GB2492425A - A Method of Forming a Composite Metal Item - Google Patents
A Method of Forming a Composite Metal Item Download PDFInfo
- Publication number
- GB2492425A GB2492425A GB1117459.6A GB201117459A GB2492425A GB 2492425 A GB2492425 A GB 2492425A GB 201117459 A GB201117459 A GB 201117459A GB 2492425 A GB2492425 A GB 2492425A
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- metal
- shell
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- item
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Classifications
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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
- 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
- B22F3/004—Filling molds with powder
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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
- B22F7/06—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 of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/08—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 of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
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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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/14—Both compacting and sintering simultaneously
- B22F3/15—Hot isostatic pressing
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Materials Engineering (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
- Powder Metallurgy (AREA)
Abstract
A method of forming a composite metal item, the method comprising the steps of: forming a shell having an outer surface arranged to define a net or near-net outer surface of the composite metal item to be formed, the outer surface of the shell being larger than the outer surface of the composite metal item to be formed, the shell defining a shell cavity and comprising a first type of metal; providing metal powder within the shell cavity, the metal power comprising a second type of metal that is different to the first type; and consolidating the shell and powder to form the composite metal item. The shell may be formed by superplastic deformation of a titanium alloy.
Description
A Method of Forming a Composite Metal Item
Background
It is known to produce items by moulding. Typically, a mould is formed to define a cavity and the cavity is filled with a material which, once consolidated, forms the item.
Moulded products often require simple external features, to enable the moulded part to be released once consolidated, meaning that it can be difficult to create mouldcd parts that havc complex shapes.
Alternatively, the mould tool may be machined away, or corroded, to leave the moulded part. However, this is wasteful in terms of material and processing time.
Once released from a mould, a part may require secondary machining to arrive at its final form, or "net shape". However, smooth, flowing surfaces may not be easily or economically achieved through mechanised material removal operations. Furthermore, surface features created by material removal operations may create points of weakness h the mouldcd part, or fatigue and corrosion initiation sites.
Summary
In accordance with a first aspect of the present invention, there is provided a method of forming a composite metal item, the method comprising the steps of: forming a shell having an outer surface arranged to define a net or near-net outer surface of the composite metal item to be formed, the outer surface of the shell being larger than the outer surface of the composite metal item to be formed, the shell defining a shell cavity and comprising a first type of metal; providing metal powder within the shell cavity, the metal power comprising a second type of metal that is different to the first type; and consolidating the shell and powder to form the composite metal item.
Thus, the metal shell defines an outer surface of the finished composite metal item. As such, the item may have a near-net shape once consolidated, which may result in less machining being required post-consolidation. The shell is initially larger than the composite metal item to be formed to enable the shell to shrink with the power as it is consolidated. The metal of the shell is different to the metal of the power which may act in synergy with the feature of the shell being initially larger than the composite metal item to be formed because it enables the selection of a metal for the shell that is suitable for the required size change and the selection of a metal for the powder that has advantageous properties, as set out in more detail below.
The first type of metal may have one or more of the following characteristics relative to the second type of metal: better fatigue tolerance; better corrosion tolerance; being easier to machine; and being more amenable to nitriding.
The second type of metal may have one or more of the following characteristics relative to the first metal: being cheaper or more abundant; having a lower density; being harder or stiffer.
The step of forming a metal shell may comprise supcrplastically forming a metal shell.
Thus, "springback" may be reduced due to superplastically forming the metal shell.
The step of forming a shell may comprise: forming a plurality of shell components each having an outer surface arranged to define part of the net or near-net outer surface of the composite metal item to be formed, the outer surface each shell component being larger than the respective part of the outer surface of the composite metal item to be formed; and joining the shell components to form the shell.
Prior to the step of consolidating, the method may comprise the step of providing one or more inserts into the cavity or cavities. The insert or inserts may comprise a rigid clement.
The rigid element may be hollow, such as tubular. Thus, inserts may be provided to impart different properties to the composite metal item to be formed.
The inserts may comprise a third type of metal. The third type of metal may be different to the first and/or the second type of metal. The third type of met& may have one or more of the following characteristics relative to the first and/or second metal: being cheaper or more abundant; having a lower or higher density; being harder or stiffer.
