US20100158742A1 - Manufacture of an article by hot isostatic pressing - Google Patents

Manufacture of an article by hot isostatic pressing Download PDF

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Publication number
US20100158742A1
US20100158742A1 US12/385,206 US38520609A US2010158742A1 US 20100158742 A1 US20100158742 A1 US 20100158742A1 US 38520609 A US38520609 A US 38520609A US 2010158742 A1 US2010158742 A1 US 2010158742A1
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US
United States
Prior art keywords
temperature
powder
pressing
pressure
tooling
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
US12/385,206
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English (en)
Inventor
Wayne E. Voice
Junfa Mei
Xinhua Wu
Nicholas Wain
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.)
Rolls Royce PLC
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Rolls Royce PLC
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
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Assigned to ROLLS-ROYCE PLC reassignment ROLLS-ROYCE PLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WU, XINHUA, MEI, JUNFA, WAIN, NICHOLAS, VOICE, WAYNE ERIC
Publication of US20100158742A1 publication Critical patent/US20100158742A1/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • F01D5/34—Rotor-blade aggregates of unitary construction, e.g. formed of sheet laminae
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
    • B23K20/021—Isostatic pressure welding
    • 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
    • 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
    • F01D5/30—Fixing blades to rotors; Blade roots ; Blade spacers
    • F01D5/3061—Fixing blades to rotors; Blade roots ; Blade spacers by welding, brazing
    • 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
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/001—Turbines

