GB2416544A - An alloy component and method of manufacture - Google Patents

An alloy component and method of manufacture Download PDF

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Publication number
GB2416544A
GB2416544A GB0416669A GB0416669A GB2416544A GB 2416544 A GB2416544 A GB 2416544A GB 0416669 A GB0416669 A GB 0416669A GB 0416669 A GB0416669 A GB 0416669A GB 2416544 A GB2416544 A GB 2416544A
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Prior art keywords
alloy
niobium
component
composition
nickel
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GB0416669A
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GB0416669D0 (en
Inventor
Xinhua Wu
Michael Loretto
Wayne Eric Voice
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Rolls Royce PLC
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Rolls Royce PLC
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Priority to GB0416669A priority Critical patent/GB2416544A/en
Publication of GB0416669D0 publication Critical patent/GB0416669D0/en
Publication of GB2416544A publication Critical patent/GB2416544A/en
Withdrawn legal-status Critical Current

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    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/008—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression characterised by the composition
    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
    • C04B35/58085—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/64—Burning or sintering processes
    • C04B35/645—Pressure sintering
    • C04B35/6455—Hot isostatic pressing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C27/00—Alloys based on rhenium or a refractory metal not mentioned in groups C22C14/00 or C22C16/00
    • C22C27/02—Alloys based on vanadium, niobium, or tantalum
    • 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
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3201—Alkali metal oxides or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/327—Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3272—Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/40—Metallic constituents or additives not added as binding phase
    • C04B2235/404—Refractory metals
    • 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
    • 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
    • F05D2230/40—Heat treatment

Abstract

An alloy component 10 comprises a first portion 20 and a second portion 22. The first portion comprises a first alloy and the second portion comprises a second alloy, the composition of the first and second alloys being different. At least one of the portions of the component is made by consolidating a powder of the respective alloy. The component can be a gas turbine engine turbine blade and the consolidation process can be hot isostatic pressing. Examples of alloys used are niobium silicides and nickel aluminides.

Description

24 1 6544
AN ALLOY COMPONENT AND A METHOD OF
MANUFACTURING AN ALLOY COMPONENT
The present invention relates to an alloy component and a method of manufacturing an alloy component, more particularly to a niobium alloy component and a method of manufacturing a niobium alloy component. In particular the present invention relates to a niobium silicide component and a method of manufacturing a niobium silicide component.
Conventionally gas turbine engine turbine blades and/or turbine vanes are manufactured from nickel based superalloys or cobalt based superalloys. However, nickel based superalloys and/or cobalt based superalloys are relatively dense/heavy and are operating close to, or above, their melting points, with the aid of cooling or cooling and thermal barrier coatings.
Niobium silicides are less dense/lighter in weight than nickel-based superalloys and cobalt based superalloys, approximately a 20% reduction in density. In addition niobium silicides are capable of allowing gas turbine engine turbine blades and/or turbine vanes to operate at temperatures of at least 100 C higher than nickel based superalloys and/or cobalt based superalloys. Also niobium silicide is capable of allowing the gas turbine engine turbine blades and/or turbine vanes to operate at even higher temperatures if the niobium silicide is cooled.
Niobium silicides, which contain relatively high amounts of niobium, e.g. 20wt% Nb to l00wt% Nb, have some ductility, but are not as strong, in creep, as niobium silicides, which contain relatively high amounts of silicon and relatively low amounts of niobium, e.g. up to 50wt% Nb but which have little ductility.
There is difficulty in developing a niobium silicide composition, which is both ductile and strong enough to perform different roles in different portions of the same component. Usually ductility is achieved at the expense of strength and/or environmental resistance and visa-versa.
At present niobium silicides are capable of being cast into turbine blades and/or turbine vanes, but the niobium silicide components do not have an acceptable balance of properties. The compositions of niobium silicides are being developed, by adding suitable alloying elements, to provide a composition, which has an acceptable balance of properties. However, at the present time no such composition exists.
In addition niobium silicides are difficult to machine to shape.
In addition nickel aluminides do not have an acceptable balance of properties. There is difficulty in developing a nickel aluminide composition, which is both ductile and strong enough to perform different roles in different portions of the same component. Usually ductility is achieved at the expense of strength and/or environmental resistance and visa-versa.
In addition nickel aluminides are difficult to machine to shape.
