EP3081322B1 - Verfahren zum sintern - Google Patents

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Publication number
EP3081322B1
EP3081322B1 EP16161344.3A EP16161344A EP3081322B1 EP 3081322 B1 EP3081322 B1 EP 3081322B1 EP 16161344 A EP16161344 A EP 16161344A EP 3081322 B1 EP3081322 B1 EP 3081322B1
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EP
European Patent Office
Prior art keywords
component
aerofoil
setter
green
sintering
Prior art date
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Active
Application number
EP16161344.3A
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English (en)
French (fr)
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EP3081322A1 (de
Inventor
Fatos DERGUTI
Alex Cendrowicz
Hector Pous Romero
Iain Todd
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce PLC
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Rolls Royce PLC
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Filing date
Publication date
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Publication of EP3081322A1 publication Critical patent/EP3081322A1/de
Application granted granted Critical
Publication of EP3081322B1 publication Critical patent/EP3081322B1/de
Active legal-status Critical Current
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/003—Apparatus, e.g. furnaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • 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
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • 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
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D5/00—Supports, screens, or the like for the charge within the furnace
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F2003/1042—Sintering only with support for articles to be sintered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the present disclosure relates to a method of sintering a metal injection-moulded, green aerofoil component.
  • Metal Injection Moulding is a metalworking process which produces components from a range of materials including steel, molybdenum, nickel, titanium and copper.
  • the MIM process involves mixing a metal powder with a plasticising binder and injecting the resulting feedstock into a mould. The mould is then removed to leave a metal powder "green" component held together by the binder. The green component may undergo some intermediate processing but eventually undergoes sintering, sometimes with the application of additional pressure, to fuse the powder particles into a single solid mass and to burn-off the binder.
  • the fusing of the powder particles during sintering results in the green component shrinking. If the entire component or isolated areas of the component are prevented from moving freely, the component can become distorted as it shrinks. However, the component also needs to be supported during sintering to prevent it being distorted under its own weight. This can be especially important for thin overhanging structures.
  • Support methods may involve placing the green component on a bed of zirconium oxide beads.
  • the beads may move unevenly as they slide over each other or even seize up at high temperature, locally preventing free movement of the green component and leading to unwanted distortion of the component. Further, the beads may not provide sufficient support to prevent deformation of thin sections under their own weight.
  • US 2008/0075619 A1 proposes a setter which supports the green component during sintering and is formed from a feedstock of molybdenum powder and a binder such that it shrinks at a similar rate to the green component during sintering.
  • FR2944721 and EP 0633440 A1 also propose a setter which supports the green component during sintering and is formed from a feedstock of powder and binder which shrinks together with the green component it supports during sintering.
  • all of these setters are made from a powder and a binder which undergo sintering, thus they can only be used in a single sintering operation.
  • the present dicsclosure provides a method of sintering a metal injection-moulded, green aerofoil component such that a setter can move with and support the green component as it shrinks during sintering.
  • the present invention provides a method of sintering a metal injection-moulded, green aerofoil component according to claim 1, the method including:
  • the method can thus reduce or eliminate unwanted distortion of components during sintering.
  • the stationary support may have a shaped surface which contacts an aerofoil surface of the aerofoil part when the green component is located on the setter, the shaped surface conforming to the shape of the aerofoil surface at the final stages of sintering.
  • the moveable platform may have a further shaped surface which contacts a surface of the end part when the green component is located on the setter, the further shaped surface conforming to the shape of the end part.
  • the aerofoil component may be a vane or a rotor blade of a gas turbine engine.
  • the aerofoil component may be a variable inlet guide vane, a variable stator vane or a compressor blade.
  • the method may further include: removing the sintered aerofoil component from the setter, and repeating the locating and sintering steps with another metal injection-moulded, green aerofoil component.