The step of forming a metal shell may comprise forming a mould tool comprising female mould cavity, enlarging the mould cavity and using the mould cavity to form the metal shell.
The outer surface of the shell may be at least 5%, 10%, 15%, 20% or 25% larger than the outer surface of the composite metal item to be formed.
The outer surface of the shell may be substantially uniformally larger than the outer surface of the composite metal item to be formed.
The mould cavity may be arranged to define one or more of the following: a filling port or ports; sheet metal fixtures; internal locating features for inserts; and flanges to assist with joining two shells together.
The first type of metal may be steel, titanium, or a titanium alloy such as Ti6-4 or Ti-6A1-4V.
The second type of metal may be steel, titanium, or a titanium alloy such as Ti3-2.5.
The third type of metal may be steel, titanium, or a titanium alloy such as Ti6-4 or Ti-6A1--4V.
The step of consolidating the shell and powder to form the composite metal item may comprise hot isostatic pressing the shell and powder.
Brief Description of the Drawings
By way of example only, certain embodiments of the invention will now be described by reference to the accompanying drawings, in which; Figure 1 is a flow diagram of a method according to an embodiment of the present invention.
Detailed Description
Figure 1 show a flow diagram of a method according to an embodiment of thc present invention.
At step 10 a mould is designed having a cavity which substantially matches the final shape a composite metal item to be formed. The cavity may be formed by a plurality of mould parts that each define a sub cavity, the sub cavities together defming the cavity. For example, two moulds may be designed, each defining a semi-spherical cavity such that the moulds, when positioned adjacent one another, together define a spherical cavity. The cavity thus defines substantially the entire outer profile of the composite metal item, although in other embodiments this need not be the ease. The cavity may be designed using a CAD program, or by any other suitable means.
At step 12 the cavity is substantially uniformly enlarged. For example, the CAD model of the cavity may be enlarged using standard CAD program features. In one embodiment, the cavity may be enlarged by approximately 15%, as this may generally equates to the green packing density loss on consolidation. The outer surface of the shell may be at least 5%, 10%, 15%, 20% or 25% larger than the outer surface of the composite metal item to be formed.
At step 14 features such as filling ports, sheet metal fixtures, internal locating features for inserts, and!or flanges to assist with joining shell parts together may be included in the mould.
At step 16 a mould is built according to the mould design obtained at step 14. The mould may be built using any suitable conventional means, such as by a CAM process. The mould may be formed of any suitable material, such as high strength mould tool steel.
The mould may comprise one or more individual mould parts that together form the mould.
At step 18 a shell is formed using the mould created at step 16. The shell has an outer surface arranged to define a net or near-net outer surface of the composite metal item to be formed. Due to the enlargement at step 12, the outer surface of the shell is larger than the outer surface of the composite metal item to be formed. The shell defines a shell cavity into which metal power may be provided.
The shell may comprise a plurality of shell components that together form the shell. The shell may be superplastically formed. Superplastic forming is a conventional metalworking process and thus for clarity will not be described in any detail. Superplastically forming the shell may enable it to have complex geometries and may reduce spring-back.
The shell is formed of a first type of metal. The first type of metal may be any suitable metal such as steel, titanium, or a titanium alloy of a first type such as Ti6-4 or Ti-6A1-4V.
At step 20 the shell is cleaned using acid etching or any other suitable cleaning process.
At step 22 one or more inserts may optionally be located within the cavity, using the locating features moulded into the shells. An insert may comprise a rigid element, such as a section of metal or metal composite material, which may be hollow, for example tubular.
Thus, inserts may be provided to impart different properties to the composite metal item to be formed.
At step 24 the shell cavity is filled with metal power to create an item. The metal powder comprises a second type of metal that is different to the first type. The second type of metal may be any suitable metal such as steel, titanium, or a titanium alloy of a second type which is different to the first type, such as Ti3-2.5. The shell cavity size may be calculated to determine the appropriate amount of powder required for a fully dense fill. When the shell cavity is filled with power, the amount of powder inserted can be determined to enable the fill density to be calculated. In some embodiments ftirther power is compressed into thc shell cavity if the fill density is calculated to be less than 85%, which would be indicative to poor packing or voids.
Metal powder can be added pure or blended with a removable binder arranged to improve flow characteristics and to help bond the green state powder once compacted.
