPing) .
- CIPing cold Isostatic process
- HIPing Hot Isostatic Pressing
- the HIPing process utilises the application of heat at approximately, but not essentially, 80% of solidus of the material of which the powder is derived.
- This process subjects the metal powder to thermo mechanical stress whereby the metal powders are mechanically deformed in a super plastic condition.
- the resulting intimate contact and movement between the powder particles results in a shear and compressive stresses being placed upon them.
- an atomic interaction (inter diffusion) between the particles takes place subsequently removing all prior practical history thus creating a solid homogenous metal form.
- a diffusion filter is provided between a graphite former and the metal powder to be pressed.
- a wet-sprayed deposit of an aqueous suspension of Boron Nitride is used to create the barrier/filter.
- the overall thickness of the coating determined primarily by the number of coats can be developed to control the amount of carbon diffusion desired or which can be tolerated.
- the method of spraying is by way of hand spraying for general application, or by the use of robotics in the case of high accuracy requirements and in applications requiring precise repeatability.
- Aqueous suspensions of boron nitride at different volume percentages can be selected through a series of tests aimed at optimising the spraying constitution and enabling accurate spraying to be undertaken.
- the boron nitride spraying is preferably applied substantially normally to provide a plurality of thin multi layers. Great care is required to ensure the thickness of the layers is controlled in order to provide the correct overall filtering level of the coating.
- adhesion of the initial coating layers is undertaken by the use of thin ghost coats applied by spraying. This helps to prevent the aqueous suspension from weeping and helps to provide adhesion of the coating to the carbon/graphite former is before the build up of secondary coats of normal strength are applied.
- Precise control of the thickness of the coating is essential in the case of net-shape forming to ensure that the finished dimensions after consolidation are accurate.
- the precise number of secondary coats used is governed to essentially control the level of carbon diffusion, but the accuracy of the finished component is also influenced by the coating thickness.
- the surface of the consolidated powder adjacent to the boron nitride filter is essentially modified by the controlled diffusion of carbon from the carbon/graphite former during consolidation.
- the activity of carbon atoms is high at the consolidation temperature that is, in case of nickel based alloys at or above 1000 0 C.
- the ability to modify the morphology of the surface of the consolidated powder is of importance in many cases and enables the surface to be tailored to specific application. For example to increase wear resistance and/or stiffness whilst the subsurface layers may be structured to provide increased toughness and/or corrosion resistance.
- the chemical analysis of the pre-consolidated powders is preferably adjusted to accommodate the diffusion of carbon. This is the case with both nickel based alloys and ferrous alloys.
- Surface modification may be utilised to enhance already structured powder formed parts. This can provide an in situ operation which requires no further diffusion processing and, particularly in the case of some nickel based alloys, requires no further heat treatment processing to achieve optimum hardness.
- the thickness of the coating also controls/influences the surface finish of the consolidated interface of the component. Thick layers of boron nitride have a high level of conformance to the interface powder during consolidation and thereby the surface will bear the topography of the powder particle shape. Thinner coatings, with subsequent higher levels of carbon diffusion, are less conformant and bear a closer surface likeness to that of the carbon/graphite former. In this case, if a high grade finish is applied to the former the consolidated powder will also bear a similar surface finish.
- the boron nitride will consolidate during both HIPing and CIPing, and when using combinations of both, and size predictions can be developed from a series of tests.
- boron nitride on graphite formers can serve a further and very important function. This is to allow the differential expansion between the powdered metal and the carbon/graphite former. This is of major importance during the cooling cycle when the two materials are cooling from the consolidation temperature. This may, for example, be from a temperature in excess of 1000 0 C, and the differential expansion typically between a nickel superalloy and some graphite can be as high as 11 x
- boron nitride can/does allow movement between the two materials to take place and thereby prevent the work from being destroyed or at best spoilt.
- This feature is particularly important in the case of long components such as linear motors and/or pumps. In this case, components up to and greater than 2 metres are produced by this method which would not be possible without the utilisation of this technique.
- hard materials and/or hard metal matrix composite powders are consolidated no further machining and or shape forming can be done therefore the incorporation of this type of technique is essential.
- the coefficient of thermal expansion of graphite can vary from 4 x 10 6 /°C to approaching 6 xlO "6 /°C which is a significant difference but not as significant as the potential difference between the different types of powdered metals that may be used in this process, which may vary between 15 x 10 6 /°C and 9 x 10 ⁇ 6 /°C. It can be clearly seen that great care is required to accommodate the CTE difference between the former and the consolidated powders when cooling.
- BN layer also acts as a release agent allowing the graphite former to be removed following HIPing.
- the surface finish of the net shape part is important. Therefore it is of additional importance to ensure that the BN layer is deposited evenly and accurately.
