US20130266469A1 - Method for near net shape manufacturing of high-temperature resistant engine components - Google Patents

Method for near net shape manufacturing of high-temperature resistant engine components Download PDF

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Publication number
US20130266469A1
US20130266469A1 US13/989,226 US201113989226A US2013266469A1 US 20130266469 A1 US20130266469 A1 US 20130266469A1 US 201113989226 A US201113989226 A US 201113989226A US 2013266469 A1 US2013266469 A1 US 2013266469A1
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US
United States
Prior art keywords
binder
intermetallic phase
point part
compact
low melting
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
US13/989,226
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English (en)
Inventor
Dan Roth-Fagaraseanu
Alexander SCHULT
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 Deutschland Ltd and Co KG
Original Assignee
Rolls Royce Deutschland Ltd and Co KG
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 Rolls Royce Deutschland Ltd and Co KG filed Critical Rolls Royce Deutschland Ltd and Co KG
Assigned to ROLLS-ROYCE DEUTSCHLAND LTD & CO KG reassignment ROLLS-ROYCE DEUTSCHLAND LTD & CO KG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ROTH-FAGARASEANU, DAN, Schult, Alexander
Publication of US20130266469A1 publication Critical patent/US20130266469A1/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
    • B22F3/12—Both compacting and sintering
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B22F3/26—Impregnating
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/047—Making non-ferrous alloys by powder metallurgy comprising intermetallic compounds
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0475—Impregnated alloys

Definitions

  • This invention relates to a method for near net shape manufacturing of high-temperature resistant engine components of geometrically complex structure by metal injection moulding.
  • a known method for near net shape manufacturing of components of geometrically complex design is metal injection moulding, also referred to as MIM.
  • metal injection moulding first a metal powder is mixed with a binder including thermoplastics and waxes to form a flowing material (feedstock) which is injected into a mould using an extruder in a conventional injection moulding process. After cooling, solidification and demoulding, a so-called green compact is created, from which the binder is removed thermally or chemically to provide a porous moulded part, the so-called brown compact. In a subsequent sintering process the porous brown compact is compacted into its final shape and has, due to its minor residual porosity, strength properties matching the properties of the solid material.
  • the object underlying the present invention is to provide a cost-efficient method for near net shape manufacturing of high-temperature resistant engine components of geometrically cornplex structure.
  • the basic idea of the invention is to mix a high melting-point part of an intermetallic phase provided as a metal powder with a binder, and to create, by metal injection moulding, from the feedstock such formed a green compact substantially matching the final contour, into the pores of said compact that remain after removal of the binder the low melting-point part of the intermetallic phase is infiltrated, with the brown compact thereby created being subjected to a specific heat treatment depending on the metallic phases used in order to create the intermetallic phase.
  • a polymer two-component binder is used, where the first binder component is removed chemically, catalytically or thermally from the green compact created by metal injection moulding, and the second binder component is removed thermally during infiltration of the low melting-point metallic part.
  • the proportion of the low melting-point part of the intermetallic phase is variable, being determined by the proportion of pores after complete removal of the binder from the green compact.
  • the proportion of pores and hence the proportion of the infiltrated low melting-point part in the intermetallic phase is determined by the setting of the mixing ratio between the metal powder and the two-component binder.
  • infiltration of the molten and low melting-point part of the intermetallic phase into the porous brown compact is performed under pressure using the squeeze casting method.
  • the brown compact can be mechanically processed after infiltration of the low melting-point part and before the heat treatment that creates the intermetallic phase.
  • An iron powder is manufactured from the high melting-point part of the intermetallic phase, in this case iron (step 1 ) and is mixed with a polymer binder including two components (step 2 ).
  • the removal of the first component of the binder can be achieved chemically, catalytically and/or thermally.
  • a porous brown compact consisting of the high melting-point metallic phase and the first component of the binder is obtained, which has a certain porosity adjustable depending on the binder proportion.
  • a low melting-point metallic phase in this case aluminum
  • a modified die-casting process so-called “squeeze casting”
  • the volume ratio between the high melting-point metallic phase (iron) and the low melting-point metallic phase (aluminum) is set using the respective porosity of the brown compact.
  • step 7 the component matching the final shape is subjected to a heat treatment (step 7 ) in order to form an intermetallic phase consisting of iron and aluminum, thereby providing a high-temperature resistant component of geometrically complex design made by metal injection moulding, for example a turbine blade for a gas-turbine engine.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
US13/989,226 2010-11-25 2011-11-18 Method for near net shape manufacturing of high-temperature resistant engine components Abandoned US20130266469A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102010061960A DE102010061960A1 (de) 2010-11-25 2010-11-25 Verfahren zur endkonturnahen Fertigung von hochtemperaturbeständigen Triebwerksbauteilen
DE102010061960.4 2010-11-25
PCT/EP2011/070439 WO2012069374A1 (de) 2010-11-25 2011-11-18 Verfahren zur endkonturnahen fertigung von hochtemperaturbeständigen triebwerksbauteilen