In embodiments where the shell is asscmblcd prior to filling with metal power, the power may be inserted via the filling port or ports. Alternatively, the metal powder may be inserted into cavitics of thc shell components and thcrcaftcr the shell components coupled to form the shell.
The first type of metal may have one or more of the fbllowing characteristics relative to the second type of metal: better fatigue tolerance; better corrosion tolerance; being easier to machine; and being more amenable to nitriding.
The second type of metal may have one or more of the following characteristics relative to the first metal: being cheaper or more abundant; having a lower density; being harder or stiffer.
The inserts described above at step 22 may comprise a thin! type of metal. The third type of metal may be different to the first and/or the second type of metal. The third type of metal may have one or more of the fbllowing characteristics relative to the first and/or second metal: being cheaper or more abundant having a lower or higher density; being harder or stiffer.
At step 26 the item is out-gassed. In some embodiments the out-gassing may comprise a vacuum hot out-gassing step, which may remove some oxide, contamination diffusible gasses such as hydrogen in titanium or binder materials. In other embodiments where no materials require out-gassing, the out-gassing may comprise a evacuating to remove air and any gas or vapours and thereafter sealing the shell under vacuum, such as by electron beam welding.
At step 28 the sealed item is consolidated. The item may be consolidated by hot isostatic pressing, sintering, or by hot pressing, all of which will be well understood by a skilled person. When the first, second and/or third metal comprise titanium, hot isostatic pressing is preferred as this avoids a molten step and may provide a more unifbrm consolidation.
The composite metal item to be formed may be any suitable part or component, such as an actuator rod lug end.
Once consolidated, the part may be substantially filly dense and may have shnink in size in line with the anticipated green state density. Should any distortions occur, the mould design at steps 10 to 14 may be modified to account for this.
At step 30 the consolidated part may be machined to remove any sealing flanges and to drill any required holes. The fact that the metal shell defines an outer surface of the finished composite metal item means that the consolidated part may have a near-net shape once consolidated, which may result in less machining being required post-consolidation.
At step 32, the part may optionally be acid etched to de-scale any non-machined parts, or those parts may be media blasted or ground and polished.
As will be appreciated by a skilled person, a number of the above mentioned steps are optional and in embodiments of the invention there is provided a method of forming a composite metal item, the method comprising the steps of: forming a shell having an outer surface arranged to define a net or near-net outer surface of the composite metal item to be formed, the outer surface of the shell being larger than the outer surface of the composite metal item to be formed, the shell defining a shell cavity and comprising a first type of metal; providing metal powder within the shell cavity; the metal power comprising a second type of metal that is different to the first type; and consolidating the shell and powder to form the composite metal item. One or more of the above mentioned steps may be combined with this method.
It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be capable of designing many alternative
S
embodiments without departing from the scope of the invention as defined by the appended claims. In the claims, any reference signs placed in parenthesis shall not be construed as limiting the claims. The word "comprising" can mean "including" or "consisting of' and therefore does not exclude the presence of elements or steps other than those listed in any S claim or the specification as a whole. The singular reference of an element does not exclude the plural reference of such elements and vice-versa. Parts of the invention may be implemented by means of hardwarc comprising several distinct elements, and/or by means of a suitably programmed computer. The mere fact that certain measures are recited iii mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantagc. Cbh
Claims (3)