Accordingly the present invention seeks to provide a novel alloy component and a method of manufacturing an alloy component, which reduces or overcomes the above mentioned problem. In particular the present invention seeks to provide a novel alloy component and a method of manufacturing an alloy component, which reduces or overcomes the above- mentioned problem.
Accordingly the present invention provides an alloy component comprising a first portion and a second portion, the first portion comprising a first alloy and the second portion comprising a second alloy, the composition of the first alloy being different to the composition of the second alloy and at least one of the first or second portions comprising consolidated powder of the first or second alloy.
Preferably the first portion and the second portion are integral.
Preferably the component comprises a turbine blade.
Preferably the turbine blade comprises a root, a shank, a platform and an aerofoil.
Preferably the first portion comprises at least a root and the second portion comprises an aerofoil. Preferably the first portion comprises a shank. Preferably the first portion comprises a platform. Alternatively the second lo portion comprises a platform.
Preferably the alloy of the first portion having greater ductility than the alloy of the second portion.
Preferably the alloy of the second portion having greater temperature capability than the alloy of the first portion.
Preferably the alloy component comprising a niobium alloy component, the first portion comprising a first niobium alloy and the second portion comprising a second niobium alloy, the composition of the first niobium alloy being different to the composition of the second niobium alloy and at least one of the first or second portions comprising consolidated powder of the first or second niobium alloy.
Preferably the niobium alloy component comprises a niobium silicide component.
Preferably the niobium silicide component comprises a niobium silicide component comprising a first portion and a second portion, the first portion comprising a first niobium silicide and the second portion comprising a second niobium silicide alloy, the composition of the first niobium silicide being different to the composition of the second niobium silicide.
Preferably the niobium silicide of the first portion comprises a niobium silicide with relatively high niobium content and relatively low silicon content and the niobium silicide of the second portion comprises a niobium silicide with relatively high silicon content and relatively low niobium content.
Preferably the niobium silicide of the first portion comprises 20w% to lOOwt% niobium and the niobium silicide of the second portion comprises up to 50wt% niobium.
Preferably the niobium silicide of the first portion comprises 50w% to lOOwt% niobium and the niobium silicide of the second portion comprises up to 50wt% niobium.
Alternatively the alloy component may comprise a nickel alloy component, the first portion comprising a first nickel alloy and the second portion comprising a second nickel alloy, the composition of the first nickel alloy being different to the composition of the second nickel alloy and at least one of the first or second portions comprising consolidated powder of the first or second nickel alloy.
The nickel alloy component may comprise a nickel aluminide component.
The nickel aluminide component may comprise a nickel aluminide component comprising a first portion and a second portion, the first portion comprising a first nickel aluminide and the second portion comprising a second nickel aluminide alloy, the composition of the first nickel aluminide being different to the composition of the second nickel aluminide.
Preferably there is a transition in composition between the first portion and the second portion. The transition in composition may be a gradual transition or a stepped transition.
The present invention also provides a method of manufacturing an alloy component comprising forming a powder of a first alloy, forming a powder of a second alloy, the composition of the first alloy being different to the composition of the second alloy, forming a mould having a first portion and a second portion, supplying the powder of the first alloy into the first portion of the mould and supplying the powder of the second alloy into the second portion of the mould, sealing the would, applying heat and pressure to the mould to consolidate the powder of the first alloy and the powder of the second alloy and to form an alloy component comprising a first portion and a second portion, the first portion comprising the first alloy and the second portion comprising the second alloy.
Preferably the first portion and the second portion are integral.
Preferably the component comprises a turbine blade.
Preferably the turbine blade comprises a root, a shank, a platform and an aerofoil.
Preferably the first portion comprises at least a root and the second portion comprises an aerofoil. Preferably the first portion comprises a shank. Preferably the first portion comprises a platform. Alternatively the second portion comprises a platform.
Preferably the alloy of the first portion having greater ductility than the alloy of the second portion.
Preferably the alloy of the second portion having greater temperature capability than the alloy of the first portion.
Preferably the alloy component comprising a niobium alloy component, the first portion comprising a first niobium alloy and the second portion comprising a second niobium alloy, the composition of the first niobium alloy being different to the composition of the second niobium alloy and at least one of the first or second portions comprising consolidated powder of the first or second niobium alloy.
Preferably the niobium alloy component comprises a niobium silicide component.