Definitions

  • This invention relates to the manufacture of an article by hot isostatic pressing (HIP), and is particularly, although not exclusively, concerned with the manufacture of a component of a gas turbine engine such as a bladed disc or “blisk”.
  • HIP hot isostatic pressing
  • bladed rotors of gas turbine engines It is common for bladed rotors of gas turbine engines to be assembled from a disc and individual blades which are separately fitted to the disc and secured by mechanical fixings. More recently, the disc and blades have been formed integrally with one another, the resulting components being referred to as “blisks”.
  • EP1702709A One method of manufacturing a component such as a blisk is disclosed in EP1702709A.
  • a union piece which is formed by hot isostatic pressing of a powder, such as a titanium alloy.
  • the powder is formed into a respective preform for each blade and the preform is set on the disc in the appropriate position and receives the blade.
  • tooling pieces are fitted between adjacent blades, to contact the union pieces.
  • the union pieces are thus situated in cavities defined by the disc, the blades and the union pieces.
  • the assembly is heated to a pressing temperature between 920 and 930° C. in an inert gas environment (for example, argon) at a pressing pressure between 100 and 150 MPa.
  • a pressing temperature between 920 and 930° C.
  • an inert gas environment for example, argon
  • the combined effect of the temperature and pressure is to force the pressing pieces radially inwardly of the assembly to consolidate the powder of the union piece preforms so that they form fully dense union pieces with “wrought” properties.
  • the union pieces are connected by diffusion bonds to the surface of the disc and to the blades.
  • each union piece over its surface extending from the respective blade to the disc is formed by the shape of respective tooling pieces on each side of the blade.
  • the tooling pieces are made from steel, and may be coated, for example with a ceramic coating such as boron nitride, to prevent adherence between the tooling pieces and the union piece so that the tooling pieces can be re-used.
  • the hot isostatic pressing process is performed by placing the assembly in an oven which is then filled with the inert gas.
  • the pressure and temperature in the oven are raised simultaneously to the required pressing temperature and pressure referred to above, and the assembly is then maintained at those conditions for a prolonged period, such as about 4 hours.
  • the material of the powder is much harder at ambient temperatures than the steel from which the tooling pieces are made. Consequently, elevation of the pressure while the temperature remains relatively low causes the tooling pieces to be pressed with great force against the union piece preform (or loose powder if the cavities are filled with loose powder instead of preforms), which deforms the surface of the tooling pieces so that they receive impressions of the individual particles of the powder.
  • a method of manufacturing an article by hot isostatic pressing of a powder in which method the temperature of the powder is raised to a pressing temperature and a pressing pressure is applied to the powder by a tooling piece, characterised in that the pressure applied to the powder is maintained below the yield stress of the material of the tool piece until the temperature of the powder has reached a predetermined temperature.
  • the powder is of a first material and the tooling piece is of a second material, the powder material being harder at ambient temperature than the tooling piece material.
  • the relative hardness of the tooling piece material and powder material may vary with temperature.
  • the hardness of the tooling piece material and powder material may be equal at a predetermined temperature, which is greater than ambient.
  • the hardness of the tooling piece material may be greater than the powder material at the pressing temperature.
  • the pressing temperature is typically greater than or equal to the predetermined temperature such that the powder is softer than the tooling material upon pressing.
  • the pressing pressure may be greater than the yield stress of the powder material but less than the yield stress of the tooling material at the pressing temperature.
  • the “hardness” of a material in the context of the present invention, is meant the stress at which plastic deformation of the material occurs.
  • the powder may be formed of, or consist of, a metallic material, for example a titanium alloy.
  • the tooling piece may be made from, or consist of, a metallic material, for example steel.
  • the tooling piece may comprise a steel body provided with a ceramic coating, for example of boron nitride.
  • the predetermined temperature is greater than 400° C.
  • the predetermined temperature may be within 100° C. of the pressing temperature, and may be approximately equal to the pressing temperature.
  • the temperature of the powder may be raised from ambient to the pressing temperature over a first time period
  • the applied pressure may be raised from a holding pressure to the pressing pressure over a second time period which begins when the temperature has reached the predetermined temperature
  • the pressing temperature and pressing pressure may be maintained for a third time period from the end of the second time period.
  • the first time period may be not less than 2.5 and not more than 3.5 hours, for example 3 hours
  • the second time period may be not less than 1.5 hours and not more than 2.5 hours, for example 2 hours
  • the third time period may be not less than 2.5 hours and not more than 3.5 hours, for example 3 hours.
  • ambient temperature is meant the temperature of the ambient atmosphere around the equipment in which the hot isostatic pressing operation takes place.
