US20060280637A1 - Method for manufacturing components with a nickel base alloy as well as components manufactured therewith - Google Patents

Method for manufacturing components with a nickel base alloy as well as components manufactured therewith Download PDF

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Publication number
US20060280637A1
US20060280637A1 US10/570,984 US57098406A US2006280637A1 US 20060280637 A1 US20060280637 A1 US 20060280637A1 US 57098406 A US57098406 A US 57098406A US 2006280637 A1 US2006280637 A1 US 2006280637A1
Authority
US
United States
Prior art keywords
nickel
substrate core
coated
metal powder
foam body
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
US10/570,984
Other languages
English (en)
Inventor
Dirk Naumann
Gunnar Walther
Alexander Bohm
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.)
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Alantum Corp
Original Assignee
Vale Canada Ltd
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
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 Vale Canada Ltd, Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV filed Critical Vale Canada Ltd
Assigned to FRAUNHOFER-GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG E.V., INCO LIMITED reassignment FRAUNHOFER-GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG E.V. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BOHM, ALEXANDER, WALTHER, GUNNAR, NAUMANN, DIRK
Publication of US20060280637A1 publication Critical patent/US20060280637A1/en
Assigned to VALE INCO LIMITED reassignment VALE INCO LIMITED CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: INCO LIMITED
Assigned to VALE INTERNATIONAL S.A. reassignment VALE INTERNATIONAL S.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: VALE INCO LIMITED
Assigned to ALANTUM CORPORATION reassignment ALANTUM CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: VALE INTERNATIONAL S.A.
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture 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
    • B22F7/002Manufacture 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 porous nature
    • B22F7/004Manufacture 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 porous nature comprising at least one non-porous part
    • B22F7/006Manufacture 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 porous nature comprising at least one non-porous part the porous part being obtained by foaming
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/04Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
    • B22F2009/041Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by mechanical alloying, e.g. blending, milling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10Processes characterised by the sequence of their steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture 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
    • B22F7/02Manufacture 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 layers