  • the setter can thus be reused and the method can reduce the amount of waste material generated during MIM and reduce the amount of variation between separately sintered aerofoil components.
  • the method may further include applying a friction reducing agent to the stationary support and/or the moveable platform at points of contact between the setter and the green component.
  • the friction reducing agent may include ceramic beads, such as zirconium oxide beads, mixed with a binder which burns off during the sintering.
  • the moveable platform may be constrained to move in a plane or along a path defined by a line or curve. This can reduce unwanted distortion of components during sintering.
  • the setter may have a stopper against which the green component is located. This can help to ensure that the green component is correctly positioned on the setter.
  • the green aerofoil component may have first and second end parts at respective ends of the aerofoil part, and the setter may have corresponding first and second moveable platforms.
  • a ducted fan gas turbine engine is generally indicated at 10 and has a principal and rotational axis X-X.
  • the engine comprises, in axial flow series, an air intake 11, a propulsive fan 12, an intermediate pressure compressor 13, a high-pressure compressor 14, combustion equipment 15, a high-pressure turbine 16, an intermediate pressure turbine 17, a low-pressure turbine 18 and a core engine exhaust nozzle 19.
  • a nacelle 21 generally surrounds the engine 10 and defines the intake 11, a bypass duct 22 and a bypass exhaust nozzle 23.
  • air entering the intake 11 is accelerated by the fan 12 to produce two air flows: a first air flow A into the intermediate-pressure compressor 13 and a second air flow B which passes through the bypass duct 22 to provide propulsive thrust.
  • the intermediate-pressure compressor 13 compresses the air flow A directed into it before delivering that air to the high-pressure compressor 14 where further compression takes place.
  • the compressed air exhausted from the high-pressure compressor 14 is directed into the combustion equipment 15 where it is mixed with fuel and the mixture combusted.
  • the resultant hot combustion products then expand through, and thereby drive the high, intermediate and low-pressure turbines 16, 17, 18 before being exhausted through the nozzle 19 to provide additional propulsive thrust.
  • the high, intermediate and low-pressure turbines respectively drive the high and intermediate-pressure compressors 14, 13 and the fan 12 by suitable interconnecting shafts.
  • the gas turbine engine 10 may have components manufactured according to the methods described and/or claimed herein.
  • Figure 2 shows schematically (a) a setter 25, (b) a green aerofoil component 33, and (c) the green aerofoil component located on the setter.
  • the setter has a stationary support 27, a moveable platform 29 which is independently moveable relative to the stationary support, and a fixed platform 30 which is fixed relative to the stationary support.
  • the green aerofoil component has an aerofoil part 35, a first end part 37 and a second end part 38, all produced by MIM.
  • the green aerofoil component is located on the setter such that the stationary support supports the aerofoil part, the moveable platform supports the first end part, and the fixed platform supports the second end part.
  • the stationary support 27 has a shaped surface 31 which contacts the aerofoil surface of the aerofoil part 35 when the green component 33 is located on the setter, the shaped surface conforming to the shape of the aerofoil surface at the final stages of sintering.
  • the movable platform 29 has a further shaped surface 32 which contacts a surface of the first end part 37 when the green component is located on the setter, the further shaped surface conforming to the shape of the first end part at the final stages of sintering.
  • the fixed platform 30 has a shaped surface 34 which contacts a surface of the second end part 38 when the green component is located on the setter, the shaped surface conforming to the shape of the second end part at the final stages of sintering.
  • such shaped surfaces provide better support for the green aerofoil component and encourage component shape conformity, thus reducing the likelihood of unwanted distortion of the green aerofoil component occurring during sintering.
  • the moveable platform 29 moves relative to the stationary support 27 to accommodate sintering-induced shrinkage of the component.
  • the setter can thus provide sufficient support to prevent sagging of the component during sintering.
  • friction between the aerofoil component and the setter 25 can be reduced, thereby decreasing unwanted distortion of the aerofoil component during sintering. This can be particularly important when producing components such as double ended vanes (as illustrated in Figure 2(b) ), which have two end parts, both of which can require support as they shrink.
  • the moveable platform 29 is shown supported by rollers 43 which enable the independent movement of the platform relative to the stationary support 27.
  • the rollers constrain the moveable platform to move along a straight line that is parallel to the length direction of the aerofoil component.
