EP2343441B1 - Procede de fabrication d'une aube a incidence variable - Google Patents

Procede de fabrication d'une aube a incidence variable Download PDF

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Publication number
EP2343441B1
EP2343441B1 EP09819268.5A EP09819268A EP2343441B1 EP 2343441 B1 EP2343441 B1 EP 2343441B1 EP 09819268 A EP09819268 A EP 09819268A EP 2343441 B1 EP2343441 B1 EP 2343441B1
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EP
European Patent Office
Prior art keywords
sinter
blade unit
unit
pressing
shaft
Prior art date
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Not-in-force
Application number
EP09819268.5A
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German (de)
English (en)
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EP2343441A1 (fr
EP2343441A4 (fr
Inventor
Yoshimitsu Kankawa
Katsunori Nakagawa
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IHI Corp
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IHI Corp
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Publication date
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Publication of EP2343441A4 publication Critical patent/EP2343441A4/fr
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D17/00—Regulating or controlling by varying flow
    • F01D17/10—Final actuators
    • F01D17/12—Final actuators arranged in stator parts
    • F01D17/14—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits
    • F01D17/16—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes
    • F01D17/162—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes for axial flow, i.e. the vanes turning around axes which are essentially perpendicular to the rotor centre line
    • 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
    • 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
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D17/00—Regulating or controlling by varying flow
    • F01D17/10—Final actuators
    • F01D17/12—Final actuators arranged in stator parts
    • F01D17/14—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits
    • F01D17/16—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes
    • F01D17/165—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes for radial flow, i.e. the vanes turning around axes which are essentially parallel to the rotor centre line
    • 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
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/22—Manufacture essentially without removing material by sintering

Definitions

  • the present invention relates to a method for manufacturing a variable vane to be incorporated in a turbocharger for use in an automobile engine or the like. More particularly, the present invention relates to a method for fabricating a variable vane, in which a sinter obtained by metal powder injection molding (i.e., an MIM method) is pressed with a die for correcting the height and thickness of a blade, a die for correcting the shape of the blade, and a die for correcting a shaft so that both of the blade and the shaft can be formed in predetermined dimensions without machining.
  • a sinter obtained by metal powder injection molding i.e., an MIM method
  • a turbocharger for use in an automobile engine or the like is designed such that the flow rate of exhaust gas is amplified so as to enable the engine to efficiently obtain an output even during a low-speed rotation, the rotation of a turbine on an exhaust side by using the resultant exhaust energy enables a turbine on an intake side connected directly to the turbine on the exhaust side to be rotated, so as to forcibly take air into the engine.
  • the turbocharger is provided with a plurality of variable vanes as parts for adjusting the flow amount and flow rate of the exhaust gas.
  • Each of the variable vanes includes a rotational center shaft and a blade for adjusting the flow amount and flow rate of the exhaust gas.
  • the blade is more reduced in thickness toward its tip.
  • variable vane has been conventionally fabricated by machining. However, this method requires a very long machining time. Only about 100 to 500 variable vanes can be fabricated by one machine per day. It has resulted in very poor efficiency.
  • Patent Literature 1 discloses a product fabricating method by cold forging and polishing a steel material.
  • Patent Literature 2 discloses a product fabricating method for, by using a material fabricated by lost wax or the MIM method, rolling the material to form a shaft whereas pressing the material in a height direction to form a blade.
  • Patent Literature 3 discloses a product fabricating method for polishing a shaft by using a sinter obtained by the MIM method.
  • Patent Literature 1 requires forging and polishing, and therefore, a stainless alloy plate is prepared as the material.
  • a stainless alloy plate is prepared as the material.
  • a product is fabricated by pressing and rolling a material obtained by lost wax or the MIM method.
  • the method disclosed in Patent Literature 2 does not refer to a material machining method, and therefore, post machining is inevitably required in an axial rolling process.
  • Precision in a height direction can be enhanced by single-shaft pressing from above.
  • dimensional variations and deformation of ⁇ 0.5% or more with respect to a product dimension are generated during debinding(degreasing) and sintering. Therefore, even if the dimensional precision of the product is enhanced in the height direction by pressing, it is difficult to correct deformation in a vane unit. As a consequence, many portions need be cut and polished.
  • the dimensional variation of a product obtained by the conventional MIM method is ⁇ 0.05 mm.
  • the blade unit is likely to be expanded by compression in the width direction (i.e., a thickness direction) of the blade unit when pressed. Consequently, a blade unit having the height and width as calculated cannot be obtained unless the sinter is excellent in dimensional precision not only in the height direction but also in the width direction.
  • Patent Literature 3 does not refer to machining by the MIM method.
  • polishing is inevitable for enhancing the precision of the squareness of a shaft unit to a polished vane unit.
  • torsion or warpage occurs at the blade unit, it is difficult to obtain a highly precise product only by pressing.