Definitions

  • the invention relates to a method for manufacturing components with a nickel base alloy as well as to components manufactured with this method. With this solution, manufacturing the most differently shaped components in various three-dimensional geometries is possible.
  • the components, thus manufactured may also represent porous structures or may comprise such porous structures.
  • this object is solved with a method which comprises the features of claim 1 .
  • the components thus manufactured have the features mentioned in the claims 17 and 18 .
  • a substrate core consisting of pure nickel or a nickel base alloy will be provided with a surface coating at least in areas.
  • the surface coating is formed from a binding agent as well as from a metal powder.
  • the metal powder to be employed according to the invention includes additional alloy forming elements which are still to be referred to subsequently, in addition to a content of at least 20 wt % of nickel.
  • a substrate core consisting of a nickel base alloy should include nickel of at least 20 wt %.
  • the metal powder to be employed according to the invention may be a powder of the respective nickel base alloy but also a powder mixture of the respective alloy forming elements with the nickel which has been preferably subjected to high energy grinding.
  • the substrate core provided with the surface coating is subsequently subjected to a stepped thermal treatment.
  • the binding agent is expelled from the surface coating.
  • Subsequent to expelling of binder agent sintering of metal powder is then achieved.
  • sinter-fusing of a nickel substrate core and/or a solid surface coating formed of a nickel base alloy is developed.
  • the content of nickel which is included in the metal powder should be smaller than the nickel content in the substrate core material.
  • the thermal treatment should be carried out at temperatures of above 1000° C. and in a reducing or inert atmosphere, but preferably in a hydrogen atmosphere.
  • the substrate cores such one can be employed which have already substantially the geometric form of the components to be finally manufactured such that they are allowed to be completely refrained from final shaping re-machining or merely minimum re-machining of the shape is correspondingly required.
  • substrate cores can also be employed in the form of porous semi-finished products having a preferably porous structure which one may denote as foam bodies as well.
  • the surface coating should be developed with a suspension/dispersion which is made of the binding agent, metal powder and an additional solvent, as the case may be, or is made of a liquid.
  • Such substrate cores having a porous structure are allowed to be fully immersed into such a suspension/dispersion, and subsequently such a substrate core charged with suspension/dispersion is allowed to be compressed in order to remove the suspension/dispersion from the pores such that merely the webs remain wetted.
  • the stepped thermal treatment can then be carried out.
  • a binding agent which has an appropriate viscosity by means of a solvent, as the case may be, will be employed for wetting the surfaces of the porous structure of such a substrate core wherein grouting can be also carried out herein for removing excess binding agent from the pores.
  • the respective metal powder is then allowed to be deposited upon the wetted surfaces, wherein a more uniform distribution of the metal powder can be achieved by vibration. Subsequent to this, the stepped thermal treatment takes place then again.
  • bending can be carried out under compliance of defined minimum bending radii.
  • bending can be carried out under compliance of defined minimum bending radii.
  • this surface area is allowed to be brought into touching contact with at least another substrate core, wherein on that occasion the adhesive effect of the binding agent can be used advantageously. Subsequent to this, the thermal treatment takes place during which a closure by adhesive force type connection of the respective substrate cores is then formed.
  • composite members can be manufactured with complex geometries, which, for example, comprise undercuts or cavities, without shaping is required to occur subsequently.
  • composite members which are formed from a substrate core having a dense structure and a substrate core having a porous structure.
  • the metal powders to be employed according to the invention may also include preferably at least 50 wt % of carbon, molybdenum, iron, cobalt, niobium, titanium, aluminium, boron, zircon, manganese, silicon and/or lanthanum in addition to nickel having a minimum content of 20 wt %.
  • the properties of the components manufactured according to the invention can also be changed in that the surface coating will be developed in a different form on defined surface areas of substrate cores.
  • This relates to the respective thickness of the surface coating which can also be carried out by means of a repeated application in a different form, on the one hand, wherein a locally different consistency of the surface coating with different contents of metal powder, compositions of metal powder and granularity of metal powder can also be provided, on the other hand.
  • components which comprise a graduated alloy composition starting from the surface.
  • a substrate core made of pure nickel it is possible with the use of a substrate core made of pure nickel to manufacture a component which still has a core area of pure nickel after sintering, wherein the content of additional alloy elements changes/increases successively towards the respective surfaces.
  • the graduated alloy compositions can also be developed in the joining area which has been formed by means of the closure by adhesive force type connections.
  • Components manufactured according to the invention have a higher ductility, creep resistance and strength compared with components which have been manufactured from nickel only, wherein this circumstance also applies in comparison with nickel aluminide.
  • the tendency of oxidation compared with nickel components can be reduced as well.
  • the components achieve a thermal stability of up to 1000° C., wherein components manufactured according to the invention with porous structures, in particular, present such extended possibilities of application themselves, which e.g. exclude the use of foams of nickel aluminide due to the brittleness thereof.
  • the components manufactured according to the invention in particular, can be employed at higher dynamic loads.
  • a substrate core made of nickel and having the size of 300 mm*150 mm*1.9 mm, and having a porosity of 94% has been immersed in an aqueous 1% solution of polyvinylpyrrolidone with a volume of 50 ml. Subsequently, pressing out on an absorbent pad has been carried out to remove the binding agent from the cavities of the pores such that merely the webs of the porous structure have been wetted.
  • the porous substrate core wetted with the binding agent has been fixed in a vibration device and has been strewed with metal powder.
  • a uniform distribution of the metal powder on the surfaces of the substrate core wetted with the binding agent could be achieved, wherein the open porosity of the structure has been maintained.
  • the metal powder comprised a composition of 0.1 wt % of carbon, 22.4 wt % of chromium, 10.0 wt % of molybdenum, 4.8 wt % of iron, 0.3 wt % of cobalt, 3.8 wt % of niobium and 58.6 wt % of nickel.
  • Such a metal powder is commercially available under the trade name of “Inconel 625”.
  • the substrate core surface coated with the metal powder and binding agent has been rolled to a cylinder shaped body. On that occasion, the adhesion of the metal powder has been ensured by means of the binding agent.
  • stepped thermal treatment has been carried out wherein it has been worked in a first step inside a drying oven in a water atmosphere.
  • the temperature has been increased, while a heating rate of 5 K/min was maintained.
  • Expelling the binding agent starts at around 300° C. and has been completed at 600° C.
  • a detention time of around 30 min should be adhered in order to ensure a complete release from the binding agent.
  • the component thus manufactured consisted of a nickel base alloy wherein the composition thereof at the surface is at least approximately equivalent to the composition of the employed metal powder.
  • the porosity is equal to 91%.
  • the component has been oxidation-resistant at temperatures of up to 1000° C., comprised a high strength, creep resistance and toughness as well. After sintering, a limited deformability of the porous foam body structure was still possible considering particular minimum bending radii.
  • a corrugated sheet of pure nickel with the size of 200 mm*200 mm*0.15 mm has been employed as a substrate core.
  • the suspension manufactured from the metal powder and binding agent after intensive stirring has been atomized by means of compressed air, and sprayed upon the substrate core from both sides.
  • the surface coating comprised a thickness of 150 ⁇ m. After drying over a time period of 1 min, approximately, the layer comprised a sufficiently great green strength such that the stepped thermal treatment could be carried out analogous to the embodiment 1.
  • the final component comprised a nickel base alloy, wherein the alloy composition thereof at the surface was approximately equivalent to the alloy composition of the used metal powder. In the air, it was oxidation-resistant at temperatures up to 1000° C. The high strength, creep resistance and toughness increased in comparison with the substrate core made of nickel.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
US10/570,984 2003-09-30 2004-09-29 Method for manufacturing components with a nickel base alloy as well as components manufactured therewith Abandoned US20060280637A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE103462813 2003-09-30
DE10346281A DE10346281B4 (de) 2003-09-30 2003-09-30 Verfahren zur Herstellung von Bauteilen mit einer Nickel-Basislegierung sowie damit hergestellte Bauteile
PCT/EP2004/010894 WO2005037467A2 (en) 2003-09-30 2004-09-29 Method for manufacturing components with a nickel base alloy as well as components manufactured therewith