- <claim-text>1. A method of forming a composite metal item, the method comprising the steps of: fbrming a shell having an outer surface arranged to define a net or near-net outer surface of the composite metal item to be formed, the outer surface of the shell being larger than the outer surface of the composite metal item to be formed, the shell defining a shell catty and comprising a first typc of mctal pmviding metal powder within the shell cavity, the metal power comprising a second type of metal that is different to the first typc; and consolidating the shell and powder to form the compositc metal item.</claim-text> <claim-text>2. A method according to claim 1, wherein the first type of metal has one or more of the following characteristics relative to the second type of metal: better fatigue tolerance; better corrosion tolerance; being easier to machine; and being more amenable to nitriding.</claim-text> <claim-text>3. A method according to any preceding claim, wherein the second type of metal has one or more of the following characteristics relative to the first metal: being cheaper or more abundant; having a lower density being harder or stiffer.</claim-text> <claim-text>4. A method according to any preceding claim, wherein the step of forming a metal shell may comprises superplastically fbrming a metal shell.</claim-text> <claim-text>5. A method according to any preceding claim, wherein the step of forming a shell comprises: fbrming a plurality of shell components each having an outer surface arranged to define part of the net or neat-net outer surface of the composite metal item to be formed, the outer surface each shell component being larger than the respective part of the outer surface of the composite metal item to be lbrmed; and joining the tell components to form the shell.</claim-text> <claim-text>6. A method according to any preceding claim comprising the step of: providing one or more inserts into the cavity or cavities.</claim-text> <claim-text>7. A method according to claim 6, wherein one or more of the inserts comprise a rigid element.</claim-text> <claim-text>8. A method according to claim 7, wherein one or more of the rigid elements is hollow.</claim-text> <claim-text>9. A method according to any of claims 6 to 8, wherein the inserts comprise a third type of metal.</claim-text> <claim-text>10. A method according to claim 9, wherein the third type of metal has one or more of the following characteristics relative to the first and/or second metal: being cheaper or more abundant; having a lower or higher density; being harder or stiffer.</claim-text> <claim-text>11. A method according to any preceding claim, wherein the step of forming a metal shell comprises forming a mould tool comprising female mould cavity, enlarging the mould cavity and using the mould cavity to form the metal shell.</claim-text> <claim-text>12. A method according to any preceding claim, wherein the outer surface of the shell is at least 5%, 10%, 15%, 20% or 25% larger than the outer surface of the composite metal item to be formed.</claim-text> <claim-text>13. A method according to any preceding claim, wherein the outer surface of the shell is substantially uniformally larger than the outer surface of the composite metal item to be formed.</claim-text> <claim-text>14. A method according to any preceding claim, wherein the mould cavity is arranged to define one or more of the following: a tilling port or ports; sheet metal fixtures; internal locating features for inserts; and flanges to assist with joining two shells together.</claim-text> <claim-text>15. A method according to any preceding claim, wherein the first type of metal comprises one or more of steel, titanium or titanium alloy of a first type.</claim-text> <claim-text>16. A method according to any preceding claim, wherein the second type of metal comprises one or more of steel, titanium or titanium alloy of a second type.</claim-text> <claim-text>17. A method according to any preceding claim, wherein the step of consolidating the shell and powder to fomi the composite metal item comprises hot isostatic pressing of the shell and powder.</claim-text> <claim-text>18. A method substantially as herein described with reference to the accompanying drawings.Amendments to the claims have been made as follows: Claims 1. A method of forming a composite metal item, the method comprising the steps of: forming a shell having an outer surface arranged to define a net or near-net outer surface of the composite metal item to be formed, the outer surface of the shell being larger than the outer surface of the composite metal item to be formed, the shell defining a shell cavity and comprising a first type of metal; providing metal powder within the shell cavity, the metal powder compnsing a second type of metal that is different to the first type; and consolidating the shell and powder to form the composite metal item.
- 2. A method according to claim 1. wherein the first type of metal has one or more of the following characteristics relative to the second type of metal: better fatigue tolerance; better corrosion tolerance; being easier to machine; and being more amenable to nitriding.r