Preferably the niobium silicide component comprises a niobium silicide component comprising a first portion and a second portion, the first portion comprising a first niobium silicide and the second portion comprising a second niobium silicide alloy, the composition of the first niobium silicide being different to the composition of the second niobium silicide.
Preferably the niobium silicide of the first portion comprises a niobium silicide with relatively high niobium content and relatively low silicon content and the niobium silicide of the second portion comprises a niobium silicide with relatively high silicon content and relatively low niobium content.
Preferably the niobium silicide of the first portion comprises 20w% to lOOwt% niobium and the niobium silicide of the second portion comprises up to 50wt% niobium.
Preferably the niobium silicide of the first portion comprises 50w% to lOOwt% niobium and the niobium silicide of the second portion comprises up to 50wt% niobium.
Alternatively the alloy component comprising a nickel alloy component, the first portion comprising a first nickel alloy and the second portion comprising a second nickel alloy, the composition of the first nickel alloy being different to the composition of the second nickel alloy and at least one of the first or second portions comprising consolidated powder of the first or second nickel alloy.
The nickel alloy component may comprise a nickel aluminide component.
The nickel aluminide component may comprise a nickel aluminide component comprising a first portion and a second portion, the first portion comprising a first nickel aluminide and the second portion comprising a second nickel aluminide alloy, the composition of the first nickel aluminide being different to the composition of the second nickel aluminide.
Preferably the applying of heat and pressure comprises hot isostating pressing.
Preferably the mould is sealed under evacuated conditions.
Preferably the mould is subsequently removed from the component. Preferably the mould is removed by machining or dissolving using an acid, which does not dissolve the niobium alloy.
Preferably there is a transition in composition between the first portion and the second portion. The transition in composition may be a gradual transition or a stepped transition.
The present invention also provides a method of manufacturing an alloy component comprising forming a first portion of the alloy component from a first alloy, forming a powder of a second alloy, the composition of the first alloy being different to the composition of the second alloy, forming a mould having a first portion and a second portion, positioning the first portion of the alloy component into the first portion of the mould and supplying the powder of the second alloy into the second portion of the mould, sealing the mould, applying heat and pressure to the mould to consolidate the powder of the second alloy and to form an alloy component comprising a first portion and a second portion, the first portion comprising the first alloy and the second portion comprising the second alloy.
It may be possible for the component to comprise a third portion comprising a third alloy, the composition of the third alloy being different to the composition of the first alloy and different to the composition of the second alloy.
The invention may be applicable to other components such as turbine vanes, combustors, turbine shrouds etc. The present invention will be more fully described by way of example with reference to the accompanying drawings in which: Figure l shows a component according to the present invention.
Figure 2 shows an alternative component according to the present invention.
Figure 3 shows an apparatus for use in a method of manufacturing a component according to the present invention.
Figure 4 shows an apparatus for use in an alternative method of manufacturing a component according to the present invention.
Figure 5 is a cross-section through the mould shown in figure 4.
A gas turbine engine turbine blade 10, as shown in figure 1, comprises a root 12, a shank 14, a platform 16 and an aerofoil 18. The turbine blade 10 comprises a first portion 20 and a second portion 22 and the first portion 20 and the second portion 22 are integral. The first portion comprises the root 12, the shank 14 and the platform 16.
The second portion comprises the aerofoil 18. The first portion 20 comprises a first niobium alloy and the second portion 22 comprises a second niobium alloy and the composition of the first niobium alloy is different to the composition of the second niobium alloy. In particular the first portion 20 comprises a first niobium silicide and the second portion 22 comprises a second niobium silicide, the composition of the first niobium silicide is different to the composition of the second niobium silicide.
It is to be noted that at least one of the first or second portions 20, 22 comprises consolidated powder of the first or second niobium alloy.
A further gas turbine engine turbine blade lOB, as shown in figure 2, is substantially the same as the turbine blade 10 shown in figure 1 and like parts are denoted by like numerals. The turbine blade lOB comprises a root 12, a shank 14, a platform 16 and an aerofoil 18. The turbine blade 10 comprises a first portion 24 and a second portion 26 and the first portion 20 and the second portion 22 are integral. The first portion 24 comprises the root 12 and the shank 14. The second portion 26 comprises the aerofoil 18 and the platform 16. The first portion 24 comprises a first niobium alloy and the second portion 26 comprises a second niobium alloy and the composition of the first niobium alloy is different to the composition of the second niobium alloy. In particular the first portion 24 comprises a first niobium silicide and the second portion 26 comprises a second niobium silicide, the composition of the first niobium silicide is different to the composition of the second niobium silicide.
