EP4370262B1 - Verbesserte gegenform zur herstellung eines aeronautischen metallteils - Google Patents

Verbesserte gegenform zur herstellung eines aeronautischen metallteils

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Publication number
EP4370262B1
EP4370262B1 EP22755244.5A EP22755244A EP4370262B1 EP 4370262 B1 EP4370262 B1 EP 4370262B1 EP 22755244 A EP22755244 A EP 22755244A EP 4370262 B1 EP4370262 B1 EP 4370262B1
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EP
European Patent Office
Prior art keywords
counter
phase
alc
powder
composite material
Prior art date
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Application number
EP22755244.5A
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English (en)
French (fr)
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EP4370262A1 (de
Inventor
Pierre Jean SALLOT
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Safran SA
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Safran SA
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Publication of EP4370262A1 publication Critical patent/EP4370262A1/de
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/003—Removing cores using heat
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/002—Removing cores by leaching, washing or dissolving
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps

Definitions

  • the invention relates to the manufacture of aeronautical parts, in particular blades or rectifiers of aeronautical turbomachines, by solid phase densification methods. More specifically, the invention relates to the counter-forms used in the manufacture of these aeronautical parts, to a method of manufacturing such a counter-form, and to a method of manufacturing such an aeronautical part.
  • Metal aeronautical parts are generally manufactured from nickel-, titanium-, or titanium aluminide-based alloys.
  • solid-phase densification manufacturing processes can be used.
  • Such solid-phase densification manufacturing processes include, for example, sintering under load, such as flash sintering or SPS (for “Spark Plasma Sintering") or hot isostatic pressing (HIP for "Hot Isostatic Pressing”), or the injection of a mixture of metal powder and a thermoplastic polymer (known as MIM process for "Metal Injection Molding” in English).
  • sintering under load such as flash sintering or SPS (for "Spark Plasma Sintering") or hot isostatic pressing (HIP for "Hot Isostatic Pressing”
  • MIM process Metal Injection Molding
  • SPS sintering is a sintering method using the Joule effect to heat the pre-compacted powder, constituting the part to be manufactured (in the present application, a powder based on nickel, titanium, or titanium aluminide) in a hollow graphite tool between two electrodes, between which a pulsed current is applied, under an inert atmosphere or under vacuum, the tool being subjected to uni-axial pressure, for example under the action of a hydraulic press.
  • the Joule effect heating of the powder thus allows the densification of the part.
  • a preform of the part to be manufactured is placed in a vacuum-evacuated container before being hermetically sealed.
  • a uniform pressure in all directions is thus applied to the part, via of the container, by injecting a neutral gas under pressure (for example argon or nitrogen) into the container enclosure.
  • a neutral gas under pressure for example argon or nitrogen
  • a powder constituting the material to be manufactured is mixed with a polymer binder.
  • the resulting mixture known as "feedstock”
  • the binder is then removed during a debinding process.
  • a sintering operation can then be carried out on the resulting part.
  • a process using such counter-forms conventionally comprises the manufacture of a counter-form by additive manufacturing, the partial sintering of the counter-form to give it rigidity, the filling of the counter-form with a powder to densify, the joint SPS sintering of the material constituting the counter-form and the powder present inside it, and finally the unsticking of the counter-form to release the sintered part.
  • the materials used for the counterforms are ceramics, or a composite thereof, such as yttria-stabilized zirconia (YSZ), alumina-reinforced zirconia (ATZ), or zirconia-reinforced alumina (ZTA).
  • YSZ yttria-stabilized zirconia
  • ATZ alumina-reinforced zirconia
  • ZTA zirconia-reinforced alumina
  • the titanium or titanium aluminide alloys used to manufacture the blades or the straighteners are conventionally sintered by SPS at temperatures above 1350°C.
  • the above ceramic materials used for the counter-forms have a density above 80%, which makes them difficult to shake out and requires a specific step involving chemical or mechanical shake out, potentially harmful to the part subsequently manufactured and to the environment, as the counter-form cannot be recycled.
  • the documents US 4,187,266 A And US 2007/056709 A1 also refer to a counter-form for the manufacture of metal aeronautical parts.
  • the materials used for the part to be manufactured and the counter-form have different coefficients of thermal expansion, which can cause the part to deform in the finest areas such as the trailing edges, break the parts, or lead to the recrystallization of certain areas under stress, inducing mechanical deformation.