- 3. A method according to any preceding claim, wherein the second type of metal has one or more of the following characteristics relative to the first metal: being cheaper or more abundant; having a lower density; being harder or stiffer. r4. A method according to any preceding claim, wherein the step of forming a metal shell may comprise superplastically forming a metal shell.5. A method according to any preceding claim, wherein the step of forming a shell comprises: forming a plurality of shell components each having an outer surface arranged to define part of the net or near-net outer surface of the composite metal item to be formed, the outer surface each shell component being larger than (he respective part of (he outer surface of the composite metal item to be formed; and joining the shell components to form the shell.6. A method according to any preceding claim comprising the step of: providing one or more inserts into the cavity.7. A method according to claim 6, wherein one or more of the inserts comprise a rigid element.8. A method according to claim 7. wherein one or more of the rigid elements is hollow.9. A method according to any of claims 6 to 8. wherein the inserts comprise a third type of metal.10. A method according to claim 9, wherein the third type of metal has one or more of the following characteristics relative to the first andlor second metal: being cheaper or more abundant; having a lower or higher density; being harder or stiffer.11. A method according to any preceding claim, wherein the step of forming a metal shell comprises forming a mould tool comprising female mould cavity, enlarging the r mould cavity and using the mould cavity to form the metal shell.12. A method according to any preceding claim, wherein the outer surface of the shell r is at least 5%, 10%, 15%, 20% or 25% larger than the outer surface of the composite metal item to be formed.13. A method according to any preceding claim, wherein the outer surface of the shell is substantially uniformally larger than the outer surface of the composite metal item to be formed.14. A method according to any preceding claim, wherein the mou'd cavity is alTanged to define one or more of the following: a filling port or ports; sheet metal fixtures; internal locating features for inserts; and flanges to assist with joining two shells together.15. A method according to any preceding claim, wherein the first type of metal comprises one or more of steel, titanium or titanium alloy of a first type.16. A method according to any preceding claim, wherein the second type of metal comprises one or more of steel, titanium or fitanium a1oy of a second type.17. A method according to any preceding claim, wherein the step of consolidating the shell and powder to form the composite meta' item comprises hot isostatic pressing of the shell and powder.18. A method substantially as herein described with reference to the accompanying drawings. (4 r r (4</claim-text>
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1117459.6A GB2492425B (en) | 2011-10-10 | 2011-10-10 | A method of forming a composite metal item |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1117459.6A GB2492425B (en) | 2011-10-10 | 2011-10-10 | A method of forming a composite metal item |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB201117459D0 GB201117459D0 (en) | 2011-11-23 |
| GB2492425A true GB2492425A (en) | 2013-01-02 |
| GB2492425B GB2492425B (en) | 2013-05-15 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB1117459.6A Active GB2492425B (en) | 2011-10-10 | 2011-10-10 | A method of forming a composite metal item |
Country Status (1)
| Country | Link |
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| GB (1) | GB2492425B (en) |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3780418A (en) * | 1972-10-10 | 1973-12-25 | Aluminum Co Of America | Method of fabricating composite multi-metallic billets useful for metal working operations |
| JPS5390110A (en) * | 1977-01-20 | 1978-08-08 | Yoshizaki Kozo | Production of composite metal sintered element |
| JPS56152908A (en) * | 1980-04-26 | 1981-11-26 | Kobe Steel Ltd | Manufacture of composite roll |
| US4602952A (en) * | 1985-04-23 | 1986-07-29 | Cameron Iron Works, Inc. | Process for making a composite powder metallurgical billet |
| US5053284A (en) * | 1989-02-02 | 1991-10-01 | Hitachi Metals, Ltd. | Wear-resistant compound roll |
| EP0510598A2 (en) * | 1991-04-22 | 1992-10-28 | Hitachi Metals, Ltd. | Wear-resistant compound roll |
| WO2000058554A1 (en) * | 1999-03-29 | 2000-10-05 | Metso Paper, Inc. | Thermoroll for a paper/board machine or finishing machine and a method for manufacturing the thermoroll |
-
2011
- 2011-10-10 GB GB1117459.6A patent/GB2492425B/en active Active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3780418A (en) * | 1972-10-10 | 1973-12-25 | Aluminum Co Of America | Method of fabricating composite multi-metallic billets useful for metal working operations |
| JPS5390110A (en) * | 1977-01-20 | 1978-08-08 | Yoshizaki Kozo | Production of composite metal sintered element |
| JPS56152908A (en) * | 1980-04-26 | 1981-11-26 | Kobe Steel Ltd | Manufacture of composite roll |
| US4602952A (en) * | 1985-04-23 | 1986-07-29 | Cameron Iron Works, Inc. | Process for making a composite powder metallurgical billet |
| US5053284A (en) * | 1989-02-02 | 1991-10-01 | Hitachi Metals, Ltd. | Wear-resistant compound roll |
| EP0510598A2 (en) * | 1991-04-22 | 1992-10-28 | Hitachi Metals, Ltd. | Wear-resistant compound roll |
| WO2000058554A1 (en) * | 1999-03-29 | 2000-10-05 | Metso Paper, Inc. | Thermoroll for a paper/board machine or finishing machine and a method for manufacturing the thermoroll |
Also Published As
| Publication number | Publication date |
|---|---|
| GB201117459D0 (en) | 2011-11-23 |
| GB2492425B (en) | 2013-05-15 |
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