Publications (1)

Publication Number Publication Date
US20130266469A1 true US20130266469A1 (en) 2013-10-10

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
US13/989,226 Abandoned US20130266469A1 (en) 2010-11-25 2011-11-18 Method for near net shape manufacturing of high-temperature resistant engine components

Country Status (4)

Country Link
US (1) US20130266469A1 (de)
EP (1) EP2643113B1 (de)
DE (1) DE102010061960A1 (de)
WO (1) WO2012069374A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114472890A (zh) * 2020-11-13 2022-05-13 盖瑞特交通一公司 可变几何结构涡轮增压器叶片的组合烧结和表面处理的方法

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4294615A (en) * 1979-07-25 1981-10-13 United Technologies Corporation Titanium alloys of the TiAl type
US4710223A (en) * 1986-03-21 1987-12-01 Rockwell International Corporation Infiltrated sintered articles
US5362791A (en) * 1990-07-07 1994-11-08 Basf Aktiengesellschaft Thermoplastic compositions for producing metallic moldings
US5701575A (en) * 1992-11-09 1997-12-23 Nhk Spring Co., Ltd. Article made of a Ti-Al intermetallic compound, and method for fabrication of same
US5858056A (en) * 1995-03-17 1999-01-12 Toyota Jidosha Kabushiki Kaisha Metal sintered body composite material and a method for producing the same
US6319437B1 (en) * 1998-03-16 2001-11-20 Hi-Z Technology, Inc. Powder injection molding and infiltration process
US20030133821A1 (en) * 2002-01-16 2003-07-17 Advanced Materials Products, Inc. Manufacture of lightweight metal matrix composites with controlled structure
US20040060683A1 (en) * 2002-09-27 2004-04-01 Sercombe Timothy Barry Infiltrated aluminum preforms
US7387763B2 (en) * 2004-07-27 2008-06-17 General Electric Company Preparation of sheet by injection molding of powder, consolidation, and heat treating

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Publication number Priority date Publication date Assignee Title
JPS6029431A (ja) * 1983-07-28 1985-02-14 Toyota Motor Corp 合金の製造方法
AU626435B2 (en) * 1989-07-10 1992-07-30 Toyota Jidosha Kabushiki Kaisha Method of manufacture of metal matrix composite material including intermetallic compounds with no micropores
US5366686A (en) * 1993-03-19 1994-11-22 Massachusetts Institute Of Technology, A Massachusetts Corporation Method for producing articles by reactive infiltration
EP0732415A1 (de) * 1995-03-14 1996-09-18 Deritend Advanced Technology Limited Verfahren zur Herstellung einer intermetallischen Verbindung
CN1174825C (zh) * 2000-06-14 2004-11-10 太原艺星科技有限公司 一种异形精密多孔元件的制造方法
DE102006053018B4 (de) * 2006-11-10 2010-04-08 Ks Aluminium-Technologie Gmbh Zylinderkurbelgehäuse für ein Kraftfahrzeug
US20100111745A1 (en) * 2007-01-31 2010-05-06 Urevich David J Method of producing composite materials through metal injection molding