  • an object of the present invention is to provide a method capable of manufacturing a variable vane having a high dimensional precision only by pressing without machining in order to solve the above-described problems.
  • a sinter having a shape approximate to that of a final product and the predetermined relationship with a desired final product is prepared.
  • the height and thickness (i.e., width) of the blade unit in the sinter are set to desired product dimensions at the same time in a first pressing process; the coaxiality between the blade unit and the shaft unit is set to a desired product dimension in a second pressing process; and the roundness(out-of-roundness) of the shaft unit is set to a desired product dimension in a third pressing process.
  • the dimensions of the shaft unit and the blade unit can be set with the dimensional precision (i.e., ⁇ 0.01 mm to 0.05 mm or less of a target dimension) without machining, thereby solving the above-described problems.
  • the present invention is featured by the method of claim 1 for manufacturing a variable vane including a planar blade unit and a columnar shaft unit positioned under the blade unit, the method comprising the step of:
  • the die for use in the first pressing process includes the lower die for holding the sinter by inserting the shaft unit under the blade unit thereinto and the upper die having the shape except the lower end of the blade unit (i.e., the shapes of the blade unit in the height and thickness directions can be defined at the same time).
  • the upper die in the case where the variable vane having the shaft unit also above the blade unit is fabricated, the die has the shape including the shaft unit above the blade unit in addition of the shape of the blade unit.
  • the upper die is pressed against the lower die, so that the blade unit is compressed at its upper surface and the blade unit is expanded and deformed at its side surface while being compressed downward, and further, the shape of the side surface conforms with the shape of the die, thus achieving the desired height of the blade unit, the shapes of the side surface and blade, and the squareness of the shaft with respect to the blade.
  • the die for use in the second pressing process includes the upper die and the lower die, each of which has the shape obtained by dividing the variable vane (i.e., the blade unit and the shaft unit) at the surface at which the thickness of the blade unit is bisected.
  • the product is fixed in a lateral direction by the lower die.
  • the upper die is compressed downward so that the blade unit and the shaft unit are pressed at the same time, thus achieving the verticality of the shaft unit with respect to the blade unit and the coaxiality of the shaft unit with respect to the blade unit.
  • the die for use in the third pressing process includes the upper die and the lower die, each of which has the semi-columnar shape in conformity with the shaft unit of the variable vane.
  • the upper and lower dies are pressed against each other in the state in which the shaft unit positioned under the blade unit of the sinter is turned at 90° from that in the second pressing process, thereby achieving the roundness of the shaft unit.
  • the sinter having the dimensions of the blade unit and the shaft unit within the dimensional ranges with respect to the desired dimensions of the final product is used as a sinter to be pressed.
  • the dimensions of the blade unit and the shaft unit can be set with the desired dimensional precision ( ⁇ 0.01 mm to 0.05 mm or less of the target dimension) without machining.
  • the sinter having a relative density of 95% or more is used, thereby achieving the dimensional precision after the pressing within the desired dimensional precision, and further, the variable vane having mechanical strength resistant against use at high temperature can be manufactured.
  • the sinter should be a sinter having a relative density of 98%.
  • the first to third pressing processes may be continuously performed by using a multiple forming machine capable of pressing and bending in directions of 360°, thus saving the energy for pressing.
  • the metallic powder (a) is powder having an average particle diameter of 1 ⁇ m to 20 ⁇ m and a tap density of 3.5 g/m 3 or more;
  • the organic binder (b) contains 5 vol% to 40 vol% of polyacetal (b1) and 5 vol% to 40 vol% of polypropylene (b2); and in adding the organic binder (b) into the metallic powder (a), the organic binder (b) is added within a range of 30 vol% to 60 vol% with respect to the total amount (a+b) of the metallic powder and the organic binder, thus achieving the sinter suitable for manufacturing the variable vane.
  • the debinding should be performed at a highest temperature of 800°C or lower in any of a reduced pressure inactive gas atmosphere, an atmospheric pressure inactive gas atmosphere, and an atmospheric pressure hydrogen atmosphere; and the sintering should be performed at a temperature from 1000°C or higher and 1500°C or lower in any of a reduced pressure inactive gas atmosphere, a pressurized inactive gas atmosphere, an atmospheric pressure inactive gas atmosphere, and an atmospheric pressure hydrogen atmosphere.
  • a primary sinter having a relative density of 94% or more should be manufactured, and then a sinter having a relative density of 98% or more should be manufactured by hot isotropic pressuring.
  • variable vane having the high dimensional precision only by pressing the sinter without machining.
  • the sinter in manufacturing the sinter, by the MIM method, it is possible to obtain the sinter for manufacturing the variable vane having the higher dimensional precision than that in the prior art by adopting the above-described particle diameter of the metallic powder, tap density, binder amount, and binder components.