It is to be noted that at least one of the first or second portions 24, 26 comprises consolidated powder of the first or second niobium alloy.
In both examples the niobium alloy of the first portion 20, 24 has greater ductility than the niobium alloy of the second portion 22, 26. The niobium alloy of the IS second portion 22, 26 has greater temperature capability than the niobium alloy of the first portion 20, 24. The niobium alloy of the second portion 22, 26 may also have greater environmental resistance, oxidation resistance and/or corrosion resistance particularly at high operating temperatures, than the niobium alloy of the first portion 20, 24.
The niobium silicide of the first portion 20, 24 comprises a niobium silicide with relatively high niobium content and relatively low silicon content and the niobium 2s silicide of the second portion 22, 26 comprises a niobium silicide with relatively high silicon content and relatively low niobium content. In particular the niobium silicide of the first portion 20, 24 comprises 20w% to lOOwt% niobium and the niobium silicide of the second portion 22, 26 comprises up to 50wt% niobium. More particularly the niobium silicide of the first portion 20, 24 comprises 50w% to lOOwt% niobium and the niobium silicide of the second portion 22, 26 comprises up to 50wt% niobium.
Preferably there is a transition in composition between the first portion 20, 24 and the second portion 22, 26. The transition in composition may be a gradual transition or a stepped transition.
The niobium alloy component, turbine blade, 10, lOB is manufactured in a first method, as shown in figure 3, by forming a powder of a first niobium alloy and forming a powder of a second niobium alloy. The composition of the first niobium alloy is different to the composition of the second niobium alloy. The powder of the first niobium alloy 31 is stored in a first hopper 30 and the powder of l0 the second niobium alloy 33 is stored in a second hopper 32. A mould 40 is formed and the mould 40 has a first portion 42 and a second portion 44. The mould 40 comprises a preformed metal can, which is vacuum tight and which is produced in substantially the required shape and dimensions l5 of the finished component 10, lOB. The powder of the first niobium alloy 31 is supplied from the first hopper 32 through a valve 34 and pipe 38 into the first portion 42 of the mould 40 and then the valve 34 is closed and the powder of the second niobium alloy 33 is supplied from the second hopper 32 through a valve 36 and the pipe 38 into the second portion 44 of the mould 40. The filled mould 40 is sealed by welding. Heat and pressure, for example by hot isostatic pressing, are applied to the mould 40 to consolidate the powder of the first niobium alloy 31 and the powder of the second niobium alloy 33 and to form a niobium alloy component 10, lOB comprising a first portion 20, 24 and a second portion 22, 26, the first portion 20, 24 comprising the first niobium alloy and the second portion 22, 26 comprising the second niobium alloy.
It is preferred that there is a transition in composition between the first portion 20 and the second portion 22. The transition in composition may be a gradual transition or a stepped transition. The transition in composition is produced by simultaneously supplying opening both valves 34 and 36 and supplying powder from both the first and second hoppers 31 and 33 and increasing the rate of flow of the powder of the second niobium alloy 33 while reducing the rate of flow of the first niobium alloy 31.
In this example the first portion 42 of the mould 40 defines the root 12, shank 14 and platform 16 of the turbine blade 10 or defines the root 12 and shank 14 of turbine blade 10B. Once the mould 40 has been removed it is then possible to machine the root 12 to exact shape and dimension, because the first niobium alloy, niobium silicide, is relatively ductile.
lo The niobium alloy component, turbine blade, 10, 10B is manufactured in a second method, as shown in figures 4 and 5, by forming a first portion 50 of the niobium alloy component from a first niobium alloy and forming a powder of a second niobium alloy 51. The composition of the first niobium alloy is different to the composition of the second niobium alloy. The powder of the second niobium alloy 51 is stored in a hopper 52. A mould 58 is formed and the mould 58 comprises a first portion 60 and a second portion 62. The mould 58 comprises a preformed metal can, which is vacuum tight and which is produced in substantially the required shape and dimensions of the finished component 10, JOB. The first portion 50 of the niobium alloy component is positioned in the first portion 60 of the mould 58 and the powder of the second niobium alloy 51 is supplied from the hopper 42 through a valve 54 and pipe 56 into the second portion 62 of the mould 58. The filled mould 58 is sealed by welding. Heat and pressure, for example hot isostatic pressure, is applied to the mould 58 to consolidate the powder of the second niobium alloy 51 and to form a niobium alloy component 10, 10B comprising a first portion 20, 24 and a second portion 22, 26, the first portion 20, 24 comprising the first niobium alloy and the second portion 22, 26 comprising the second niobium alloy.
It is to be noted that the first portion 50 of the niobium alloy component comprising the first niobium alloy extends into the second portion 62 of the mould 50, but the powder of the second niobium alloy 51 is able to flow around the first portion 50 so that the resulting second portion 22, 26 is keyed into the first portion 20, 24 of the niobium alloy component 10.
In this example the second portion 62 of the mould 50 defines the root 12, shank 14 and platform 16 of the turbine blade 10. Once the mould 58 has been removed it is then possible to machine the root 12 to exact shape and dimension, because the second niobium alloy, niobium l0 silicide, is relatively ductile and the first niobium alloy, niobium silicide, has greater temperature capability and has greater environmental resistance. The first portion 60 of the mould 58 defines the aerofoil 18 of the turbine blade 10.
It may be possible for the second portion 62 of the mould 50 to define the aerofoil 18 of the turbine blade 10 and the first portion 60 of the mould 58 to define the root 12, shank 14 and platform 16.
The first portion 50 of the niobium alloy component 10 may be manufactured by any suitable process, for example casting, forging or again by consolidation of powder metal.
In both of the methods the mould 40, 58 is sealed under evacuated conditions.
In both of the methods the mould 40, 58 is subsequently removed from the finished component and preferably the mould 40, 58 is removed by machining or dissolving using an acid, which does not dissolve the niobium alloy.
The advantage of the present invention is that it allows different portions of a niobium alloy, in particular a niobium silicide, component to have different properties tailored to the requirements of each of the portions of the component. The present invention achieves this by using different niobium alloy powders and consolidating them to produce a component with different properties at the different portions of the component. The present invention uses the niobium alloy powders and the consolidation technique overcome the difficulties associated with casting, forging and machining processes. For example niobium silicides are difficult to machine, the use of the powder alloy route enables the component to produced to near net shape without the use of, or very little, final machining.
Although the present invention has been described with reference to niobium alloys, it is possible to use the same procedure to manufacture nickel aluminide components from two different nickel aluminide powders or from one nickel aluminize powder and one nickel aluminide portion.
The present invention may be used to manufacture components from other different alloys.

Claims (38)

  1. Claims: 1. An alloy component comprising a first portion and a second
    portion, the first portion comprising a first alloy and the second portion comprising a second alloy, the composition of the first alloy being different to the composition of the second alloy and at least one of the first or second portions comprising consolidated powder of the first or second alloy.
  2. 2. An alloy component as claimed in claim 1 wherein the first portion and the second portion are integral.
  3. 3. An alloy component as claimed in claim 1 or claim 2 wherein the component comprises a turbine blade.
  4. 4. An alloy component as claimed in claim 3 wherein the turbine blade comprises a root, a shank, a platform and an aerofoil.
  5. 5. An alloy component as claimed in claim 4 wherein the first portion comprises at least a root and the second portion comprises an aerofoil.
  6. 6. An alloy component as claimed in claim 5 wherein the first portion comprises a shank.
  7. 7. An alloy component as claimed in claim 5 or claim 6 wherein the first portion comprises a platform.
  8. 8. An alloy component as claimed in any of claims 1 to 7 wherein the alloy of the first portion having greater ductility than the alloy of the second portion.
  9. 9. An alloy component as claimed in any of claims 1 to 8 wherein the alloy of the second portion having greater temperature capability than the alloy of the first portion.
  10. 10. An alloy component as claimed in any of claims 1 to 9 wherein, the alloy component comprising a niobium alloy component, the first portion comprising a first niobium alloy and the second portion comprising a second niobium alloy, the composition of the first niobium alloy being different to the composition of the second niobium alloy and at least one of the first or second portions comprising consolidated powder of the first or second niobium alloy.
  11. 11. An alloy component as claimed in claim 10 wherein the niobium alloy component comprises a niobium silicide component.