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4294615A (en) * 1979-07-25 1981-10-13 United Technologies Corporation Titanium alloys of the TiAl type
US4710223A (en) * 1986-03-21 1987-12-01 Rockwell International Corporation Infiltrated sintered articles
US5362791A (en) * 1990-07-07 1994-11-08 Basf Aktiengesellschaft Thermoplastic compositions for producing metallic moldings
US5701575A (en) * 1992-11-09 1997-12-23 Nhk Spring Co., Ltd. Article made of a Ti-Al intermetallic compound, and method for fabrication of same
US5858056A (en) * 1995-03-17 1999-01-12 Toyota Jidosha Kabushiki Kaisha Metal sintered body composite material and a method for producing the same
US6319437B1 (en) * 1998-03-16 2001-11-20 Hi-Z Technology, Inc. Powder injection molding and infiltration process
US20030133821A1 (en) * 2002-01-16 2003-07-17 Advanced Materials Products, Inc. Manufacture of lightweight metal matrix composites with controlled structure
US20040060683A1 (en) * 2002-09-27 2004-04-01 Sercombe Timothy Barry Infiltrated aluminum preforms
US7387763B2 (en) * 2004-07-27 2008-06-17 General Electric Company Preparation of sheet by injection molding of powder, consolidation, and heat treating

Non-Patent Citations (5)

* Cited by examiner, † Cited by third party
Title
"Cast nonferrous: heat treatable aluminum alloys." Key to Metals, August 5, 2009. Web. https://web.archive.org/web/20090805212927/http://www.keytometals.com/Article39.htm Accessed March 3, 2015. *
A. Laptev, O. Vyal, M. Bram, H. P. Buchkremer, D. St�ver. "Green strength of powder compacts provided for production of highly porous titanium parts." Powder Metallurgy Vol. 48, No. 4 (2005) 358-634. *
C. G. Goetzel, J. Groza. "Infiltration" ASM Handbook, Volume 7: Powder Metal Technologies and Applications. P 541-564. 1998. *
Squeeze Casting Process: Part One. http://www.totalmateria.com/page.aspx?ID=CheckArticle&site=ktn&NM=172 Published June 2007. Accessed July 24, 2015. *
T. Murphy "Aluminum Claims No. 2 Ranking." Wards Auto, March 10 2006. Web. http://wardsauto.com/ar/auto_aluminum_claims_no Accessed March 3, 2015. *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114472890A (zh) * 2020-11-13 2022-05-13 盖瑞特交通一公司 可变几何结构涡轮增压器叶片的组合烧结和表面处理的方法
US20220152702A1 (en) * 2020-11-13 2022-05-19 Garrett Transportation I Inc Methods for the combined sintering and surface treatment of variable geometry turbocharger vanes
EP4000764A1 (de) * 2020-11-13 2022-05-25 Garrett Transportation I Inc. Verfahren zur kombinierten sinterung und oberflächenbehandlung von turboladerschaufeln mit variabler geometrie
US11618075B2 (en) * 2020-11-13 2023-04-04 Garrett Transportation I Inc. Methods for the combined sintering and surface treatment of variable geometry turbocharger vanes

Also Published As

Publication number Publication date
EP2643113A1 (de) 2013-10-02
DE102010061960A1 (de) 2012-05-31
EP2643113B1 (de) 2016-11-16
WO2012069374A1 (de) 2012-05-31

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Owner name: ROLLS-ROYCE DEUTSCHLAND LTD & CO KG, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ROTH-FAGARASEANU, DAN;SCHULT, ALEXANDER;REEL/FRAME:030664/0131

Effective date: 20130618

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION