US20060251536A1 - Microwave processing of mim preforms - Google Patents

Microwave processing of mim preforms Download PDF

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Publication number
US20060251536A1
US20060251536A1 US10/908,292 US90829205A US2006251536A1 US 20060251536 A1 US20060251536 A1 US 20060251536A1 US 90829205 A US90829205 A US 90829205A US 2006251536 A1 US2006251536 A1 US 2006251536A1
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United States
Prior art keywords
preform
binder
component
mixture
heating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/908,292
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English (en)
Inventor
Thomas Kelly
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Priority to US10/908,292 priority Critical patent/US20060251536A1/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KELLY, THOMAS JOSEPH
Priority to JP2006128266A priority patent/JP2006312784A/ja
Priority to EP06252361A priority patent/EP1719566B1/en
Priority to CA2545699A priority patent/CA2545699C/en
Priority to BRPI0601718-5A priority patent/BRPI0601718A/pt
Priority to DE602006008208T priority patent/DE602006008208D1/de
Priority to SG200807853-7A priority patent/SG147458A1/en
Priority to SG200603029A priority patent/SG126932A1/en
Publication of US20060251536A1 publication Critical patent/US20060251536A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1017—Multiple heating or additional steps
    • B22F3/1021—Removal of binder or filler
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1017—Multiple heating or additional steps
    • B22F3/1021—Removal of binder or filler
    • B22F3/1025—Removal of binder or filler not by heating only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/227—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by organic binder assisted extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F2003/1042—Sintering only with support for articles to be sintered
    • B22F2003/1046—Sintering only with support for articles to be sintered with separating means for articles to be sintered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B22F2003/1054—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding by microwave
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • This invention relates generally to sintered metallic components and more particularly to components sintered by microwave heating.
  • MIM Metal Injection Molding
  • Prior art methods of sintering for MIM preforms require furnace heat treatment at temperatures capable of causing the metal powders to sinter together to make the preform mechanically strong enough for further processing. This is a time consuming process that results in a non uniform product due to the heating process being “from the outside in”, meaning the outer portion of the preform gets more time at high temperature and can sinter earlier causing voids to be trapped inside the preforms. This can also result in non-uniform mechanical properties.
  • the present invention which according to one aspect provides a method of producing a metallic component including: providing a mixture of a metallic powder and a binder; melting the binder and forming the mixture into a preform in the shape of the component; remove a majority of the binder from the preform; and heating the preform with microwave energy to remove the remainder of the binder and to sinter the metal powder together to form the component.
  • a method of producing a metallic component includes providing a mixture of a metallic powder and a binder; melting the binder and forming the mixture into a continuous preform in the shape of a desired component; removing a majority of the binder from the preform; and heating the preform with microwave energy to remove the remainder of the binder and to sinter the metallic powder together to form the component.
  • FIG. 1 is a perspective view of a compressor blade constructed in accordance with the present invention
  • FIG. 2 is block diagram of a manufacturing process carried out in accordance with the present invention.
  • FIG. 3 is a schematic side view of an injection molding apparatus
  • FIG. 4 is a schematic side view of a preform being removed from the mold shown in FIG. 3 ;
  • FIG. 5 is a schematic cross-sectional view of a preform inside a microwave chamber
  • FIG. 6 is schematic side view of an apparatus for carrying out an alternative molding and sintering process
  • FIG. 7 is a schematic perspective view of a weld wire produced by the present invention.
  • FIG. 8 is a schematic perspective view of the weld wire of FIG. 7 wound onto a spindle for further processing
  • FIG. 9 is a schematic view of an alternative extruding apparatus.
  • FIG. 10 is a schematic perspective view of a metallic sheet wound onto a spindle for further processing.
  • FIG. 1 depicts an exemplary compressor blade 10 for a gas turbine engine.
  • the present invention is equally applicable to the construction of other types of metallic components, non-limiting examples of which include rotating turbine blades, stationary turbine vanes, turbine shrouds, and the like.
  • the compressor blade 10 comprises an airfoil 12 having a leading edge 14 , a trailing edge 16 , a tip 18 , a root 19 , and opposed sides 20 and 22 .
  • An arcuate inner platform 24 is attached to the root 19 of the airfoil 12 .