  • a variable vane for use in a turbocharger includes a blade unit (i.e., a nozzle vane unit) for adjusting the flow rate of exhaust gas and a shaft unit (i.e., a vane shaft unit) for pivotally supporting the blade unit, wherein the shaft unit is continuously connected at least onto one side (downward) from a rotational center position near the center of the blade unit.
  • the shaft unit is columnar: in contrast, the blade unit is a flat wedge which is reduced in thickness toward the tip. In most case, the blade unit is finely and asymmetrically curved so as to readily adjust the flow rate of the exhaust gas, thereby enhancing incorporating stability and operational stability.
  • an end on a side opposite to an end continuously connected to the blade unit should be formed into a flat shape as a molded surface is, and further, the boundary between the end and a peripheral wall surface of the shaft unit should be curved. In this manner, there is no portion which is unnecessarily machined from the mechanical viewpoint, and further, strength can be enhanced. Moreover, the end of the shaft unit is curved, thereby enhancing incorporating stability and turning stability.
  • FIG. 1A a product having a flat top of a blade
  • FIG. 1B a product having a rotary shaft also on the top
  • FIG. 2 i.e., a process flowchart
  • variable vane In manufacturing the variable vane, it is necessary to first manufacture a sinter having a shape similar to a desired final product.
  • a molding material is obtained by adding the required amount of an organic binder to metallic powder as a raw material, to be then molded in a die in previous consideration of a shrinkage ratio of a sintered product, thus achieving a molded body.
  • Metal used for the variable vane has corrosion resistance and heat resistance.
  • metallic materials suitable for manufacturing the sinter is mainly used SUS310 or SCH21 (HK30) containing 19.0 to 22.0 wt% of Ni and 23.0 to 27.0 wt% of Cr.
  • Ni-based alloys such as Inconel may be used.
  • the metallic powder made of the above-described metallic material is normally used alloy powder produced by a water or gas atomizing method.
  • element powder which is adjusted to become an alloy component in sintering may be added according to a composition.
  • the water atomized powder can be produced in more quantity than the gas atomized powder, and therefore, a production cost is reduced.
  • the powdery shape is liable to be varied, and therefore, tap density tends to be reduced, and further, oxygen amount contained in the powder becomes larger.
  • the gas atomized powder is produced at a high cost, globular powder can be readily obtained, thereby enhancing the tap density.
  • the water atomized powder and the gas atomized powder may be used in mixture.
  • the metallic powder (a) according to the present invention should preferably have an average particle diameter of 1 ⁇ m to 20 ⁇ m.
  • the average particle diameter is less than 1 ⁇ m, an increase in surface area of the powder increases binder addition amount, thereby enlarging deformation in debinding.
  • the binder amount becomes large, the shrinkage ratio in sintering also becomes great, thereby increasing dimensional variations after sintering. Therefore, it is difficult to obtain a product having a high dimensional precision in pressing in a post process.
  • the average particle diameter exceeds 20 ⁇ m, it is difficult to stably obtain a sintering density (i.e., a relative density) of 95% or more.
  • a more preferred average particle diameter ranges from 5 ⁇ m to 12 ⁇ m, and desirably, from 8 ⁇ m to 10 ⁇ m.
  • the average particle diameter signifies an average diameter of weight accumulation of 50% measured by using a particle size distribution measuring device utilizing laser diffraction or scattering.
  • a particle size distribution measuring device may be used an SALD-2000 type measuring device manufactured by Shimadzu Corporation.
  • the metallic powder (a) according to the present invention should preferably have a tap density of 3.5 g/m 3 or more.
  • the tap density of the powder is less than 3.5 g/m 3
  • an increase in surface area of the powder requires an increase in binder amount to be added. This causes dimensional variations during debinding and sintering.
  • the more preferred tap density is 4.0 g/m 3 or more, and more preferably, 4.2 g/m 3 or more.
  • the upper limit is not particularly defined, a satisfactory effect can be produced when the tap density is 5.0 g/m 3 or less.
  • the tap density may be measured by a measuring method disclosed in JPMA P 08 of Tap Density Test Method for Metallic Powder published by Japan Powder Metallurgy Association .
  • organic binder (b) an organic binder containing 5 vol% to 40 vol% of polyacetal (b1) and 5 vol% to 40 vol% of polypropylene (b2). Since the organic binder contains polyacetal and polypropylene, deformation during debinding can be suppressed in comparison with a conventional binder containing polyethylene, ethylene vinyl acetate, or an acrylic resin.
  • Polyacetal is essential in enhancing the strength of the molded body, preventing deformation of the molded body against the sintering at 600°C or lower, and preventing carbide from remaining after the sintering.
  • Polypropylene imparts tenacity to the molded body so as to inhibit any sintering crack or separation of an added compound having a low-melting point.