- (B) Thin shell net shape profiled bore walls can be produced for the high performance automotive industry. These parts are required to be manufactured in high quality ferrous steel alloy, and in this particular application of the invention it is essential to control the level of carbon diffusion into the surrounding steel part and to keep it as low as possible. Whilst in this case the accuracy is not so important, the quality and subsequent performance of the material is of great importance.
- the BN diffusion barrier in this application is applied to a thickness that is so chosen as to reduce carbon diffusion into the steel to an insignificant level.
- Typical materials suitable for surface modification by the diffusion of carbon are nickel-based alloys containing Si, B, Fe, Cr and C in this case the carbon content of the alloy is enhanced by the diffusion of further carbon during the HIPing process. It may be desirable to adjust the specified carbon and/or chromium content to optimise the post process properties of the material.
- a Nickel based alloy is typically:- Cl.0, Crl5, Si 4.0, B3.5, Fe4.5 Ni Balance, by weight percent.
- a Ferrous alloy is typically:
- the diffusion of carbon into other alloy steels followed by an appropriate heat treatment may be beneficial to increase both stiffness and the surface performance of components even though the materials are not ordinarily treated in such a way.
- the duration of the peak HIPing temperature can be adjusted to optimise the depth of carbon diffusion; provided the increase in time does not have a detrimental effect upon the overall morphology of the consolidated material. For example increased grain growth and/or undesirably affect the volume fraction or dimensions of precipitates.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Powder Metallurgy (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Filtering Materials (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP13179763.1A EP2662167B1 (en) | 2007-11-22 | 2008-11-21 | Hot pressed net or near net shape powder component |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GBGB0722850.5A GB0722850D0 (en) | 2007-11-22 | 2007-11-22 | Net or near net shape powder metallurgy process |
US2293508P | 2008-01-23 | 2008-01-23 | |
PCT/GB2008/003906 WO2009066082A1 (en) | 2007-11-22 | 2008-11-21 | Net or near net shape powder metallurgy process |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP13179763.1A Division-Into EP2662167B1 (en) | 2007-11-22 | 2008-11-21 | Hot pressed net or near net shape powder component |
EP13179763.1A Division EP2662167B1 (en) | 2007-11-22 | 2008-11-21 | Hot pressed net or near net shape powder component |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2217395A1 true EP2217395A1 (en) | 2010-08-18 |
EP2217395B1 EP2217395B1 (en) | 2014-07-23 |
Family
ID=38925835
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP08852655.3A Active EP2217395B1 (en) | 2007-11-22 | 2008-11-21 | Powder metallurgy process for producing a net shape or near net shape |
EP13179763.1A Active EP2662167B1 (en) | 2007-11-22 | 2008-11-21 | Hot pressed net or near net shape powder component |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP13179763.1A Active EP2662167B1 (en) | 2007-11-22 | 2008-11-21 | Hot pressed net or near net shape powder component |
Country Status (10)
Country | Link |
---|---|
US (1) | US20110038750A1 (en) |
EP (2) | EP2217395B1 (en) |
CN (1) | CN101868315B (en) |
BR (1) | BRPI0820415B1 (en) |
CA (1) | CA2744268A1 (en) |
EA (1) | EA026007B1 (en) |
ES (1) | ES2511843T3 (en) |
GB (1) | GB0722850D0 (en) |
MX (1) | MX336975B (en) |
WO (1) | WO2009066082A1 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB0922488D0 (en) * | 2009-12-23 | 2010-02-03 | Advanced Interactive Materials | Improvements in or relating to hot isostatic pressing |
CN106319267A (en) * | 2015-06-26 | 2017-01-11 | 华中科技大学 | Hot-isostatic-pressing forming method for in-situ generation of continuous spatial net structure |
CN105436505B (en) * | 2015-11-14 | 2017-10-13 | 华中科技大学 | A kind of high temperature insostatic pressing (HIP) manufacturing process for being used to improve surface quality of workpieces |
WO2019122958A1 (en) * | 2017-12-19 | 2019-06-27 | Arcelormittal | A coated steel substrate |
Family Cites Families (23)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB846292A (en) * | 1957-04-02 | 1960-08-31 | Atomic Energy Authority Uk | Production of shaped boron bodies |
US3049795A (en) * | 1958-05-02 | 1962-08-21 | Emery I Valyi | Gas permeable body |