  • Another option is to use wheels to support the moveable platform. The use of wheels can similarly constrain the platform to move in a line.
  • the rollers or wheels allow the moveable platform to move freely in the length direction of the aerofoil component 33, while preventing any undesired lateral movement, thereby reducing the likelihood of the moveable platform inhibiting sintering induced shrinkage and helping to prevent unwanted distortion of the green aerofoil component.
  • the moveable platform 29 has a stopper 44.
  • the stopper 44 ensures the green aerofoil component 33 is located in the correct position on the setter 25 and helps to prevents the component falling off the platform.
  • the amount of variation between sintered components can thus be reduced. Stoppers may also be attached to the stationary support 27 and/or the fixed platform 30.
  • a friction reducing agent can be applied to the stationary support 27, the fixed platform 30 and/or the moveable platform 29 at points of contact between the setter 25 and the green aerofoil component 33.
  • this further reduces the frictional force between the green aerofoil component and the setter.
  • An example of a suitable friction reducing agent is a paste of ceramic beads, such as zirconium oxide beads, mixed with a binder.
  • a possible composition of a friction reducing agent is 85-90% by weight of ceramic beads and 10-15% by weight of binder.
  • the ceramic beads are larger than the roughness of the materials used in the setter, and typically are about 300 microns in diameter.
  • the binder used in the friction reducing agent burns-off at a comparable rate to the binders in the green component. This results in the ceramic beads in the friction reducing agent being released before sintering-induced shrinkage of the component begins.
  • a friction reducing agent may be applied between the moveable platform 29 and the adjacent support surface (e.g. in addition to or as an alternative to the rollers or wheels) to promote the movement of the moveable platform.
  • the aerofoil component 33 is removed from the setter 25.
  • Another green aerofoil component can then be located on the setter for subsequent sintering.
  • the setter can thus be re-used.
  • a re-usable setter reduces the amount of waste material. Further, due to potential non-uniformities between single-use setters, the parts produced using a re-usable setter may exhibit less variation than those produced using single-use setters.
  • Figures 3 and 4 each show schematically a respective setter which has a first 29 and a second 41 moveable platform.
  • Green aerofoil components each having an aerofoil part 35, a first end part 37 and a second end part 38, are located on the setters such that the first and second moveable platforms support the first 37 and second 38 end parts respectively.
  • Figure 3 shows (a) its setter alone, and (b) a green aerofoil component located on the setter, while Figure 4 shows just a green aerofoil component located on the setter.
  • the moveable platforms have shaped surfaces 32, 34 to better support the respective end parts as well as stoppers 44 to ensure that components are correctly located on the setters.
  • the setters each have a stationary support 27 with a shaped surface 31 to support the aerofoil part 35 of the green aerofoil components.
  • the first moveable platforms 29 shown in Figures 3 and 4 are both supported by rollers 43 which constrain the platforms to move in the length direction of the respective aerofoil components.
  • the second moveable platform 41 shown in Figure 3 is hinged about a hinge 45 and the second moveable platform shown in Figure 4 is pivoted about a pivot 45.
  • the hinge and pivot constrain the second movable parts to move in an arc about the respective hinge or pivot. Having both first and second moveable platforms (as opposed to just one moveable platform, as shown in Figure 2 ) improves the accommodation of movement of both of the end parts, reducing friction between the aerofoil component and the setter. Advantageously, this further reduces the amount of unwanted distortion of the aerofoil component during sintering.
  • the setter may have other combinations of moveable platforms other than those illustrated in Figures 2 to 4 .
  • For a setter may have first and second moveable platforms which are both supported by rollers or wheels, or which are both pivoted or hinged.
  • a setter 25 may have one or more interchangeable parts.
  • a setter may have a permanently attached stationary support which is suitable to support a range of aerofoil parts and a set of interchangeable moveable platforms which can be temporarily and movably attached to the setter, each platform suitable to support a specific type of aerofoil component.
  • One setter can therefore be used to produce a range of aerofoil components and may thus reduce the time taken swapping setters when changing between production of different types of component.
  • the setter 25 itself may be produced by injection moulding and sintering. It can then be machined to a final shape. Particularly high precision regions, such as areas in contact with the aerofoil, may be produced by freeze casting.