  • holding pressure is meant an initial pressure to which the powder, or a preform made from the powder, is subjected by the tooling piece before the assembly is subjected to the increased temperature and pressure.
  • the holding pressure is sufficient to maintain the components of the assembly (for example a disc, an array of blades, and preforms formed from the powder) in their correct relationships with each other, but lower than that required to cause any significant compaction of the powder.
  • application of the holding pressure is not considered to be initiation of the application of the pressing pressure.
  • the article is a bladed disc for a gas turbine engine.
  • FIG. 1 shows a schematic cross section of a bladed disc arrangement for manufacture in accordance with the present invention
  • FIG. 2 shows a schematic cross section of the bladed disc and tooling during manufacture
  • FIG. 3 is a graph of stress plotted against strain for a titanium alloy (Ti-6-4) against mild steel at ambient temperature;
  • FIG. 4 corresponds to FIG. 3 but represents stress plotted against strain at 800° C.
  • FIG. 5 is a graph plotting temperature in ° C. and pressure in bar against time for a known hot isostatic pressing process
  • FIG. 6 corresponds to FIG. 3 but represents a process in accordance with the present invention
  • FIG. 7 is a photo-micrograph of the interface between a compacted titanium alloy powder and a tooling piece following completion of a known hot isotatic pressing process.
  • FIG. 8 corresponds to FIG. 5 , but represents the condition of the components following completion of a hot isostatic pressing process in accordance with the present invention.
  • a compressor blisk 1 comprises a central workpiece, cylindrical disc 3 , manufactured from a titanium alloy forging.
  • a number of second workpieces, aerofoil blades 5 forged from the same titanium alloy, are attached to the disc 3 , distributed evenly about the radially outer surface 7 of the disc and projecting radially therefrom.
  • Each blade 5 is attached to the disc 3 via a union piece 6 , consolidated from a powdered titanium alloy, in the present case Ti6/4, with particle sizes, before consolidation, of about 250 micron or less.
  • Each union piece 6 provides a blended, radiussed fillet joint between the disc 3 and each blade 5 .
  • this joint has a mean radius of about 5 mm.
  • the union piece 6 extends around the entire blade section and each union piece 6 comprises a piece of titanium alloy with similar properties to a forged item of the same material, the base of which defines a lower surface which conforms with the outer surface 7 of the disc 3 , and defines a footprint of similar shape to the compressor blade 5 cross-section but of larger area, by at least 100%.
  • the union 6 tapers upwards and inwards from this footprint to a height of about 5 mm from the base, at which height it blends with the external gas-washed surface of the aerofoil 5 , with minimal step.
  • the taper is shaped to form the radiussed fillet joint between each blade 5 and the disc 3 .
  • Such joints serve to reduce stresses at the blade/disc interface.
  • the union material 6 is centrally relieved to provide a blind socket which forms a close-fitting location feature to receive the blade 5 , which is diffusion bonded to the union 6 .
  • the base of each blade is diffusion bonded to the socket base and the blade gas-washed surfaces are diffusion bonded to the socket sidewalls.
  • the base of the union piece 6 is diffusion bonded to the disc surface 7 .
  • FIG. 2 shows a cross section through part of a blisk assembly used in the manufacture of the blisk 1 .
  • the titanium alloy powder which provides the union material is supplied to cavity 9 formed between each blade 5 and the disc 3 .
  • Tooling pieces 4 are inserted into the region between adjacent blades 5 and form a close fit therewith.
  • the assembly is enclosed within a mild steel surround 11 .
  • Each tooling piece 4 comprises a block of mild steel, provided with a boron nitride coating, which occupies substantially the whole volume between adjacent blades 5 . With the tooling pieces 4 in place, the assembly forms a substantially solid disc with outer diameter equal to the blade tip diameter.
  • Each tooling piece has faces shaped to closely conform to the surface of an adjacent blade 5 . Accordingly, the tooling piece comprises a convex blade engagement surface and an opposing a concave blade engagement surface, those surfaces being shaped to conform to respective pressure and suction surfaces of the adjacent blades.
  • each tooling piece 4 The opposing side faces of each tooling piece 4 are tapered to form a wedge which narrows in the direction of the disc surface 7 .
  • the radially inner surface 15 of this wedge is truncated and relieved to provide one or more forging surfaces shaped to conform to the opposing fillet joints of the adjacent blades 5 and the region of the disc surface 7 which lies between the blade fillet joints.
  • the tooling pieces 4 are pressed radially inwards during formation of the blisk to apply the desired shape to the union pieces 6 .
  • the metal powder for the union 6 is supplied as a ‘partially-consolidated’ preform, with solid-like properties, but with a material density of typically about 67%.
  • the preform is shaped to define a socket which facilitates location of the preform about the base of the corresponding blade 5 .
  • the mild steel surround 11 comprises a drum-like structure which fully encloses the assembly therein and which wraps around, and abuts the blade tips and outer surfaces of the tooling pieces 4 .
  • the surround 11 is evacuated prior to sealing about the components of the blisk assembly.
  • titanium alloy, and particularly Ti-6-4 is substantially harder than mild steel.
  • the elastic limit of mild steel is reached at approximately 300 MPa, while that for Ti-6-4 is reached at approximately 900 MPa.
  • FIG. 4 it has been discovered that the position is reversed at 800° C., with the elastic limit for Ti-6-4 being reached below 20 MPa, while that for mild steel is reached at approximately 30 MPa.
