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
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
  • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/12—All metal or with adjacent metals
  • Y10T428/12361—All metal or with adjacent metals having aperture or cut

Definitions

• the invention relates to net-shape or near net-shape powder isostatic pressing processes, as applied to metallic and/or cermet/MMC (metal matrix composites) powder.
• the invention is concerned particularly, but not exclusively, with the production of a bore of substantial length, typically longer than 750 mm, in a component of hard wear-resistant material.
• Such components can be made by Hot Isostatic Pressing (HIPing) but it is extremely difficult to produce bores in the formed components by machining. With difficulty, straight bores of small length such as 10 mm can be machined.
• HIPing Hot Isostatic Pressing
• a method of producing a net or near net-shape component from metal powder comprises producing an insert of accurate dimensions corresponding to the dimensions of a bore to be created in the finished component, the bore having a length of at least 750 mm, supporting the insert within a mould cavity, filling the mould cavity with metal powder, subjecting the powder to isostatic pressing, and subsequently removing the material of the insert.
• the mould may be an independent mould that is removed after an initial step to bind the powder together into a pre-form, and the pre-form is then encapsulated in a suitable containment which may be a canister or a sprayed coating, or a canister of suitable internal shape may be used as the mould, and the canister itself is evacuated prior to HIPing
• the insert is supported in position in the mould cavity by a plurality of formers of a material that is compatible with the finally consolidated powder.
• the insert may be a metallic insert of a material that is subsequently removable by chemical etching, preferably copper.
• the chemical etching may be assisted by electrolytic reaction.
• the insert need only be coated with a material that can subsequently be removed by etching, in order to release the insert, which can then be extracted.
• the metallic insert is coated with a suitable material that provides a diffusion barrier to prevent the material of the insert from diffusing by atomic diffusion into the powder being consolidated during HIPing.
• the invention can enable a helical bore to be provided in a component.
• Such a helical bore could be used for various purposes, such as to convey a fluid and/or to accommodate an electrical or fibre-optic cable to provide sensor or control system communications for example.
• a copper rod of a diameter in the range of 6 to 10 mm for example and of length greater than 2 m, is first bent into a helix of the required dimensions and this is then held in position in a powder containment prior to filling the containment with powder.
• the containment enclosing the powder, rod and former, is then consolidated by solid state diffusion using the HIPing method.
• the diffusion barrier may be Al 2 O 3 applied by vapour phase deposition or by high velocity spraying.
• the diffusion barrier may be created by applying boron nitride as an aqueous solution by spraying.
• a preformed metal tube of 6 mm to 10 mm diameter for example, is filled with ceramic particles and is bent to a helical shape and placed within the powder containment prior to filling the containment with powder.
• the tube is held in position with formers compatible with the finally consolidated powder.
• the entire containment encompassing the metallic and/or cermet/MMC powder is then consolidated by solid state diffusion using the HIPing method.
• the metal tube may become totally diffusion bonded into the consolidated component but the ceramic particles will remain in the pre-process particle form and thereby can be removed mechanically via vibration techniques to leave a clean hole through the component.
• the invention can be used to provide one or more holes in one or more helical lobes provided internally of the stator body of a helicoidal positive displacement pump, the stator body having a length of as much as 2 m or more.
• Such stator bodies can be used to form the radially outer part of a linear motor and/or mud pump used in down-hole drilling.
• the hole or holes can be positioned to follow the core of a helical flute, which may have a pitch of about 1 m and a radius of 50 mm about the body axis.
• the helical lobes are defined by helical grooves in a mandrel that is positioned in the mould during pressing of the stator body.

Landscapes

• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Powder Metallurgy (AREA)
• Pressure Welding/Diffusion-Bonding (AREA)

Applications Claiming Priority (3)

Publications (1)

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Family Applications (1)

Country Status (9)

Cited By (2)

Families Citing this family (5)

Citations (11)

Family Cites Families (1)

• 2008
  • 2008-03-20 GB GBGB0805242.5A patent/GB0805242D0/en not_active Ceased
• 2009
  • 2009-03-20 CN CN2009801098127A patent/CN102026752A/zh active Pending
  • 2009-03-20 ES ES09721920.8T patent/ES2530092T3/es active Active
  • 2009-03-20 EA EA201001527A patent/EA019527B1/ru not_active IP Right Cessation
  • 2009-03-20 EP EP09721920.8A patent/EP2262599B1/en not_active Not-in-force
  • 2009-03-20 MX MX2010010146A patent/MX2010010146A/es unknown
  • 2009-03-20 WO PCT/GB2009/000757 patent/WO2009115821A1/en active Application Filing
  • 2009-03-20 US US12/736,207 patent/US20110033725A1/en not_active Abandoned
  • 2009-03-20 BR BRPI0909088A patent/BRPI0909088A2/pt not_active IP Right Cessation

Patent Citations (11)

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