  • Polypropylene also is equipped with the feature of preventing carbide from remaining after the sintering.
  • the much preferred contents of polyacetal range from 10 vol% to 30 vol%, and further, much preferred contents of polypropylene range from 10 vol% to 30 vol%.
  • Examples of usable organic materials other than polyacetal and polypropylene are as follows:
  • polyethylene in order to impart fluidity during the molding and flexibility to the molded body, there may be used polyethylene, amorphous polyolefin, ethylene vinyl acetate copolymers, acrylic resins, polyvinylbutyral resins, glycidyl methacrylate resins, and the like.
  • amorphous polyolefin ethylene vinyl acetate copolymers
  • acrylic resins polyvinylbutyral resins
  • glycidyl methacrylate resins and the like.
  • particularly preferred materials are listed polyethylene and amorphous polyolefin.
  • the organic binder (b) should range from 30 vol% to 60 vol% with respect to the total amount (a + b) of the metallic powder (a) and the organic binder (b), more preferably, from 35 vol% to 50 vol%.
  • the organic binder and the metallic powder in the above-described ratio are heated and kneaded for about 2 hours at about 160°C to 180°C, so that the metallic powder is completely dispersed and mixed in the organic binder. Thereafter, the resultant product are taken out and formed into a pellet having a diameter of about 5 mm by an extruder or a grinder, thereby obtaining a molding material.
  • the shape of the die need be determined in consideration of the dimensions after the sintering. These dimensions are obtained after the sintering or hot isotropic pressurizing, and further, they depend upon sintering density, so that the die need be designed in full consideration of dimensional variations thereafter. As a consequence, the dimension of the die need be designed in consideration of the dimensional precision, and further, the shrinkage ratio from the molding to the sintering need be calculated in advance.
  • the deformation occurs during debinding, and therefore, it is very difficult to obtain a product within the dimensional range of the above-described sinter.
  • the sinter having a higher dimensional precision than that in the prior art can be manufactured by the MIM method by achieving the above-described particle diameter of the metallic powder, tap density, binder amount, and binder components.
  • the thickness of the blade unit in the variable vane is gradually reduced in thickness from the rear end of the blade unit (left in FIG. 1 ) toward the fore end (right in FIG. 1 ), as shown in FIG. 1 , and therefore, it depends upon a portion to be measured.
  • the thickness of the blade unit within the range of -0.6% to -0.0% with respect to the target dimension of the final product signifies that a difference when the final product and the sinter (having a shape approximate to that of the final product) are measured at corresponding portions falls within the above-described range.
  • the height of the blade unit As for the height of the blade unit, the diameter of the shaft unit, and the length from the lower end of the blade unit to the lower end of the shaft unit, if they depend upon a portion to be measured, they signify that the difference when the final product and the sinter are measured at the corresponding portions, like the thickness of the blade unit, falls within the above-described range.
  • the die is fixed to an injection molder, followed by molding.
  • the number of molded bodies obtained may be one to eight per die in consideration of the size of the product and the mass-produced number-
  • the capacity of the injection molder is appropriately adjusted according to the number taken by the die or the size of the product.
  • molding is performed by using a molder having a caulking force from about 20 ton to about 100 ton.
  • An injection speed and pressure are adjusted such that no deficiency such as bubbles or cracks occurs in the molded body.
  • the die need be provided with a gas relief for effectively relieving air staying inside of the die and gas generated from the molding material. If there is no effective gas relief, the air or gas generated from the molding material is taken into the molded body, and thus, bubbles are generated in the molded body.
  • the resultant molded body is put into a debinding furnace, and then, the added organic binder is removed.
  • the organic binder is removed in the debinding furnace in any one of a reduced pressure inactive gas atmosphere, an atmospheric inactive gas atmosphere, and an atmospheric hydrogen gas atmosphere.
  • debinding and sintering can be performed consistently.
  • a batch type or a continuous type i.e., a belt type, a pusher type, or a walking beam type
  • debinding is effectively carried out by using a jig having a shape in conformity with the shape of the molded body so as to suppress the deformation to the minimum.
  • the debinding is carried out at a highest temperature of 800°C or less in any one of the reduced pressure inactive gas atmosphere, the atmospheric inactive gas atmosphere, and the atmospheric hydrogen gas atmosphere.
  • the debinding is carried out in the air, the powder is oxidized at 300°C or higher, and therefore, the amount of oxygen after sintering becomes large, thereby largely influencing on the strength of a sinter.
  • the debinding is carried out in the reduced pressure inactive gas atmosphere, the atmospheric inactive gas atmosphere, or the atmospheric hydrogen gas atmosphere.
  • Nitrogen or argon is used as the inactive gas.
  • nitrogen gas is desired from the viewpoint of a cost.
  • a temperature increasing rate is desirably 50°C/hr from room temperature to 400°C or lower in consideration of the deformation at the time of the debinding.