Publications (1)

Publication Number Publication Date
US20060280637A1 true US20060280637A1 (en) 2006-12-14

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Family Applications (1)

Application Number Title Priority Date Filing Date
US10/570,984 Abandoned US20060280637A1 (en) 2003-09-30 2004-09-29 Method for manufacturing components with a nickel base alloy as well as components manufactured therewith

Country Status (9)

Country Link
US (1) US20060280637A1 (zh)
EP (1) EP1667808B1 (zh)
JP (1) JP4647604B2 (zh)
KR (1) KR100741613B1 (zh)
CN (2) CN102653001A (zh)
CA (1) CA2533118C (zh)
DE (1) DE10346281B4 (zh)
ES (1) ES2612730T3 (zh)
WO (1) WO2005037467A2 (zh)

Cited By (7)

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WO2012051326A1 (en) 2010-10-12 2012-04-19 The Regents Of The University Of Michigan Transition metal carbide or nitride or boride based supercapcitors with metal foam electrode substrate
US20140004259A1 (en) * 2010-08-10 2014-01-02 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Open-porous metal foam body and a method for fabricating the same
US9384905B2 (en) 2010-10-12 2016-07-05 The Regents Of The University Of Michigan, University Of Michigan Office Of Technology Transfer High performance transition metal carbide and nitride and boride based asymmetric supercapacitors
CN107119248A (zh) * 2017-05-23 2017-09-01 哈尔滨工业大学 一种分级多孔结构泡沫金属的制备方法
WO2018038791A1 (en) * 2016-08-24 2018-03-01 Wal-Mart Stores, Inc. Cart inventory system and associated methods
KR20200124210A (ko) * 2017-09-19 2020-11-02 알란텀 유럽 게엠베하 개질된 표면을 갖고 금속으로 형성된 개방 기공 성형체의 제조방법 및 이 방법을 사용하여 제조된 성형체
KR20230020319A (ko) * 2021-08-03 2023-02-10 주식회사 화승알앤에이 굽힘 가공 시스템