  12. 12. An alloy component as claimed in claim 11 wherein the niobium silicide component comprises a niobium silicide component comprising a first portion and a second portion, the first portion comprising a first niobium silicide and the second portion comprising a second niobium silicide alloy, the composition of the first niobium silicide being lO different to the composition of the second niobium silicide.
  13. 13. An alloy component as claimed in claim 12 wherein the niobium silicide of the first portion comprises a niobium silicide with relatively high niobium content and relatively low silicon content and the niobium silicide of the second portion comprises a niobium silicide with relatively high silicon content and relatively low niobium content.
  14. 14. An alloy component as claimed in any of claims 11 to 13 wherein the niobium silicide of the first portion comprises 20w% to lOOwt% niobium and the niobium silicide of the second portion comprises up to 50wt% niobium.
  15. 15. An alloy component as claimed in claim 14 wherein the niobium silicide of the first portion comprises 50w% to lOOwt% niobium and the niobium silicide of the second portion comprises up to 50wt% niobium.
  16. 16. An alloy component as claimed in any of claims 1 to 9 wherein, the alloy component comprising a nickel alloy component, the first portion comprising a first nickel alloy and the second portion comprising a second nickel alloy, the composition of the first nickel alloy being different to the composition of the second nickel alloy and at least one of the first or second portions comprising consolidated powder of the first or second nickel alloy.
  17. 17. An alloy component as claimed in claim 16 wherein the nickel alloy component comprises a nickel aluminide component.
  18. 18. An alloy component as claimed in claim 17 wherein the nickel aluminide component comprises a nickel aluminide component comprising a first portion and a second portion, the first portion comprising a first nickel aluminide and the second portion comprising a second nickel aluminide alloy, the composition of the first nickel aluminide being lO different to the composition of the second nickel aluminide.
  19. 19. An alloy component substantially as hereinbefore described with reference to and as shown in the accompanying drawings.
    Is
  20. 20. A method of manufacturing an alloy component comprising forming a powder of a first alloy, forming a powder of a second alloy, the composition of the first alloy being different to the composition of the second alloy, forming a mould having a first portion and a second portion, supplying the powder of the first alloy into the first portion of the mould and supplying the powder of the second alloy into the second portion of the mould, sealing the mould, applying heat and pressure to the mould to consolidate the powder of the first alloy and the powder of the second alloy and to form a alloy component comprising a first portion and a second portion, the first portion comprising the first alloy and the second portion comprising the second alloy.
  21. 21. A method of manufacturing an alloy component comprising forming a first portion of the alloy component from a first alloy, forming a powder of a second alloy, the composition of the first alloy being different to the composition of the second alloy, forming a mould having a first portion and a second portion, positioning the first portion of the alloy component into the first portion of the mould and supplying the powder of the second alloy into the second portion of the mould, sealing the mould, applying heat and pressure to the mould to consolidate the powder of the second alloy and to form an alloy component comprising a first portion and a second portion, the first portion comprising the first alloy and the second portion comprising the second alloy.
  22. 22. A method as claimed in claim 20 or claim 21 wherein the first portion and the second portion are integral.
  23. 23. A method as claimed in claim 20, claim 21 or claim 22 lO wherein the component comprises a turbine blade.
  24. 24. A method as claimed in claim 23 wherein the turbine blade comprises a root, a shank, a platform and an aerofoil.
  25. 25. A method as claimed in claim 24 wherein the first portion comprises at least a root and the second portion comprises an aerofoil.
  26. 26. A method as claimed in claim 25 wherein the first portion comprises a shank.
  27. 27. A method as claimed in claim 26 wherein the first portion comprises a platform.
  28. 28. A method as claimed in any of claims 20 to 27 wherein the alloy of the first portion having greater ductility than the alloy of the second portion.
  29. 29. A method as claimed in any of claims 20 to 28 wherein the alloy of the second portion having greater temperature capability than the alloy of the first portion.
  30. 30. A method as claimed in any of claims 20 to 29 wherein, the alloy component comprising a niobium alloy component, the first portion comprising a first niobium alloy and the second portion comprising a second niobium alloy, the composition of the first niobium alloy being different to the composition of the second niobium alloy and at least one of the first or second portions comprising consolidated powder of the first or second niobium alloy.
  31. 31. A method as claimed in claim 30 wherein the niobium alloy component comprises a niobium silicide component.
  32. 32. A method as claimed in claim 31 wherein the niobium silicide component comprises a niobium silicide component comprising a first portion and a second portion, the first portion comprising a first niobium silicide and the second portion comprising a second niobium silicide alloy, the composition of the first niobium silicide being different to the composition of the second niobium silicide.
  33. 33. A method as claimed in claim 31 or claim 32 wherein the niobium silicide of the first portion comprises a niobium silicide with relatively high niobium content and relatively low silicon content and the niobium silicide of the second portion comprises a niobium silicide with relatively high silicon content and relatively low niobium content.
  34. 34. A method as claimed in claim 33 wherein the niobium silicide of the first portion comprises 20w% to lOOwt% niobium and the niobium silicide of the second portion comprises up to 50wt% niobium.
  35. 35. A method as claimed in claim 34 wherein the niobium silicide of the first portion comprises 50w% to lOOwt% niobium and the niobium silicide of the second portion comprises up to 50wt% niobium.
  36. 36. A method as claimed in any of claims 20 to 29 wherein, the alloy component comprising a nickel alloy component, the first portion comprising a first nickel alloy and the second portion comprising a second nickel alloy, the composition of the first nickel alloy being different to the composition of the second nickel alloy and at least one of the first or second portions comprising consolidated powder of the first or second nickel alloy.
  37. 37. A method as claimed in claim 36 wherein the nickel alloy component comprises a nickel aluminide component.
  38. 38. A method of manufacturing an alloy component substantially as hereinbefore described with reference to figure 4 of the accompanying drawings.
    38. An alloy component as claimed in claim 37 wherein the nickel aluminide component comprises a nickel aluminide component comprising a first portion and a second portion, the first portion comprising a first nickel aluminide and the second portion comprising a second nickel aluminide alloy, the composition of the first nickel aluminize being different to the composition of the second nickel aluminize.
    39. A method as claimed in any of claims 20 to 38 the applying of heat and pressure comprises hot isostating pressing.
    40. A method as claimed in any of claims 20 to 39 comprising sealing the mould under evacuated conditions.
    lo 41. A method as claimed in any of claims 20 to 40 comprising subsequently removing the mould from the component.
    42. A method as claimed in claim 41 comprising removing the mould by machining or by dissolving using an acid, Is which does not dissolve the niobium alloy.
    43. A method as claimed in any of claims 20 to 42 comprising providing a transition in composition between the first portion and the second portion.
    44. A method as claimed in claim 43 comprising providing a gradual transition in composition or a stepped transition in composition.
    37. A method of manufacturing an alloy component substantially as hereinbefore described with reference to figure 3 of the accompanying drawings.
GB0416669A 2004-07-27 2004-07-27 An alloy component and method of manufacture Withdrawn GB2416544A (en)

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WO2011077150A3 (en) * 2009-12-23 2011-09-22 Advanced Interactive Materials Science Limited Improvements in or relating to hot isostatic pressing
WO2012131625A3 (en) * 2011-03-31 2013-11-21 Centre National De La Recherche Scientifique Method for manufacturing a part having a complex shape by flash sintering, and device for implementing such a method
US8944762B2 (en) 2011-10-28 2015-02-03 United Technologies Corporation Spoked spacer for a gas turbine engine
EP3069803A1 (en) * 2015-03-17 2016-09-21 MTU Aero Engines GmbH Blade for a turbine engine made from different materials and method for producing the same
US9938831B2 (en) 2011-10-28 2018-04-10 United Technologies Corporation Spoked rotor for a gas turbine engine

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WO2011077150A3 (en) * 2009-12-23 2011-09-22 Advanced Interactive Materials Science Limited Improvements in or relating to hot isostatic pressing
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US8944762B2 (en) 2011-10-28 2015-02-03 United Technologies Corporation Spoked spacer for a gas turbine engine
US9938831B2 (en) 2011-10-28 2018-04-10 United Technologies Corporation Spoked rotor for a gas turbine engine
US10760423B2 (en) 2011-10-28 2020-09-01 Raytheon Technologies Corporation Spoked rotor for a gas turbine engine
EP3069803A1 (en) * 2015-03-17 2016-09-21 MTU Aero Engines GmbH Blade for a turbine engine made from different materials and method for producing the same

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