  • the use of the jig in consideration of the deformation of the molded body at the time of the debinding can suppress the deformation of the molded body at the time of the debinding.
  • the debinding temperature ranges from 400°C to 500°C to the maximum.
  • the use of a sintering furnace equipped with a debinding function is effective in preventing any collapse of the molded body, and further, in transiting to the sintering without any decrease in temperature also after the completion of the debinding.
  • the debinding and sintering can be continuously carried out without any intermission by connecting a continuous type (i.e., a belt type, a pusher type, or a walking beam type) debinding furnace and a continuous type (i.e., a belt type, a pusher type, or a walking beam type) sintering furnace to each other.
  • a continuous type i.e., a belt type, a pusher type, or a walking beam type
  • a continuous type i.e., a belt type, a pusher type, or a walking beam type
  • the atmosphere in the sintering process is selected from a reduced pressure inactive gas atmosphere, an atmospheric inactive gas atmosphere, a pressurizing inactive gas atmosphere, and an atmospheric hydrogen gas atmosphere. Since a stainless material is mostly used in sintering, argon gas should be preferably used as inactive gas in consideration of the nitrogenation of a material.
  • the sintering is carried out at a temperature of 1000°C or higher to 1500°C or lower. At a temperature of lower than 1000°C, the sintering is insufficient: in contrast, in excess of 1500°C, the molded body is melted during the sintering.
  • the temperatures from 1200°C to 1400°C should be desirable so as to achieve a sintering density of 95% or more, and 1250°C to 1380°C should be more desirable.
  • the molded body should be desirably held for about 2 to 4 hours at a highest temperature in consideration of the enhancement of the sintering density during the sintering and the dimensional variations during the sintering. Additionally, like in the debinding process, deformation is liable to be generated at a high temperature also in the sintering process, and therefore, the use of a jig for preventing any deformation of a sinter is effective.
  • Mechanical strength and hardness can be held at high temperature by setting the density of the sinter to a relative density of 95% or more. If the relative density does not reach 95%, the mechanical strength, in particular, elongation and the hardness are reduced at the high temperature, thereby making the continuous use at the high temperature difficult.
  • the relative density of the sinter may be measured by the Archimedean method.
  • the resultant sinter is further processed by the hot isotropic pressurizing (HIP) method in order to further increase the sintering density so as to enhance the mechanical strength and enhance the reliability of the mechanical strength in a high-temperature region.
  • the HIP process is performed at a high pressure from about 10 MPa to 180 MPa at a temperature lower by 10°C to 100°C than the sintering temperature, thereby stably obtaining a sinter having a relative density of 98% or more without any pinholes inside thereof.
  • a sinter having a relative density of 98% or more can be obtained without using the HIP method in post-processes by using a sintering HIP device capable of pressurizing at about 6 MPa at highest.
  • the sinter after the sintering or the HIP process is formed in a desired dimension of a final product by pressing illustrated in FIGS. 4 and 5 .
  • the dimensions of the blade unit in the height and width (i.e., thickness) directions are set to those of the desired product at the same time in a first pressing process.
  • the coaxiality of the blade unit and the shaft unit is set to the desired dimension of the product in a second pressing process.
  • the roundness of the shaft is set to the desired dimension of the product in a third pressing process.
  • the shaft unit and the blade unit can be shaped into the desired dimensions without machining.
  • a die In the first pressing process, a die includes a lower die for holding a sinter and an upper die for defining the blade unit in both the height and width directions at the same time.
  • the blade unit is compressed downward by pressing the upper die against the lower die.
  • the side portion When the upper surface of the blade unit is compressed, the side portion is expanded and deformed in conformity with the shape of the die, thus achieving the desired height and side surface of the blade unit, the shape of the blade, and the squareness of the shaft with respect to the blade.
  • a die in the second pressing process, includes an upper die and a lower die formed into a shape in which the blade unit and the shaft unit in the variable vane are bisected (the dies are bisected on a surface bisecting the thickness of the blade unit).
  • the sinter is fixed to the lower die in a lateral direction whereas the upper die is pressed downward, so that the blade unit and the shaft unit are compressed at the same time, thereby achieving the verticality of the shaft with respect to the blade unit and the coaxiality of the shaft with respect to the blade unit.
  • a die in the third pressing process, includes an upper die and a lower die formed into a shape (i.e., semi-columnar shape) in which the shaft unit under the blade unit is bisected in the axial direction.
  • the shaft unit of the sinter obtained in the second pressing process is turned at 90°, followed by vertical pressing, thereby achieving the roundness of the shaft unit.
  • the above-described sinter is subjected to post-processing in the three-step pressing, so that the desired variable vane can be obtained without machining.
  • the material of the die for use in pressing is selected from die steel, high-speed steel, and carbide steel in consideration of the lifetime.