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GR1005904B (el) 2005-10-31 2008-05-15 ΑΡΙΣΤΟΤΕΛΕΙΟ ΠΑΝΕΠΙΣΤΗΜΙΟ ΘΕΣΣΑΛΟΝΙΚΗΣ-ΕΙΔΙΚΟΣ ΛΟΓΑΡΙΑΣΜΟΣ ΑΞΙΟΠΟΙΗΣΗΣ ΚΟΝΔΥΛΙΩΝ ΕΡΕΥΝΑΣ (κατά ποσοστό 40%) Καταλυτικο φιλτρο μεταλλικου αφρου για το καυσαεριο των κινητηρων ντηζελ.
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DE102009034390B4 (de) * 2009-07-23 2019-08-22 Alantum Europe Gmbh Verfahren zur Herstellung von in Gehäuse integrierten Metallschaumkörpern
KR101483039B1 (ko) * 2013-04-02 2015-01-19 한국기계연구원 스폰지 티타늄을 이용한 금속 다공체의 표면 합금화 방법
US10675686B2 (en) 2017-03-29 2020-06-09 General Electric Company Hybrid component with multiple cores and method for treating a component
DE102017216569A1 (de) * 2017-09-19 2019-03-21 Alantum Europe Gmbh Verfahren zur Herstellung eines offenporösen Formkörpers, der mit einem Metall gebildet ist und einen mit dem Verfahren hergestellten Formkörper
CN111906301A (zh) * 2020-08-13 2020-11-10 合肥工业大学 一种铜基石墨自润滑梯度功能材料及其制备方法

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Cited By (16)

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Publication number Priority date Publication date Assignee Title
US20140004259A1 (en) * 2010-08-10 2014-01-02 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Open-porous metal foam body and a method for fabricating the same
US9346240B2 (en) * 2010-08-10 2016-05-24 Alantum Open-porous metal foam body and a method for fabricating the same
US10157712B2 (en) 2010-10-12 2018-12-18 The Regents Of The University Of Michigan High performance transition metal carbide and nitride and boride based asymmetric supercapacitors
US8780527B2 (en) 2010-10-12 2014-07-15 The Regents Of The University Of Michigan Transition metal carbide or nitride or boride based supercapacitors with metal foam electrode substrate
US9384905B2 (en) 2010-10-12 2016-07-05 The Regents Of The University Of Michigan, University Of Michigan Office Of Technology Transfer High performance transition metal carbide and nitride and boride based asymmetric supercapacitors
WO2012051326A1 (en) 2010-10-12 2012-04-19 The Regents Of The University Of Michigan Transition metal carbide or nitride or boride based supercapcitors with metal foam electrode substrate
GB2567588A (en) * 2016-08-24 2019-04-17 Walmart Apollo Llc Cart inventory system and associated methods
WO2018038791A1 (en) * 2016-08-24 2018-03-01 Wal-Mart Stores, Inc. Cart inventory system and associated methods
GB2567588B (en) * 2016-08-24 2022-03-09 Walmart Apollo Llc Cart inventory system and associated methods
CN107119248A (zh) * 2017-05-23 2017-09-01 哈尔滨工业大学 一种分级多孔结构泡沫金属的制备方法
KR20200124210A (ko) * 2017-09-19 2020-11-02 알란텀 유럽 게엠베하 개질된 표면을 갖고 금속으로 형성된 개방 기공 성형체의 제조방법 및 이 방법을 사용하여 제조된 성형체
JP2020534434A (ja) * 2017-09-19 2020-11-26 アランタム ヨーロッパ ゲーエムベーハーAlantum Europe Gmbh 表面改質された金属製の開孔成型体の製造方法、および該方法により製造された成型体
JP7383601B2 (ja) 2017-09-19 2023-11-20 アランタム ヨーロッパ ゲーエムベーハー 表面改質された金属製の開孔成型体の製造方法
KR102612696B1 (ko) * 2017-09-19 2023-12-13 알란텀 유럽 게엠베하 개질된 표면을 갖고 금속으로 형성된 개방 기공 성형체의 제조방법 및 이 방법을 사용하여 제조된 성형체
KR20230020319A (ko) * 2021-08-03 2023-02-10 주식회사 화승알앤에이 굽힘 가공 시스템
KR102552389B1 (ko) 2021-08-03 2023-07-07 주식회사 화승알앤에이 굽힘 가공 시스템

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ES2612730T3 (es) 2017-05-18
EP1667808B1 (en) 2016-11-09
KR20060035789A (ko) 2006-04-26
CN102653001A (zh) 2012-09-05
WO2005037467A3 (en) 2005-10-27
JP4647604B2 (ja) 2011-03-09
WO2005037467A2 (en) 2005-04-28
DE10346281B4 (de) 2006-06-22
DE10346281A1 (de) 2005-05-04
CA2533118C (en) 2015-07-07
EP1667808A2 (en) 2006-06-14
KR100741613B1 (ko) 2007-07-23
CN1842387A (zh) 2006-10-04
JP2007502368A (ja) 2007-02-08
CA2533118A1 (en) 2005-04-28

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