  • a dovetail 26 extends downward for mounting the blade 10 in a rotor slot.
  • the compressor blade 10 is made from a metal alloy suitable for the intended operating conditions.
  • FIG. 2 depicts the process for constructing the compressor blade 10 according to the method of the present invention. Initially, as shown in block 28 , a metallic powder and a suitable binder are provided.
  • the metallic powder may be a single alloy or it may be a mechanical mixture of more than one alloy.
  • the particle size of the metallic powder should be about 100 micrometers or less.
  • known alloys suitable for constructing compressor blades include titanium alloys such as Ti-6Al-4V, nickel-based alloys such as INCO 718 or UDIMENT 720, and iron-based alloys such as A286.
  • the binder may be any material which is chemically compatible with the metallic powder and which allows the required processing (e.g. mixing, injection, solidification, and leaching).
  • suitable binders include waxes and polymer resins.
  • the binder may be provided in a powder form.
  • the binder and the metallic powder are thoroughly mixed together, as shown in block 30 .
  • the mixture is then heated to melt the binder and create a fluid with the metallic powder coated by the binder (block 32 ).
  • the mixture is formed into a predetermined shape at block 34 .
  • One way of forming the mixture is to use a known injection-molding apparatus.
  • a schematic view of an injection molding apparatus 36 including a hopper 38 and an extruder 40 with rotating screw 42 is shown in FIG. 3 .
  • the mixture is extruded into the cavity 44 of a mold 46 .
  • the mold 46 may optionally be heated to avoid excessively rapid solidification of the binder which would result in a brittle preform 48 .
  • the mixture could be molded in a continuous manner using known injection molding equipment capable of melting the binder as it passes through the screw 42 .
  • the mold 46 is opened as shown in FIG. 4 and the resulting uncompacted or “green” preform 48 is removed (see block 50 in FIG. 2 ).
  • the preform 48 comprises metal particles suspended in the solidified binder.
  • the preform 48 is not suitable for use as a finished component, but merely has sufficient mechanical strength to undergo further processing.
  • the preform 48 is leached to remove the majority of the binder. This may be done by submerging or washing the preform 48 with a suitable solvent which dissolves the binder but does not attack the metallic powder
  • the preform 48 is microwave sintered. As shown in FIG. 5 , The preform 48 is placed in a chamber 56 which includes means for creating a suitable atmosphere to prevent undesired oxidation of the preform 48 or other reactions during the sintering process.
  • a supply 58 of inert gas such as argon is connected to the interior of the chamber 56 .
  • the sintering could also be performed under a vacuum.
  • a microwave source 60 such as a known type of cavity magnetron with an output in the microwave frequency range is mounted in communication with the chamber 56 .
  • the microwave spectrum covers a range of about 1 GHz to 300 GHz. Within this spectrum, an output frequency of about 2.4 GHz is known to couple with and heat metallic particles without passing through solid metals.
  • the microwave source 60 is activated to irradiate the preform 48 .
  • the microwave source 60 is depicted as having a direct line-of-sight to the entire preform 48 .
  • the chamber 56 which would typically be metallic, so that the preform is heated by a combination of direct and reflected microwaves. Because of the small metallic particle size in the preform 48 , the microwaves 62 couple with the particles and heat them.
  • the preform 48 is heated to a temperature below the liquidus temperature of the metallic powder and high enough to cause the metallic powder particles to fuse together and consolidate. The high temperature also melts and drives out any remaining binder.
  • the preform 48 is held at the desired temperature for a selected time period long enough to result in a consolidated compressor blade 10 .
  • the heating rate i.e. the output wattage of the microwave source
  • the heating rate is selected depending on variables such as the mass of the preform 48 , the shape of the chamber 48 and the and the desired cycle time of the sintering process.
  • the combination of the MIM-formed preform 48 with the microwave sintering step gives the compressor blade 10 a significantly greater density, that is, freedom from voids, in less time.
  • the compressor blade 10 When the sintering cycle is complete, the compressor blade 10 is removed from the chamber 56 and allowed to cool. When required, the compressor blade 10 may be subjected to further consolidation using a known hot isostatic pressing (“HIP”) process to result in a substantially 100% dense component, as noted in block 63 of FIG. 2 . If desired, the compressor blade 10 may be subjected to additional processes such as final machining, coating, inspection, etc. in a known manner (see block 64 of FIG. 2 ).
  • HIP hot isostatic pressing
  • FIGS. 6 and 7 illustrate an alterative method suitable for producing continuous components.
  • the metallic powder may be a single alloy or it may be a mechanical mixture of more than one alloy.