GB941795A (en) * | 1962-01-08 | 1963-11-13 | Valyi Emery I | Improvements in or relating to permeable bodies |
GB1408572A (en) * | 1972-01-19 | 1975-10-01 | Lucas Industries Ltd | Method of producing a boron nitride coating on an article |
US3975121A (en) * | 1973-11-14 | 1976-08-17 | Smith International, Inc. | Wafer elements for progressing cavity stators |
DE2437208C3 (en) * | 1974-08-02 | 1979-07-19 | Mannesmann Ag, 4000 Duesseldorf | Storage and retrieval vehicle for high-rise freight container storage |
ZA79440B (en) * | 1978-02-10 | 1980-09-24 | Oakes Ltd E T | Drive arrangement |
JPS56130451A (en) | 1980-03-13 | 1981-10-13 | Daijietsuto Kogyo Kk | Cubic boron nitride sintered body |
JPS57181338A (en) | 1981-04-30 | 1982-11-08 | Tatsuro Kuratomi | Production of consolidated body of cubic boron nitride |
JPS60184649A (en) | 1984-02-29 | 1985-09-20 | Sumitomo Electric Ind Ltd | Manufacture of sintered body of high pressure phase boron nitride |
JPH02279575A (en) * | 1989-04-18 | 1990-11-15 | Nkk Corp | Production of sintered ceramic body having dense ceramic film |
US5171139A (en) * | 1991-11-26 | 1992-12-15 | Smith International, Inc. | Moineau motor with conduits through the stator |
US5799238A (en) * | 1995-06-14 | 1998-08-25 | The United States Of America As Represented By The United States Department Of Energy | Method of making multilayered titanium ceramic composites |
US5832604A (en) * | 1995-09-08 | 1998-11-10 | Hydro-Drill, Inc. | Method of manufacturing segmented stators for helical gear pumps and motors |
US5822853A (en) * | 1996-06-24 | 1998-10-20 | General Electric Company | Method for making cylindrical structures with cooling channels |
JP3410326B2 (en) * | 1997-04-25 | 2003-05-26 | 日立粉末冶金株式会社 | Method for producing iron-based sintered alloy, iron-based sintered alloy produced by this method, and bearing cap |
JPH1121116A (en) | 1997-06-30 | 1999-01-26 | Nippon Steel Corp | Carbonaceous powder and carbonaceous fiber, coated with boron nitride |
CN1112460C (en) * | 1998-04-17 | 2003-06-25 | 清华大学 | Method of preparing ceramic coating by laser smelting coating after metal surface plasma spray |
CN1076012C (en) * | 1998-04-24 | 2001-12-12 | 中国科学院上海硅酸盐研究所 | Process for preparation of transparent aluminium nitride ceramic |
US6241494B1 (en) * | 1998-09-18 | 2001-06-05 | Schlumberger Technology Company | Non-elastomeric stator and downhole drilling motors incorporating same |
US6837915B2 (en) * | 2002-09-20 | 2005-01-04 | Scm Metal Products, Inc. | High density, metal-based materials having low coefficients of friction and wear rates |
US7261855B2 (en) * | 2004-03-26 | 2007-08-28 | Igor Troitski | Method and system for manufacturing of complex shape parts from powder materials by hot isostatic pressing with controlled pressure inside the tooling and providing the shape of the part by multi-layer inserts |
US7739792B2 (en) * | 2006-07-31 | 2010-06-22 | Schlumberger Technology Corporation | Method of forming controlled thickness resilient material lined stator |
-
2007
- 2007-11-22 GB GBGB0722850.5A patent/GB0722850D0/en not_active Ceased
-
2008
- 2008-11-21 US US12/734,746 patent/US20110038750A1/en not_active Abandoned
- 2008-11-21 EP EP08852655.3A patent/EP2217395B1/en active Active
- 2008-11-21 EA EA201000852A patent/EA026007B1/en not_active IP Right Cessation
- 2008-11-21 BR BRPI0820415-2A patent/BRPI0820415B1/en not_active IP Right Cessation
- 2008-11-21 ES ES08852655.3T patent/ES2511843T3/en active Active
- 2008-11-21 CA CA2744268A patent/CA2744268A1/en not_active Abandoned
- 2008-11-21 EP EP13179763.1A patent/EP2662167B1/en active Active
- 2008-11-21 MX MX2010005306A patent/MX336975B/en active IP Right Grant
- 2008-11-21 WO PCT/GB2008/003906 patent/WO2009066082A1/en active Application Filing
- 2008-11-21 CN CN2008801172563A patent/CN101868315B/en active Active
Non-Patent Citations (1)
Title |
---|
See references of WO2009066082A1 * |
Also Published As
Publication number | Publication date |
---|---|
US20110038750A1 (en) | 2011-02-17 |
CN101868315B (en) | 2013-06-12 |
BRPI0820415B1 (en) | 2017-09-12 |
WO2009066082A1 (en) | 2009-05-28 |
EP2217395B1 (en) | 2014-07-23 |
GB0722850D0 (en) | 2008-01-02 |
EP2662167A3 (en) | 2014-03-05 |
MX336975B (en) | 2016-02-09 |
EA026007B1 (en) | 2017-02-28 |
EA201000852A1 (en) | 2010-10-29 |
ES2511843T3 (en) | 2014-10-23 |
CA2744268A1 (en) | 2009-05-28 |
BRPI0820415A2 (en) | 2015-05-19 |
MX2010005306A (en) | 2010-08-31 |
EP2662167A2 (en) | 2013-11-13 |
CN101868315A (en) | 2010-10-20 |
EP2662167B1 (en) | 2017-03-22 |
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