  • the pressing capacity per hour can be remarkably enhanced by using a part feeder and a progressive device in comparison with the conventional machining. Specifically, the number of products machined per hour can be increased up to about 300 to 600.
  • the pressed product is subjected to barrel polishing or electrolytic polishing, as required, thereby enhancing surface roughness, and further, removing a burr.
  • the sinter which has been obtained by the MIM process and whose dimensional precision has been controlled in advance is used as the material. Consequently, it is possible to fabricate the variable vane having the desired shape excellent in dimensional precision without cutting or polishing by machining in post-processing.
  • the adoption of the MIM method in particular, can suppress the material fabrication loss down to 5% or less even in comparison with a lost wax or the punching of a plate material in the prior art, and thus, cost can be effectively reduced-
  • the fabrication efficiency becomes 5 to 10 times in comparison with the fabrication by the conventional machining by automating the pressing.
  • the adoption of the MIM method can implement the mass production of the thin variable vane having the complicated shape which could be hardly obtained with ease in the prior art.
  • the sinter according to the present invention was manufactured- The molding material and the conditions of heating/kneading, injection molding, debinding, sintering, and the like were as described below. A hundred molded bodies were molded, followed by debinding and sintering, and then, dimensional variations were measured.
  • variable vane had the shape shown in FIG. 3A .
  • the dimensions of the desired final product were described below.
  • A1 designates the height of the blade unit; B1, the thickness of the blade unit; C1, the diameter of the shaft unit; and D1, the length of the shaft unit positioned under the blade unit (i.e., the length from the lower end of the blade unit to the lower end of the shaft unit).
  • a molding machine having a caulking pressure of 30 ton was used.
  • the dimensions of the manufactured sinter were described below. The dimensions were measured by using a tool microscope.
  • the pressing was performed according to the process illustrated in FIG. 4 .
  • the dimensions after the pressing were described below.
  • the desired dimensions of the final product could not be obtained.
  • the product having the dimensions which fell within dimensional tolerances of the final product in the pressing could be obtained.
  • the sinter according to the present invention was manufactured.
  • the molding material and the conditions of heating/kneading, injection molding, debinding, sintering, and the like were as described below.
  • a hundred molded bodies were molded, followed by debinding and sintering, and then, dimensional variations were measured.
  • variable vane had the shape shown in FIG. 3B .
  • the desired dimensions of the final product were described below.
  • A2 designates the height of the blade unit; B2, the thickness of the blade unit; C2, the diameter of the shaft unit; and D2, the length of the shaft unit positioned under the blade unit.
  • a molding machine having a caulking pressure of 30 ton was used.
  • the dimensions of the manufactured sinter were described below. The dimensions were measured by using a tool microscope.
  • C2a designates the diameter of the shaft unit positioned under the blade unit: in contrast, C2b designates the diameter of the shaft unit positioned above the blade unit.
  • the pressing was performed according to the process illustrated in FIG. 5 .
  • the dimensions after the pressing were described below.
  • the desired dimensions of the final product could not be obtained.
  • the product having the dimensions which fell within dimensional tolerances of the final product in the pressing could be obtained.
  • the sinter was subjected to the three-step pressing under the same conditions as those in EXAMPLE 1.
  • the dimensions after the pressing were as follows.
  • the product whose sinter had the dimensions approximate to those of the final product was manufactured. However, the product could not have the dimensions A1 and C1 which fell within the dimensional tolerance of the final product. In addition, the coaxiality and verticality could not fall within the tolerance.
  • +0.3 ⁇ +0.5 -0.3 ⁇ +0.7 ⁇ +0.9 ⁇ +1.0 +0.6 ⁇ A was more than defined dimension.
  • +0.6 -0.7 ⁇ B was less than defined dimension.
  • -0.6 ⁇ -0.4 -0.3 ⁇ -0.2 ⁇ -0.0 ⁇ +0.1 ⁇ B was more than defined dimension.
  • -0.3 +0.2 ⁇ C was less than defined dimension.
  • +0.3 ⁇ +0.5 ⁇ +0.7 ⁇ +0.9 ⁇ +1.0 ⁇ C was more than defined dimension.
  • +0.6 -0.7 ⁇ D was less than defined dimension.
  • -0.6 ⁇ -0.4 ⁇ -0.2 ⁇ -0.0 ⁇ +0.1 ⁇ D was more than defined dimension.
  • the sinter before the pressing had the dimensions below with respect to the desired dimensions of the final product (i.e., the target dimensions): the height of the blade unit ranged from +0.3% to +0.9%; the thickness of the blade unit ranged from -0.6% to -0.0%; the diameter of the shaft unit ranged from +0.3% to +0.9%; the length from the lower end of the blade unit to the lower end of the shaft unit ranged from -0.6% to -0.0%; and the sintering density was 95% or more of the relative density. In this case, it was found that the final product having the desired dimensional tolerance could be obtained only by pressing.