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

Claims (9)

  1. Verfahren zum Sintern einer metallpulverspritzgegossenen Tragflächen-Grünlingskomponente (33), wobei das Verfahren beinhaltet:
    Bereitstellen eines Einrichters (25) mit einem feststehenden Träger (27), der zum Tragen eines Tragflächenstücks (35) der Komponente ausgelegt ist, und einer bewegbaren Plattform (29), die zum Tragen eines Endstücks (37) der Komponente angeordnet ist, wobei die bewegbare Plattform in Relation zu dem feststehenden Träger unabhängig bewegbar ist, die bewegbare Plattform von Rollen (43) oder Rädern getragen oder aufgehangen oder geschwenkt wird, um die unabhängige Bewegung der Plattform in Relation zu dem feststehenden Träger zu ermöglichen und die bewegbare Plattform zu zwingen, sich entlang einer Linie zu bewegen, die parallel zur Längsrichtung der Tragflächenkomponente verläuft,
    Anordnen der Grünlingskomponente auf dem Einrichter, sodass das Tragflächenstück und das Endstück jeweils von dem feststehenden Träger bzw. der bewegbaren Plattform getragen werden, und
    Sintern der getragenen Grünlingskomponente, wobei sich die bewegbare Plattform während des Sinterns in Relation zu dem feststehenden Träger bewegt, um eine durch Sintern induzierte Schrumpfung der Komponente aufzunehmen.
  2. Verfahren nach Anspruch 1, wobei der feststehende Träger eine geformte Fläche (31) aufweist, welche eine Tragflächenoberfläche des Tragflächenstücks berührt, wenn die Grünlingskomponente auf dem Einrichter angeordnet wird, wobei sich die geformte Fläche in den Endphasen des Sinterns der Form der Tragflächenoberfläche anpasst.
  3. Verfahren nach Anspruch 1 oder 2, wobei die bewegbare Plattform eine weitere geformte Fläche (32) aufweist, welche eine Oberfläche des Endstücks berührt, wenn die Grünlingskomponente auf dem Einrichter angeordnet wird, wobei sich die weitere geformte Fläche der Oberfläche des Endstücks anpasst.
  4. Verfahren nach einem der vorhergehenden Ansprüche, wobei die Tragflächenkomponente ein Luftleitblech oder eine Laufschaufel eines Gasturbinentriebwerks ist.
  5. Verfahren nach einem der vorhergehenden Ansprüche, weiter beinhaltend:
    Entfernen der gesinterten Tragflächenkomponente aus dem Einrichter, und
    Wiederholen der Schritte des Anordnens und Sinterns mit einer anderen metallpulverspritzgegossenen Tragflächen-Grünlingskomponente.
  6. Verfahren nach einem der vorhergehenden Ansprüche, wobei das Verfahren ferner ein Anwenden eines reibungsreduzierenden Mittels auf den feststehenden Träger und/oder die bewegbare Plattform an Kontaktstellen zwischen dem Einrichter und der Grünlingskomponente beinhaltet.
  7. Verfahren nach Anspruch 6, wobei das reibungsreduzierende Mittel Keramikperlen beinhaltet.
  8. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Einrichter mit einer Anschlagplatte (44) versehen ist, gegen welche die Grünlingskomponente angeordnet wird.
  9. Verfahren nach einem der vorhergehenden Ansprüche, wobei die Tragflächen-Grünlingskomponente an jeweiligen Enden des Tragflächenstücks erste (37) und zweite (38) Endstücke aufweist und der Einrichter entsprechende erste (29) und zweite (41) bewegbare Plattformen aufweist.
EP16161344.3A 2015-04-16 2016-03-21 Verfahren zum sintern Active EP3081322B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB1506484.3A GB201506484D0 (en) 2015-04-16 2015-04-16 A method of sintering

Publications (2)

Publication Number Publication Date
EP3081322A1 EP3081322A1 (de) 2016-10-19
EP3081322B1 true EP3081322B1 (de) 2017-08-23

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EP16161344.3A Active EP3081322B1 (de) 2015-04-16 2016-03-21 Verfahren zum sintern

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US (1) US20160303654A1 (de)
EP (1) EP3081322B1 (de)
GB (1) GB201506484D0 (de)

Cited By (1)

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US11000900B2 (en) 2018-06-06 2021-05-11 General Electric Company Setter assembly for additive manufacturing

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DE102015210770A1 (de) * 2015-06-12 2016-12-15 Rolls-Royce Deutschland Ltd & Co Kg Bauteilkonstruktion, Bauteil für eine Gasturbine und Verfahren zur Herstellung eines Bauteils einer Gasturbine durch Metallpulverspritzgießen
GB2544577B (en) * 2015-07-06 2019-05-15 Safran Aircraft Engines Tooling for use during heat treatment to support a preform made of powder
US10940535B2 (en) 2018-06-08 2021-03-09 General Electric Company Method and system for additive manufacturing

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US3904352A (en) * 1974-01-17 1975-09-09 Coors Porcelain Co Assembly and method for supporting ceramics and the like during firing
JPH09110535A (ja) * 1995-10-06 1997-04-28 Inax Corp 陶磁器製品の焼成方法
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US11000900B2 (en) 2018-06-06 2021-05-11 General Electric Company Setter assembly for additive manufacturing

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Publication number Publication date
US20160303654A1 (en) 2016-10-20
GB201506484D0 (en) 2015-06-03
EP3081322A1 (de) 2016-10-19

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