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 PDFInfo
- 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
- Authority
- 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
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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.
Landscapes
- 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)
Abstract
For near net shape manufacturing of a high-temperature resistant component of complex design a high melting-point part of an intermetallic phase provided as a metal powder is mixed with a binder, and from the feedstock such formed a green compact substantially matching the final contour is produced by metal injection moulding, into the pores of said compact that remain after removal of the binder the low melting-point part of the intermetallic phase is infiltrated. The brown compact thereby created is mechanically processed, if required, and subjected to a specific heat treatment depending on the metallic phases used in order to create the intermetallic phase. This permits engine components consisting of intermetallic phases and having a geometrically complex structure to be manufactured cost-efficiently.
Description
- 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. In 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. In order to enable near net shape production also of high-temperature resistant engine components, e.g. turbine blades, the proposal has already been made to produce a powder consisting of an intermetallic phase and to use this powder in the manner described above for metal injection moulding. The manufacture of intermetallic phases and of a powder made therefrom for metal injection moulding however involves high manufacturing effort and costs.
- 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.
- It is a particular object of the present invention to provide solution to the above problematics by a method in accordance with the features of
patent claim 1. - Advantageous developments of the present invention become apparent from the sub-claims.
- 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.
- This permits high-temperature resistant and lightweight engine components of geometrically complex structure, such as for example turbine blades, to be manufactured cost-efficiently from high-performance materials.
- In an embodiment of the invention, 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.
- In a further embodiment of the invention, 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.
- In a further embodiment of the invention, 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.
- In a further embodiment of the invention, 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 embodiment of the invention is described in more detail below in conjunction with the enclosed processing flow chart using the example of manufacture of a turbine blade consisting of an intermetallic phase based on iron and aluminum.
- 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).
- From the iron powder/binder mixture, the so-called feedstock—provided in the form of a granulate—a green compact is produced using a screw extruder in a conventional injection process (step 3), from which green compact the first component of the polymer binder is removed after cooling, solidification and demoulding (step 4). The removal of the first component of the binder can be achieved chemically, catalytically and/or thermally. As a result of partial debindering, 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. In the following process step, a low melting-point metallic phase—in this case aluminum—is infiltrated in a modified die-casting process, so-called “squeeze casting”, into the cavities of the brown compact at high pressure, thermally removing the second component of the binder from the brown compact (step 5). 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. After this step, mechanical processing of the infiltrated brown compact (step 6) can take place if necessary, which can be performed in a simple manner at this point in time. Then 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.
- In the same way, other high-temperature resistant and lightweight components of geometrically complex structure can also be manufactured, efficiently and inexpensively with low expenditure on material, from an intermetallic phase, produced for example on the basis of nickel, iron, titanium and aluminum.
Claims (7)
1. Method for near net shape manufacturing of high-temperature resistant engine components of geometrically complex structure by metal injection moulding, the engine components consisting of an intermetallic phase of a high melting-point part and a low melting-point part, characterized in that the high melting-point part provided as a metal powder is mixed with a binder, that a green compact of the engine component is first produced by metal injection moulding, that a porous brown compact is created after removal of the binder, that subsequently the low melting-point part of the intermetallic phase is infiltrated into the pores of the brown compact in the molten state and that finally the brown compact such prepared is subjected to a heat treatment generating the intermetallic phase.
2. Method in accordance with claim 1 , characterized in that the proportion of the low melting-point part of the intermetallic phase is variable and is determined by the proportion of pores after complete removal of the binder from the green compact.
3. Method in accordance with claim 2 , characterized in that the proportion of pores is determined by the setting of the mixing ratio between the metal powder and the two-component binder.
4. Method in accordance with claim 1 , characterized in that the 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.
5. Method in accordance with claim 1 , characterized in that the brown compact is mechanically processed after infiltration of the low melting-point part and before the heat treatment that creates the intermetallic phase.
6. Method in accordance with claim 1 , characterized in that a polymer two-component binder is used, where the first binder component is removed from the green compact created by metal injection moulding, and the second binder component is removed during infiltration of the low melting-point part of the intermetallic phase.
7. Method in accordance with claim 1 , characterized in that the first binder component is removed chemically, catalytically and/or thermally, and the second binder component is removed thermally.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102010061960.4 | 2010-11-25 | ||
DE102010061960A DE102010061960A1 (en) | 2010-11-25 | 2010-11-25 | Process for near-net-shape production of high-temperature-resistant engine components |
PCT/EP2011/070439 WO2012069374A1 (en) | 2010-11-25 | 2011-11-18 | Method for the near net shape manufacture of high temperature resistant jet engine components |
Publications (1)
Publication Number | Publication Date |
---|---|
US20130266469A1 true US20130266469A1 (en) | 2013-10-10 |
Family
ID=45063109
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 (en) |
EP (1) | EP2643113B1 (en) |
DE (1) | DE102010061960A1 (en) |
WO (1) | WO2012069374A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114472890A (en) * | 2020-11-13 | 2022-05-13 | 盖瑞特交通一公司 | Method for combined sintering and surface treatment of variable geometry turbocharger vanes |
Citations (9)
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 |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS6029431A (en) * | 1983-07-28 | 1985-02-14 | Toyota Motor Corp | Production of alloy |
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 (en) * | 1995-03-14 | 1996-09-18 | Deritend Advanced Technology Limited | Method of making an intermetallic compound |
CN1174825C (en) * | 2000-06-14 | 2004-11-10 | 太原艺星科技有限公司 | Method for making precision shaped porous component |
DE102006053018B4 (en) * | 2006-11-10 | 2010-04-08 | Ks Aluminium-Technologie Gmbh | Cylinder crankcase for a motor vehicle |
WO2008095080A1 (en) * | 2007-01-31 | 2008-08-07 | Arcmelt Company, Lc. | Method of producing composite materials through metal injection molding |
-
2010
- 2010-11-25 DE DE102010061960A patent/DE102010061960A1/en not_active Withdrawn
-
2011
- 2011-11-18 WO PCT/EP2011/070439 patent/WO2012069374A1/en active Application Filing
- 2011-11-18 EP EP11788791.9A patent/EP2643113B1/en not_active Not-in-force
- 2011-11-18 US US13/989,226 patent/US20130266469A1/en not_active Abandoned
Patent Citations (9)
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)
Title |
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"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)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114472890A (en) * | 2020-11-13 | 2022-05-13 | 盖瑞特交通一公司 | Method for combined sintering and surface treatment of variable geometry turbocharger vanes |
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 (en) * | 2020-11-13 | 2022-05-25 | Garrett Transportation I Inc. | Methods for the combined sintering and surface treatment of variable geometry turbocharger vanes |
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 |
---|---|
DE102010061960A1 (en) | 2012-05-31 |
EP2643113A1 (en) | 2013-10-02 |
WO2012069374A1 (en) | 2012-05-31 |
EP2643113B1 (en) | 2016-11-16 |
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AS | Assignment |
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 |
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STCB | Information on status: application discontinuation |
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