  • a sinter was manufactured in the same manner as EXAMPLE 1 except that polyacetal out of the components of the organic binder in EXAMPLE 1 was replaced with an ethylene vinyl acetate resin.
  • a blade unit in a molded body was inclined at 30° or more, as shown in FIG. 6 . Due to the large deformation, the molded body could not be subjected to the following sintering and pressing.
  • a blade unit in a molded body was inclined at 10° or more after debinding, as shown in FIG. 6 . Due to the large deformation, the molded body could not be subjected to the following sintering and pressing.
  • molded bodies were made of various injection molding materials, to be subjected to debinding and sintering.
  • metallic powder having an average particle diameter of 1 ⁇ m to 20 ⁇ m and a tap density of 3.5 g/m 3 or more was used, and further, an organic binder including 5 vol% to 40 vol% of polyacetal and 5 vol% to 40 vol% of polypropylene was used, wherein the organic binder ranged from 30 vol% to 60 vol% with respect to the total amount of the metallic powder and the organic binder, it was found that a sinter suitable for the use in the pressing according to the present invention could be obtained.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Powder Metallurgy (AREA)
  • Supercharger (AREA)

Claims (6)

  1. Procédé de fabrication d'une aube à incidence variable (1) comportant une unité de pale (2) plane et une unité d'arbre (3) colonnaire positionnée sous l'unité de pale (2), le procédé comprenant l'étape consistant à :
    presser un aggloméré ayant une forme se rapprochant de celle d'un produit final souhaité ;
    dans lequel l'aggloméré est constitué intégralement de l'unité de pale (2) et de l'unité d'arbre (3), et a la hauteur (A) de l'unité de pale (2) à +0,3% à +0,9% près, l'épaisseur (B) de l'unité de pale (2) à -0,6% à -0,0% près, le diamètre (C) de l'unité d'arbre (3) à +0,3% à +0,9% près, la longueur (D) depuis l'extrémité inférieure de l'unité de pale (2) jusqu'à l'extrémité inférieure de l'unité d'arbre (3) à -0,6% à -0,0% près par rapport aux dimensions cibles du produit final, et une densité de frittage, à savoir une densité relative, de 95% ou plus, et
    dans lequel le processus de compression comporte trois processus :
    dans un premier processus de compression, l'aggloméré est pressé avec une matrice inférieure comportant un trou d'insertion d'unité d'arbre et une matrice supérieure ayant une forme de l'unité de pale (2) sauf d'une surface d'extrémité inférieure de celle-ci, de manière à ajuster la hauteur et l'épaisseur de l'unité de pale (2) ;
    dans un deuxième processus de compression, l'unité de pale (2) et l'unité d'arbre (3) de l'aggloméré sont pressées en même temps avec une matrice supérieure et une matrice inférieure, lesquelles ont chacune une forme obtenue en divisant l'aube à incidence variable (1) au niveau d'une surface à laquelle l'épaisseur de l'unité de pale (2) est bissectée, de manière à ajuster l'angle de l'unité d'arbre (3) relativement à l'unité de pale (2) et la coaxialité de l'unité d'arbre (3) relativement à l'unité de pale (2) ; et
    dans un troisième processus de compression, l'unité d'arbre (3) de l'aggloméré est pressé dans une direction tournée à 90% par rapport à celle dans le deuxième processus de pression avec une matrice supérieure et une matrice inférieure, lesquelles ont chacune une forme semi-colonnaire correspondant à l'unité d'arbre (3) de l'aube à incidence variable (1), de manière à ajuster la rondeur de l'unité d'arbre (3).
  2. Procédé de fabrication d'une aube à incidence variable (1) selon la revendication 1, dans lequel l'aggloméré est un aggloméré ayant une densité relative de 98% ou plus.
  3. Procédé de fabrication d'une aube à incidence variable (1) selon la revendication 1 ou la revendication 2, dans lequel les premier à troisième processus de compression sont exécutés de manière continue en utilisant une machine de formages multiples capable de presser et de plier dans des orientations de 360°.
  4. Procédé de fabrication d'une aube à incidence variable (1) selon l'une quelconque des revendications 1 à 3, comprenant en outre un processus de fabrication de l'aggloméré qui comporte l'ajout d'un liant organique (b) dans une poudre métallique (a), suivi d'un chauffage et d'un mixage, l'obtention d'un matériau de moulage par injection par pulvérisation ou pastillage, la préparation d'un corps moulé par moulage par injection du matériau de moulage, et le déliantage thermique du corps moulé résultant,
    dans lequel la poudre métallique (a) est une poudre ayant un diamètre particulaire moyen de 1 µm à 20 µm et une masse volumique tassée de 3,5 g/m<3> ou plus ;
    le liant organique (b) contient 5 % en volume à 40 % en volume de polyacétal (b1) et 5 % en volume à 40 % en volume de polypropylène (b2) ; et
    lors de l'ajout du liant organique (b) dans la poudre métallique (a), le liant organique (b) est ajouté dans une plage de 30 % en volume à 60 % en volume par rapport à la quantité totale (a+b) de la poudre métallique et du liant organique.
  5. Procédé de fabrication d'une aube à incidence variable (1) selon la revendication 4, dans lequel dans la fabrication de l'aggloméré, le déliantage est exécuté à une température supérieure de 800 °C ou moins dans n'importe laquelle d'une atmosphère de gaz inactif à pression réduite, d'une atmosphère de gaz inactif à la pression atmosphérique, et d'une atmosphère d'hydrogène à la pression atmosphérique ; et
    le frittage est effectué à une température de 1000 °C ou plus et 1500 °C ou moins dans n'importe laquelle d'une atmosphère de gaz inactif à pression réduite, d'une atmosphère de gaz inactif pressurisé, d'une atmosphère de gaz inactif à la pression atmosphérique, et d'une atmosphère d'hydrogène à la pression atmosphérique.
  6. Procédé de fabrication d'une aube à incidence variable (1) selon la revendication 4 ou la revendication 5, dans lequel dans le processus de fabrication par frittage, un aggloméré primaire ayant une densité relative de 94% ou plus est fabriqué, puis un aggloméré ayant une densité relative de 98% ou plus est obtenu par compression isotrope à chaud.
EP09819268.5A 2008-10-09 2009-10-09 Procede de fabrication d'une aube a incidence variable Not-in-force EP2343441B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2008262547A JP4317906B1 (ja) 2008-10-09 2008-10-09 可変ベーンの製造方法
PCT/JP2009/067621 WO2010041735A1 (fr) 2008-10-09 2009-10-09 Procédé de fabrication d'une aube à incidence variable

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EP2343441A1 EP2343441A1 (fr) 2011-07-13
EP2343441A4 EP2343441A4 (fr) 2014-09-17
EP2343441B1 true EP2343441B1 (fr) 2015-12-23

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JP (1) JP4317906B1 (fr)
CN (1) CN102177324B (fr)
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US11661861B2 (en) 2021-03-03 2023-05-30 Garrett Transportation I Inc. Bi-metal variable geometry turbocharger vanes and methods for manufacturing the same using laser cladding

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JP2010196583A (ja) * 2009-02-25 2010-09-09 Ihi Corp ノズルベーンの製造方法
JP5857688B2 (ja) 2011-11-30 2016-02-10 セイコーエプソン株式会社 射出成形用組成物および焼結体の製造方法
JP5970794B2 (ja) 2011-11-30 2016-08-17 セイコーエプソン株式会社 射出成形用組成物および焼結体の製造方法
WO2013126623A1 (fr) 2012-02-24 2013-08-29 Hoeganaes Corporation Système de lubrification améliorée à utiliser dans la métallurgie à poudre
WO2014050530A1 (fr) * 2012-09-28 2014-04-03 株式会社Ihi Unité à buse variable, compresseur à capacité variable et procédé de fabrication d'éléments de transmission de puissance
CN104117677B (zh) * 2013-04-23 2017-02-08 昆山广兴电子有限公司 一种金属扇轮的制造方法
DE102014112377A1 (de) * 2014-08-28 2016-03-03 Robert Bosch Automotive Steering Gmbh Herstellverfahren für komponenten eines schwenkmotors für ein lenksystem
US9995166B2 (en) * 2014-11-21 2018-06-12 General Electric Company Turbomachine including a vane and method of assembling such turbomachine
KR101649584B1 (ko) * 2015-12-28 2016-08-19 한국피아이엠(주) 금속과립분말을 이용한 내열부품 제조방법
CN106735236A (zh) * 2016-12-06 2017-05-31 江苏精研科技股份有限公司 金属注射成型后处理滚光工艺
JP7049149B2 (ja) * 2018-03-28 2022-04-06 三菱重工航空エンジン株式会社 翼の製造方法

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JP2008088849A (ja) 2006-09-29 2008-04-17 Itou Parts Kogyo:Kk ノズルベーン部材の製造方法およびノズルベーン部材
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US11661861B2 (en) 2021-03-03 2023-05-30 Garrett Transportation I Inc. Bi-metal variable geometry turbocharger vanes and methods for manufacturing the same using laser cladding

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CN102177324B (zh) 2013-06-19
HUE028680T2 (en) 2016-12-28
WO2010041735A1 (fr) 2010-04-15
JP2011157816A (ja) 2011-08-18
JP4317906B1 (ja) 2009-08-19
EP2343441A1 (fr) 2011-07-13
EP2343441A4 (fr) 2014-09-17
CN102177324A (zh) 2011-09-07

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