  • FIG. 5 In a known hot isostatic pressing process, the sequence of operation is shown in FIG. 5 .
  • a single y-axis scale is shown, so that the same scale can represent both the temperature in ° C. and the pressure in bar.
  • FIG. 5 relates to the manufacture of a bladed disc for a gas turbine engine. It will be appreciated that from time 0 (ie the time at which the assembled disc, union piece, preforms and blades) are placed in an oven, that both the temperature and pressure begin to rise immediately as power is supplied to the heating means of the oven and inert gas (such as argon) is admitted to the oven and pressurised, both by means of a pump and by means of the increasing temperature. The temperature rises to approximately 930° C. over a period of approximately 3 hours, and the pressure rises to 100 MPa (100 bar) over the same time period. When the pressure and temperature reach these pressing values, they are maintained for 4 hours, following which heating is terminated and the temperature and pressure are allowed to return to the ambient values.
  • inert gas such as argon
  • the pressure increases significantly while the temperature rises from the ambient level to the level at which the hardnesses of Ti-6-4 and mild steel become equal (i.e. a condition between the two conditions represented in FIGS. 3 and 4 ).
  • the predetermined temperature at which this happens will vary with the precise composition of the titanium alloy and the mild steel, but in many cases will fall in the range 400 to 500° C.
  • the compacted titanium alloy union piece 6 at the end of the pressing operation does not have a smooth surface finish, with the result that a finishing operation may be required to eliminate surface roughness.
  • the surface of the steel cooling piece is deformed from its initial smooth configuration to the rough, indented configuration shown in FIG. 7 . Consequently, the surface of the tooling piece 4 is degraded, possibly making it unsuitable for re-use in a subsequent hot isostatic pressing operation. If the tooling piece has a ceramic coating, the indenting of the surface can cause cracking of the coating
  • FIG. 6 corresponds to FIG. 5 , but represents a hot isostatic pressing operation in accordance with the present invention.
  • the temperature is increased, as before, to 930° C. over a first time period of three hours.
  • the increase in pressure is deferred until the temperature has reached the pressing temperature of 930° C. Instead, a relatively low holding pressure of the order of 5 MPa is maintained in the oven as the temperature is raised.
  • the pressure is increased to the pressing pressure of 100 MPa over a second time period of approximately two hours.
  • the steel tooling pieces will be harder at the pressing temperature than the titanium alloy of the powder.
  • the pressure rises it is the particles of the titanium alloy powder that are deformed by contact with the steel tooling pieces 4 , so that the steel tooling pieces maintain their surface smoothness and the same smoothness is imparted to the surfaces of the union pieces. Consequently, as shown in FIG. 8 , the interface between the compacted titanium powder and the steel tooling piece 4 is smooth, by comparison with the roughened interface shown in FIG. 7 .
  • the pressing temperature and pressure are maintained for a third time period of 3 hours from the end of the second time period (ie when the pressing pressure has been reached), in order to complete compaction of the titanium alloy powder.
  • the temperature and pressure are returned to ambient in the same manner as for the known process presented in FIG. 5 .
  • the resulting surface of the union piece 6 formed from the titanium alloy powder means that the surface definition and surface quality of the union piece 6 is improved over that achieved with the known process. Consequently, the union piece 6 does not need subsequent processing prior to use, and the process can be regarded as a true net-shape process which achieves the desired finish surface directly from the hot isostatic pressing operation.
  • the use of a ceramic coating on the steel tooling piece 4 assists with the removal of the tooling piece 4 from the formed titanium powder union piece 6 or other component, and prevents any reaction, or undesired bonding, between the titanium alloy and the tooling piece 4 .
  • the increase in pressure need not be deferred until the increase in temperature to the pressing temperature of 930° C. is complete. Instead, the second time period during which the pressure is increased can begin earlier, provided that the pressure applied to the powder remains below the yield stress of the material of the tooling piece until a temperature has been reached at which the hardness of the material of the tooling piece 4 (for example steel) is at or above the hardness of the material of the powder, (for example titanium alloy).
  • the hardness of the material of the tooling piece 4 for example steel
  • the hardness of the material of the powder for example titanium alloy
  • the applied pressure is kept at an appropriate level blow the yield stress of the tooling piece material to take account of the higher temperature of the tool as heating progresses, and to take account of stress concentrations at the surface of the tooling piece as a result of uneven contact between the tooling piece and the powder in the early stages of pressure application.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)
  • Forging (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Press Drives And Press Lines (AREA)
US12/385,206 2008-04-29 2009-04-01 Manufacture of an article by hot isostatic pressing Abandoned US20100158742A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0807703.4 2008-04-29
GB0807703A GB2459653A (en) 2008-04-29 2008-04-29 Manufacture of an article by hot isostatic pressing

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US20100158742A1 true US20100158742A1 (en) 2010-06-24

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US (1) US20100158742A1 (fr)
EP (1) EP2113321B1 (fr)
AT (1) ATE516095T1 (fr)
GB (1) GB2459653A (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150298247A1 (en) * 2012-11-30 2015-10-22 European Space Agency Method of manufacturing a metallic component from individual units arranged in a space filling arrangement
US20160138408A1 (en) * 2014-11-17 2016-05-19 General Electric Company Blisk rim face undercut
CN115070041A (zh) * 2021-03-10 2022-09-20 中国航发商用航空发动机有限责任公司 一种gh4169和tc17同种、异种材料多级转子组件及其制备方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102126023B (zh) * 2011-03-11 2012-09-05 北京航空航天大学 一种钛合金整体叶片盘的粉末热等静压成型方法

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5113583A (en) * 1990-09-14 1992-05-19 United Technologies Corporation Integrally bladed rotor fabrication
US20060266801A1 (en) * 2005-03-17 2006-11-30 Rolls-Royce Plc Assembly and method for manufacture of component by hot isostatic pressing

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DE1758141B2 (de) * 1967-05-24 1972-07-06 Crucible Inc., Pittsburgh, Pa. (V.StA.) Verfahren zur pulvermetallurgischen herstellung von formkoerpern aus stahl
DE3010299C2 (de) * 1980-03-18 1981-07-30 MTU Motoren- und Turbinen-Union München GmbH, 8000 München Kapsel für das heißisostatische Pressen und Verfahren zum heißisostatischen Pressen unter Verwendung der Kapsel
SE430481B (sv) * 1982-03-29 1983-11-21 Asea Ab Sett att sammanfoga delar av solitt material genom varm isostatisk pressning
US4952353A (en) * 1989-12-28 1990-08-28 Gte Laboratories Incorporated Hot isostatic pressing
AU2002342490A1 (en) * 2002-07-23 2004-02-09 Elmicron Ag Method for fastening microtool components to objects
AU2003286496A1 (en) * 2002-10-18 2004-05-04 The Regents Of The University Of California Isostatic pressure assisted wafer bonding method
GB2419835A (en) * 2004-11-06 2006-05-10 Rolls Royce Plc Method of diffusion bonding
GB0610468D0 (en) * 2006-05-26 2006-07-05 Rolls Royce Plc A method of manufacturing a component

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5113583A (en) * 1990-09-14 1992-05-19 United Technologies Corporation Integrally bladed rotor fabrication
US20060266801A1 (en) * 2005-03-17 2006-11-30 Rolls-Royce Plc Assembly and method for manufacture of component by hot isostatic pressing

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150298247A1 (en) * 2012-11-30 2015-10-22 European Space Agency Method of manufacturing a metallic component from individual units arranged in a space filling arrangement
US20160138408A1 (en) * 2014-11-17 2016-05-19 General Electric Company Blisk rim face undercut
US10731484B2 (en) * 2014-11-17 2020-08-04 General Electric Company BLISK rim face undercut
CN115070041A (zh) * 2021-03-10 2022-09-20 中国航发商用航空发动机有限责任公司 一种gh4169和tc17同种、异种材料多级转子组件及其制备方法

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EP2113321A3 (fr) 2010-11-24
EP2113321B1 (fr) 2011-07-13
ATE516095T1 (de) 2011-07-15
GB0807703D0 (en) 2008-06-04
EP2113321A2 (fr) 2009-11-04
GB2459653A (en) 2009-11-04

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