  • the particle size of the metallic powder should be about 100 micrometers or less in diameter. This process is particularly suitable for alloys which are difficult to cold work and which are ordinarily cast. Examples of such alloys include so-called “superalloys” based on nickel or cobalt and containing a high percentage of a gamma-prime phase component. Examples of such alloys include RENE 77, RENE 80, RENE 142, and RENE N4 and N5 nickel-based alloys.
  • the binder may be any material which is chemically compatible with the metallic powder and which allows the required processing (e.g. mixing, injection, solidification, and leaching).
  • suitable binders include waxes and polymer resins.
  • the binder may be provided in a powder form.
  • FIG. 6 A schematic view of an injection molding apparatus 136 including a hopper 138 and an extruder 140 with rotating screw 142 is shown in FIG. 6 .
  • the mixture is extruded through a die 144 of a known type to produce a continuous preform 148 of a constant cross-section.
  • a die 144 having a circular opening of about 1.27 mm (0.050 in.) in diameter may be used to produce a preform 148 for use as a welding filler wire.
  • the die 144 may optionally be heated to avoid excessively rapid solidification of the binder which would result in a brittle preform 148 .
  • the conveyor belt 150 carries the preform 148 through a solvent bath 152 which leaches the majority of the binder out of the preform 148 . This may be done with a suitable solvent which dissolves the binder but does not attack the metallic powder.
  • the preform 148 then passes into a sintering chamber 156 where it is microwave sintered.
  • the chamber 156 includes means for creating a suitable atmosphere to prevent undesired oxidation of the preform 148 or other reactions during the sintering process.
  • a supply 158 of inert gas such as argon, or a gas fore creating a reducing atmosphere such as hydrogen is connected to the interior of the chamber 156 .
  • the processing could also be performed under a vacuum.
  • a microwave source 160 similar to the source 60 described above is mounted in communication with the chamber 156 . The microwave source 160 is activated to irradiate the preform 148 .
  • the microwaves couple with the particles and heat them.
  • the heating rate i.e. the output wattage of the microwave source
  • the speed of the conveyor belt 150 are selected so that the preform 148 is held at the desired temperature for a selected time period long enough to result in a consolidated completed component 162 .
  • FIG. 7 illustrates a short section of the component 162 , which in this case is a welding filler wire 162 .
  • the component 162 passes out of the chamber 156 and allowed to cool. If desired, the product 162 may be subjected to additional processes such as coating, inspection, etc. in a known manner.
  • the welding filler wire 162 may be subjected to further consolidation using a known hot isostatic pressing (“HIP”) process to result in a substantially 100% dense component. As shown in FIG. 8 , This step may be facilitated by winding the welding filler wire 162 on to a spindle 164 , with a small spacing “S” between the individual coils. The loaded spindle 164 may then be placed into a chamber (not shown) for the HIP process.
  • HIP hot isostatic pressing
  • the continuous process described above may be used to produce any other type of component with a constant cross-section.
  • the process may be used to produce sheet materials. As shown schematically in FIG. 9 , this may be done by providing a die 244 of the desired width “W” for extruding a wide, thin preform 248 . In order to supply an adequate feed of a binder-metallic power mixture to the die 244 , a plurality of side-by side injection molding apparatuses 236 may be provided. The extruded preform 248 is then leached and microwave sintered as described above, to result in a metallic sheet 262 , shown in FIG. 10 .
  • the metallic sheet 262 may be subjected to further consolidation using a HIP process to result in a substantially 100% dense component. As shown in FIG. 10 , This step may be facilitated by winding the metallic sheet on to a spindle 264 . A release compound may be placed between the layers of the metallic sheet 262 to prevent undesired consolidation and diffusion bonding of the layers. The loaded spindle 264 may then be placed into a chamber (not shown) for the HIP process.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
US10/908,292 2005-05-05 2005-05-05 Microwave processing of mim preforms Abandoned US20060251536A1 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US10/908,292 US20060251536A1 (en) 2005-05-05 2005-05-05 Microwave processing of mim preforms
JP2006128266A JP2006312784A (ja) 2005-05-05 2006-05-02 Ｍｉｍプリフォームをマイクロ波処理する方法
EP06252361A EP1719566B1 (en) 2005-05-05 2006-05-04 Microwave processing of MIM preforms
CA2545699A CA2545699C (en) 2005-05-05 2006-05-04 Microwave processing of mim preforms
BRPI0601718-5A BRPI0601718A (pt) 2005-05-05 2006-05-04 processamento em microondas de pré-formas "mim"
DE602006008208T DE602006008208D1 (de) 2005-05-05 2006-05-04 Mikrowellenbehandlung von MIM-Vorformen
SG200807853-7A SG147458A1 (en) 2005-05-05 2006-05-05 Microwave processing of mim preforms
SG200603029A SG126932A1 (en) 2005-05-05 2006-05-05 Microwave processing of mim preforms