  • the first phase is of the "MAX phase” type, a crystalline structure with the generic formula M n+1 AX n , combining characteristics of both metals and ceramics, and notably presenting good thermal and electrical conductivity, good machinability, as well as tolerance to damage and resistance to oxidation at high temperature.
  • the use of aluminum on the A site and carbon on the X site ensures good chemical compatibility with the Al 4 C 3 phase. Furthermore, the use of aluminum on the A site ensures the formation of a protective alumina layer by oxidation of the counter-form. In addition, the use of carbon on the X site is advantageous in that it does not present the risk of contaminating the materials present, nor of reacting negatively with the Al 4 C 3 phase, unlike nitrogen.
  • titanium or chromium used on site M, have melting temperatures higher than the temperatures used during sintering of the part to be manufactured, allowing their structure and stability to be preserved during sintering. Furthermore, they have coefficients of thermal expansion compatible with those of the materials to be densified, in particular alloys based on nickel, titanium, or titanium aluminide, and good thermal conductivity.
  • this first phase with a second phase of formula Al 4 C 3 is particularly advantageous.
  • aluminum carbide (Al 4 C 3 ) is an inorganic compound, whose melting temperature is very high (2200°C), and which can easily hydrolyze at room temperature, in the presence of a water-rich atmosphere.
  • the composite material used for the counter-form of the present presentation integrates this second phase of aluminum carbide into the grain boundaries of the first phase. This makes the composite material particularly reactive to atmospheres containing water.
  • the degradation of the aluminum carbide is accompanied by a variation in volume and a release of gas, capable of fragmenting the grain boundary and propagating cracks in the first initial phase. It is thus possible to propagate the hydrolysis phenomenon over relatively large distances, and thus facilitate the fragmentation and detachment of the counter-form.
  • the composite material forming the counterform can be initially dense and massive, and be reduced to powder by hydrolysis.
  • the chemical gradient between the aluminum carbide and the first phase containing aluminum and carbon is very limited, which makes it possible to limit the interdiffusion between the different chemical elements during the counter-form shaping and casting stages.
  • a fragmented material composed of grains from the first phase and hydrated aluminum, can be recovered. After drying, this material can be "recharged” with Al 4 C 3 and reused to manufacture new counter-forms.
  • the composite material of the counter-form according to the present disclosure thus combines the aforementioned advantages linked to the first phase, with the use of a second phase of formula Al 4 C 3 , allowing the production of parts with complex shapes without having to resort to complex graphite tools, while allowing easy and rapid detachment of the counter-form not requiring chemical solutions potentially harmful to the part subsequently manufactured and to the environment, and which can be recycled.
  • the first phase is of one of Cr 2 AlC, Ti 3 AlC 2 , Ti 2 AlC, Nb 4 AlC 3 , Nb 2 AlC or Mo 2 TiAlC 2 .
  • the Cr 2 AlC, Ti 3 AlC 2 , Ti 2 AlC phases also have the advantage of covering the densification temperature ranges and thermal expansion coefficients of the materials considered and used to manufacture the part.
  • the Cr 2 AlC, Ti 3 AlC 2 , Ti 2 AlC phases are aluminoforming. Since the other phases are not aluminoforming, it is preferable to add a coating allowing the formation of a protective layer. This addition is however not essential, other oxides having a similar function to alumina, although less adherent than the latter, can form on the counter-form when it is subjected to an oxidation step.
  • the composite material comprises between 1 and 50% of second phase by volume of the composite material, preferably between 1 and 20%. These values make it possible to ensure the fragmentation of the composite material by hydrolysis, while leaving a sufficient volume of first phase in the composite material, making it possible to retain the technical advantages linked to this first phase. In addition, this fraction of Al 4 C 3 phase makes it possible to ensure the chemical stability of the material at high temperature, while making it possible to induce a hydrolysis phenomenon facilitating debonding.
  • an inner surface of the counterform is covered with a layer of alumina.
  • the degradation of the counterform by hydrolysis of the aluminum carbide in an atmosphere containing water, should only occur when the counterform is shaken out.
  • the presence of a dense, adherent alumina layer on the internal surface of the counterform protects the composite material from degradation during the other stages of manufacturing a part prior to shakeout of the counterform.
  • the alumina layer has a thickness of between 1 and 50 ⁇ m. This thickness ensures protection of the counterform during the manufacture of a part. More specifically, the alumina layer thus formed is thin enough not to have an impact on the mechanical shrinkage of the part during cooling, but chemically insulates the powder and the counterform.
  • the mixture of powders used to obtain the first phase may in particular comprise the mixture of pure powders of carbon, aluminum, titanium and/or chromium, and/or chromium carbide, and/or chromium carbide, and/or titanium carbide, and/or aluminum carbide.
  • the composite material constituting the counter-form is obtained by reacting the different powders of the constituent elements of this material at high temperature. This process has the advantage of involving, in the production of the composite material, the Al 4 C 3 phase, making it possible to provide the necessary elements AI and C, thus providing the aforementioned advantages.
  • the shaping step may include the injection of a binder onto a powder (called “binder jetting” in English), the injection of a mixture of metal powder and a thermoplastic polymer (or MIM process for "Metal Injection Molding” in English) or any other suitable known 3D printing process, preferably followed by sintering, or sintering under load called “flash sintering” (or SPS sintering for "Spark Plasma Sintering” in English), for example.
  • the mixing step comprises mixing the pure powders constituting the first phase so as to obtain the first phase in powder form, then mixing said first phase in powder form with an Al 4 C 3 powder so as to obtain the second phase.
  • pure powders of carbon, aluminum, titanium and/or chromium and/or chromium carbide, and/or chromium carbide, and/or titanium carbide, and/or aluminum carbide for example are mixed first, so as to obtain the first phase in a first step, then the first phase obtained is mixed with an aluminum carbide powder in a second step, so as to obtain the second phase.
  • the mixing step comprises mixing pure powders constituting the first phase with excess Al 4 C 3 powder so as to form the composite material in one operation.
  • the mixing of the powders is not carried out in two stages (manufacturing of the first phase in the first stage, then mixing with an aluminum carbide powder), but the aforementioned pure powders are mixed in the same operation with an excess Al 4 C 3 powder, i.e. in over-stoichiometry, thus allowing the formation of the composite material "in situ".
  • the fact of reacting the Al 4 C 3 powder in over-stoichiometry with respect to the first desired phase makes it possible to maintain a controlled volume fraction of this phase in the final material.
  • a supply channel configured to allow the supply of powder constituting the part to be manufactured, is provided in the counter-form.
  • a supply channel is provided in the structure of the counter-form, so as to put the internal cavity of the counter-form forming the negative of the part to be manufactured, in fluid communication with the exterior of the counter-form.
  • This channel makes it easier to supply powder of the material constituting the part to be manufactured and densified.
  • the first phase is of formula Cr 2 AlC, Ti 3 AlC 2 or Ti 2 AlC, the method comprising, after the step of shaping the counter-form, an oxidation step allowing the formation of an alumina layer on an internal surface of the counter-form.
  • the phases of formula Cr 2 AlC, Ti 3 AlC 2 or Ti 2 AlC are aluminoforming, and thus allow the formation of an alumina layer by simple oxidation of the counter-form, without requiring the addition of a complex multi-layer coating allowing the formation of this protective layer.
  • This oxidation step makes it possible to produce an adherent and dense alumina layer on a wall of the internal cavity of the counter-form forming the negative of the part to be manufactured, capable of protecting the composite material, further improving the densified part debonding and limiting the risks of interdiffusion between the densified powder and the composite material constituting the counter-form.
  • the subsequent densification step is carried out under vacuum, the latter does not pose any particular problem with respect to the composite material.
  • the oxidation step is carried out by placing the counter-form in an enclosure under air between 1000°C and 1400°C.
  • the present disclosure also relates to a method for manufacturing a metal aeronautical part, in particular a turbine part by solid phase densification, using a counter-form obtained by a method according to any one of the preceding embodiments, the method comprising, after steps of filling the counter-form with a powder constituting the part to be manufactured and of densifying said powder in the counter-form, a step of unmolding the counter-form by baking.
  • the assembly is placed in a device, for example an oven, preferably with controlled humidity.
  • a device for example an oven, preferably with controlled humidity.
  • the presence of the Al 4 C 3 phase between the grain boundaries allows, in air laden with water, the disintegration of the core of the counter-form. This thus facilitates the demoulding and therefore the demoulding of the part, while avoiding the use of chemical solutions, such as acids, which are potentially harmful to the manufactured part.
  • the method comprises, after the demoulding step, a recovery step, in which the material demoulded by baking is recovered so as to be reused for the manufacture of another counter-form starting from the mixing step.
  • FIG. 1 represents a perspective view of a turbine blade 10 comprising an aerodynamic profile 12 having a lower surface 13 and an upper surface 14, a blade root 15 at its lower end, and a heel 16 at its upper end.
  • the blade 10 further comprises two sealing lips 17 and 18 formed on the upper face of the heel 16 arranged transversely to the lower surface 13 and upper surface 14 sides.
  • Such a blade is obtained, according to the present disclosure, by densification of a powder of the material constituting the blade, in particular alloys based on nickel (Ni), titanium (Ti), or titanium aluminide (TiAl), in a counter-form corresponding to the negative of the part to be manufactured, that is to say of the blade 10 in the present example.
  • Such a counter-form 1, in accordance with the present presentation, is represented in perspective on the figure 2 , with the blade 10 shown schematically in this figure.
  • the counter-form 1 comprises two parts 1a and 1b arranged on either side of the blade 10, each comprising a half cavity, and intended to be assembled to form a counter-form 1 containing a complete cavity corresponding to the negative of the blade 10.
  • Each half cavity respectively comprises a first portion 2a, 2b, a second portion 5a, 5b, a third portion 6a, 6b and locations 7a, 7b and 8a, 8b.
  • a passage 9a, 9b is also provided in each part 1a, 1b respectively of the counter-form 1 so as to form a supply channel 9 in the counter-form 1 after assembly of the two parts 1a and 1b, and to allow the supply of the aforementioned powder constituting the blade to be manufactured, when the parts 1a and 1b are assembled.
  • FIG. 3 shows the counter-form 1 after assembly of the two parts 1a and 1b. It should be noted, however, that this example is not limiting, the counter-form 1 being able to be manufactured in a single piece in a single operation by a method described in more detail in the remainder of the description, so as to form a cavity comprising the different portions 2, 5, 6, 7, 8 and 9 mentioned above.
  • the counter-form 1 comprises a composite material making it possible in particular to facilitate its removal, during the unsticking step described later.
  • the composite material comprises two phases: a first phase called the “MAX phase”, and a second phase with the formula Al 4 C 3 , in other words aluminium carbide.
  • the element used in group A is aluminum (Al) to ensure the formation of an alumina layer when aluminoforming phases are used.
  • the element used at site X is carbon (C). Indeed, phases containing nitrogen (N) often have lower melting temperatures than their carbon-containing counterparts and chemical compatibility with the Al 4 C 3 phase is not assured.
  • the element used on site M is determined so that the melting temperature and the coefficient of thermal expansion of the MAX phases considered are compatible with the constituent materials of the part to be sintered, in particular nickel-based alloys (Ni), having a coefficient of thermal expansion between 14 and 16x10 -6 /°C, titanium (Ti), having a coefficient of thermal expansion between 10 and 13x10 -6 /°C, or titanium aluminide (TiAl), having a coefficient of thermal expansion between 10 and 13x10 -6 /°C.
  • Ni nickel-based alloys
  • Ti titanium
  • TiAl titanium aluminide
  • the sintering temperatures of these materials are also higher than 1350°C.
  • the first phases retained may be of formula Cr 2 AlC, having a melting temperature greater than 1500°C and a coefficient of thermal expansion of approximately 13x10 -6 /°C, Ti 3 AlC 2 having a melting temperature greater than 1550°C and a coefficient of thermal expansion of between 9 and 12x10 -6 /°C, or Ti 2 AlC having a melting temperature greater than 1550°C and a coefficient of thermal expansion of between 7 and 10x10 -6 /°C.
  • the second phase of formula Al 4 C 3 is a known carbide with a very high melting temperature (2200°C). It is also aluminoformable at high temperatures.
  • the particularly advantageous property in the context of the invention is the ease with which this phase hydrolyzes at room temperature in the presence of a water-rich atmosphere.
  • the decomposition of this phase follows the following reaction: Al 4 C 3 + 12 H 2 O ⁇ 4 Al(OH) 3 + 3 CH 4
  • This reaction can be catalyzed by optimizing the humidity level but also the temperature.
  • the counter-form 1 comprising this composite material can be easily eliminated by being degraded by hydrolysis, at the end of the manufacturing process of the blade or the rectifier.
  • a first example of a method for manufacturing blades according to the present disclosure is a process by sintering under load, called SPS sintering (for “Spark Plasma Sintering” in English) in the remainder of the description.
  • SPS sintering for “Spark Plasma Sintering” in English
  • the first step S100 of this process consists of manufacturing the counter-form 1 described above, in one or two parts.
  • step S100 of manufacturing the counter-form 1 is divided into several steps. Firstly, metal powders are mixed together, so as to obtain a composite powder comprising the first and second phases (step S110).
  • metal powders are mixed together, so as to obtain a composite powder comprising the first and second phases (step S110).
  • pure powders of aluminum (Al), carbon (C), chromium (Cr) and/or titanium (Ti), and/or chromium carbide (CrC), and/or chromium carbide (Cr 7 C 3 ), and/or titanium carbide (TiC) are mixed with an excess powder of aluminum carbide Al 4 C 3 , so as to form in situ a composite material comprising the first phase and the second phase, such that the second phase represents between 1 and 50%, preferably between 1 and 20% of the total volume of the composite material.
  • the counter-form 1 is shaped (step S120), so that the latter takes the desired shape.
  • This step can be carried out by various known methods such as the injection of a binder onto a powder (called “binder jetting” in English), the injection of a mixture of metal powder and a thermoplastic polymer (or MIM process for “Metal Injection Molding” in English) or any other suitable known 3D printing process, preferably followed by sintering, or SPS sintering, for example, or any other suitable known process, or a combination of these different methods.
  • a supply channel 9 is provided, allowing the subsequent injection of metal powder.
  • step S130 a step of forming an alumina layer, making it possible to form a protective alumina layer with a thickness of between 1 and 50 ⁇ m can be carried out (step S130).
  • This step is carried out by oxidizing the counter-form 1 by bringing the latter to a temperature of between 1000 and 1400°C.
  • This step is made possible by the fact that the phases of formula Cr 2 AlC, Ti 3 AlC 2 or Ti 2 AlC are aluminoform.
  • the counter-form 1 thus manufactured in step S100, and comprising the cavity described above corresponding to the negative of the blade, is then filled with a powder constituting the blade to be manufactured (step S200), in particular a powder based on titanium (Ti), a nickel-based superalloy (Ni), or an intermetallic alloy such as titanium aluminide (TiAl), via the supply channel 9.
  • a powder constituting the blade to be manufactured in particular a powder based on titanium (Ti), a nickel-based superalloy (Ni), or an intermetallic alloy such as titanium aluminide (TiAl)
  • An ultrasonic table can be used to facilitate the flow of the powder into the counter-form and its filling.
  • first phase of formula Cr 2 AlC is preferred, and for the densification of materials based on titanium or titanium aluminide, the use of a first phase of formula Ti 2 AlC or Ti 3 AlC 2 is preferred.
  • first phase of formula Ti 2 AlC or Ti 3 AlC 2 is preferred.
  • the counter-form 1 containing the powder to be densified is then placed in a tool (not shown), preferably made of graphite, configured to carry out SPS sintering (step S300).
  • SPS sintering is then carried out (step S400).
  • the counter-form 1 is placed in a press exerting axial pressure on the counter-form 1.
  • a pulsed current is then applied to the counter-form 1, so as to heat the powder present in it by the Joule effect, allowing the densification of the powder.
  • Step S500 of stripping the counter-form 1 can be carried out by placing the assembly in a hygrometry-controlled oven (relative humidity RH >50%) or preferably in a steam autoclave, at temperatures between 100 and 180°C, and pressures between 6 and 12 bars.
  • RH >50% relative humidity
  • RH relative humidity
  • This step allows the disintegration of the counter-form 1, taking into account the presence of the second phase of formula Al 4 C 3 between the grain boundaries of the first phase.
  • a cleaning and finishing step of the blade obtained can also be carried out.
  • the demoulding step S500 may be followed by a recovery step (step S600), or recycling, in which the composite material demoulded by baking, then in powder form, is recovered so as to be reused for the manufacture of another counter-form 1, starting again from the mixing step S110. More precisely, once the degradation of the counter-form 1 has been carried out, a fragmented material composed of grains of the first phase and hydrated aluminum is recovered. After drying, this material may be “recharged” with Al 4 C 3 and reused in order to manufacture new counter-forms 1.
  • step S110 of mixing the powders differs from the method according to the first embodiment in that step S110 of mixing the powders is broken down into two sub-steps.
  • step S110 of mixing the powders in the context of the second embodiment comprises, firstly, the mixing of pure powders making it possible to obtain the first phase (step S111), the grinding in powder form of this first phase, then the mixing of the first phase thus obtained with an Al 4 C 3 powder making it possible to obtain the composite material ex situ (step S112).
  • a first phase of formula Ti 3 AlC 2 can be obtained by mixing pure powders of titanium, aluminum and titanium carbide (Ti: Al: TiC) in the molar proportions 1: 1.05: 1.9 respectively.
  • the titanium grains have a diameter of less than 45 ⁇ m, a purity of 99.5%.
  • the aluminum grains have a diameter of between 45 and 150 ⁇ m, a purity of 99.5% and the titanium carbide grains have a diameter of 2 ⁇ m, a purity of 99.5%, and a density of 7.82 g/cm3.
  • These different powders can be mixed in a ball mixer, then subjected to reactive sintering up to 1450°C. The porous mass thus obtained is ground to be reduced to powder.
  • step S600 in which the composite material detached by baking is recovered so as to be reused for the manufacture of another counter-form 1, the material can be "recharged” with Al 4 C 3 starting again from step S112.
  • the pure powders can also be mixed with an Al 4 C 3 powder.
  • the Al 4 C 3 powder contributes to the formation of the first phase, but is not in sufficient quantity to form the composite material in situ, such that the second step S112 is necessary, and makes it possible to add a necessary quantity of Al 4 C 3 powder, making it possible to obtain the proportions of Al 4 C 3 mentioned previously in the composite material.
  • step S200 of filling the counter-form 1 with a powder constituting the blade to be manufactured is also carried out, then, in step S300, the counter-form 1 containing said powder is placed in a deformable container.
  • HIP densification is carried out in step S400, in which a neutral gas (for example argon or nitrogen) is injected into the pressure chamber, then applying a uniform pressure in all directions on the container containing the counter-form 1.
  • step S200 an injection of a mixture of metal powder and a thermoplastic polymer (called MIM process for "Metal Injection Molding” in English) can be carried out.
  • MIM process Metal Injection Molding
  • the counter-form 1 is inserted into a MIM injection press and a constituent powder of the material to be manufactured, mixed with a polymer binder, is injected into the counter-form 1.
  • the polymer binder is then removed during a debinding process. Natural sintering without pressure on the resulting part can then be carried out. If the latter allows the part to be sufficiently densified, in particular if the relative density is greater than 99%, the counter-form 1 can be de-sintered, in accordance with step S500.
  • the natural sintering can be completed by a SPS or HIP densification cycle under pressure, by repeating steps S300 and S400 described above.
  • the debinding mentioned above can be immediately followed by SPS or HIP densification in accordance with steps S300 and S400, without going through natural sintering.
  • either of the densification modes may be used for the manufacture of the metal part, and apply to both embodiments described previously and described with reference to figures 4 And 5
  • steps S100 for manufacturing counter-form 1, S500 for unsticking and S600 for recovering the material are common to all the densification methods (SPS, HIP or MIM) used.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Ceramic Products (AREA)

Claims (12)

  1. Gegenform (1) zur Herstellung eines metallischen Luftfahrtteils, insbesondere eines Turbinenteils, durch Festphasenverdichtung, umfassend ein Verbundmaterial, umfassend einerseits eine erste Phase von Formel Mn+1AlCn, wobei n = 1 bis 3 und M ein Übergangsmetall ist, das ausgewählt ist aus der Gruppe, bestehend aus Titan, Molybdän, und/oder Niob, und/oder Chrom, wobei das Verbundmaterial andererseits umfassend eine zweite Phase von Formel Al4C3.
  2. Gegenform (1) nach Anspruch 1, wobei die erste Phase von einer der Formeln Cr2AlC, Ti3AlC2, Ti2AlC, Nb4AlC3, Nb2AlC oder Mo2TiAlC2 ist.
  3. Gegenform (1) nach Anspruch 1 oder 2, wobei das Verbundmaterial zwischen 1 und 50 % zweite Phase, bezogen auf das Volumen des Verbundmaterials, vorzugsweise zwischen 1 und 20 %, umfasst.
  4. Gegenform (1) nach einem der Ansprüche 1 bis 3, wobei eine innere Oberfläche der Gegenform (1) mit einer Schicht aus Aluminiumoxid überzogen ist.
  5. Gegenform (1) nach Anspruch 4, wobei die Aluminiumoxidschicht eine Stärke zwischen 1 und 50 µm aufweist.
  6. Verfahren zur Herstellung einer Gegenform (1) für die Herstellung eines hohlen metallischen Luftfahrtteils, insbesondere eines Turbinenteils, durch Festphasenverdichtung, die Gegenform (1) umfassend ein Verbundmaterial, umfassend einerseits eine erste Phase von Formel Mn+1AlCn, wobei n = 1 bis 3 und M ein Übergangsmetall ist, das ausgewählt ist aus der Gruppe, bestehend aus Titan, und/oder Molybdän, und/oder Niob, und/oder Chrom, das Verbundmaterial andererseits umfassend eine zweite Phase von Formel Al4C3, wobei die Gegenform (1) durch ein pulvermetallurgisches Verfahren erlangt wird, umfassend einen Mischschritt, bei dem Pulver gemischt werden, die es ermöglichen, das Verbundmaterial zu erlangen, und einen Formgebungsschritt.
  7. Verfahren nach Anspruch 6, wobei der Mischschritt das Mischen von reinen Pulvern, die die erste Phase bilden, um die erste Phase in Pulverform zu erlangen, und dann das Mischen der ersten Phase in Pulverform mit einem Al4C3-Pulver, um die zweite Phase zu erlangen, umfasst.
  8. Verfahren nach Anspruch 6, wobei der Mischschritt das Mischen von reinen Pulvern, die die erste Phase bilden, mit einem überschüssigen Al4C3-Pulver umfasst, um das Verbundmaterial in einem Vorgang zu bilden.
  9. Verfahren nach einem der Ansprüche 6 bis 8, wobei bei dem Formgebungsschritt der Gegenform in der Gegenform ein Versorgungskanal bereitgestellt ist, der konfiguriert ist, um die Versorgung mit Pulver, das das herzustellende Teil bildet, zu ermöglichen.
  10. Verfahren nach einem der Ansprüche 6 bis 9, wobei die erste Phase von Formel Cr2AlC, Ti3AlC2 oder Ti2AlC ist, das Verfahren umfassend nach dem Formgebungsschritt der Gegenform einen Oxidationsschritt, der die Bildung einer Aluminiumoxidschicht auf einer Innenfläche der Gegenform ermöglicht.
  11. Verfahren zur Herstellung eines metallischen Luftfahrtteils, insbesondere eines Turbinenteils, durch Festphasenverdichtung unter Verwendung einer Gegenform (1), die durch ein Verfahren nach einem der Ansprüche 6 bis 10 erlangt wird, das Verfahren umfassend nach dem Füllschritt der Gegenform mit einem Pulver, das das herzustellende Teil bildet, und Verdichtungsschritt des Pulvers in der Gegenform einen Entformungsschritt der Gegenform durch Wärmebehandlung umfasst.
  12. Verfahren nach Anspruch 11, das nach dem Wärmebehandlungsschritt einen Rückgewinnungsschritt umfasst, wobei das Wärmebehandlung entformte Material zurückgewonnen wird, sodass es für die Herstellung einer weiteren Gegenform beginnend mit dem Mischschritt, wiederverwendet werden kann.
EP22755244.5A 2021-07-16 2022-07-08 Verbesserte gegenform zur herstellung eines aeronautischen metallteils Active EP4370262B1 (de)

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FR2107728A FR3125239B1 (fr) 2021-07-16 2021-07-16 Contre-forme améliorée pour la fabrication de pièce aéronautique métallique
PCT/FR2022/051385 WO2023285758A1 (fr) 2021-07-16 2022-07-08 Contre-forme améliorée pour la fabrication de pièce aéronautique métallique

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US4187266A (en) * 1977-10-06 1980-02-05 General Electric Company Process for making a ceramic article having a dense integral outer barrier layer and a high degree of porosity and crushability characteristics
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FR3125239B1 (fr) 2023-07-14
EP4370262A1 (de) 2024-05-22
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CN117693406A (zh) 2024-03-12
FR3125239A1 (fr) 2023-01-20

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