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/908,292 US20060251536A1 (en) 2005-05-05 2005-05-05 Microwave processing of mim preforms

Publications (1)

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US20060251536A1 true US20060251536A1 (en) 2006-11-09

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Family Applications (1)

Application Number Title Priority Date Filing Date
US10/908,292 Abandoned US20060251536A1 (en) 2005-05-05 2005-05-05 Microwave processing of mim preforms

Country Status (7)

Country Link
US (1) US20060251536A1 (enExample)
EP (1) EP1719566B1 (enExample)
JP (1) JP2006312784A (enExample)
BR (1) BRPI0601718A (enExample)
CA (1) CA2545699C (enExample)
DE (1) DE602006008208D1 (enExample)
SG (2) SG147458A1 (enExample)

Cited By (8)

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US20080141825A1 (en) * 2006-12-15 2008-06-19 General Electric Company Process and apparatus for forming wire from powder materials
US20080232996A1 (en) * 2007-03-22 2008-09-25 Commissariat A L'energie Atomique Method for Fabricating Parts by PIM or MICROPIM
US10072506B2 (en) 2014-06-30 2018-09-11 Rolls-Royce Corporation Coated gas turbine engine components
CN109277574A (zh) * 2018-11-23 2019-01-29 湖南英捷高科技有限责任公司 一种空调压缩机摇块的制备方法
US10377082B2 (en) 2016-12-02 2019-08-13 Markforged, Inc. Supports for sintering additively manufactured parts
US10464131B2 (en) 2016-12-02 2019-11-05 Markforged, Inc. Rapid debinding via internal fluid channels
US10800108B2 (en) 2016-12-02 2020-10-13 Markforged, Inc. Sinterable separation material in additive manufacturing
US20220195875A1 (en) * 2020-12-17 2022-06-23 Rolls-Royce Deutschland Ltd & Co Kg Blade component, method for manufacture of same, and gas turbine

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CN104117677B (zh) * 2013-04-23 2017-02-08 昆山广兴电子有限公司 一种金属扇轮的制造方法
GB201418258D0 (en) * 2014-10-15 2014-11-26 Rolls Royce Plc Manufacture method
CN109014176A (zh) * 2018-08-07 2018-12-18 深圳市铂科新材料股份有限公司 一种燃气涡轮发动机叶片的制备方法
US20230364674A1 (en) * 2020-02-21 2023-11-16 Rovalma, S.A. Method for the obtaining of cost effective geometrically complex pieces
EP3907022A1 (de) 2020-05-08 2021-11-10 Siemens Aktiengesellschaft Verfahren zur herstellung einer materiallage

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080141825A1 (en) * 2006-12-15 2008-06-19 General Electric Company Process and apparatus for forming wire from powder materials
US8409318B2 (en) * 2006-12-15 2013-04-02 General Electric Company Process and apparatus for forming wire from powder materials
US20080232996A1 (en) * 2007-03-22 2008-09-25 Commissariat A L'energie Atomique Method for Fabricating Parts by PIM or MICROPIM
US10072506B2 (en) 2014-06-30 2018-09-11 Rolls-Royce Corporation Coated gas turbine engine components
US10989057B2 (en) 2014-06-30 2021-04-27 Rolls-Royce Corporation Coated gas turbine engine components
US10377083B2 (en) 2016-12-02 2019-08-13 Markforged, Inc. Supports for sintering additively manufactured parts
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EP1719566A3 (en) 2007-04-04
BRPI0601718A (pt) 2006-12-26
DE602006008208D1 (de) 2009-09-17
EP1719566B1 (en) 2009-08-05
CA2545699A1 (en) 2006-11-05
JP2006312784A (ja) 2006-11-16
CA2545699C (en) 2015-10-20
SG126932A1 (en) 2006-11-29
SG147458A1 (en) 2008-11-28
EP1719566A2 (en) 2006-11-08

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