WO2005000504A1 - Pulver metallurgical component production - Google Patents

Pulver metallurgical component production Download PDF

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Publication number
WO2005000504A1
WO2005000504A1 PCT/FI2004/000408 FI2004000408W WO2005000504A1 WO 2005000504 A1 WO2005000504 A1 WO 2005000504A1 FI 2004000408 W FI2004000408 W FI 2004000408W WO 2005000504 A1 WO2005000504 A1 WO 2005000504A1
Authority
WO
WIPO (PCT)
Prior art keywords
powder
solid
accordance
isostatic pressing
blanks
Prior art date
Application number
PCT/FI2004/000408
Other languages
French (fr)
Inventor
Jari Ilmari Liimatainen
Original Assignee
Metso Powdermet Oy
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 Metso Powdermet Oy filed Critical Metso Powdermet Oy
Priority to EP04742151A priority Critical patent/EP1638718A1/en
Publication of WO2005000504A1 publication Critical patent/WO2005000504A1/en

Links

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
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/001—Interlayers, transition pieces for metallurgical bonding of workpieces
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2241/00—Treatments in a special environment
    • C21D2241/01—Treatments in a special environment under pressure
    • C21D2241/02—Hot isostatic pressing

Definitions

  • the present invention is related to manufacturing components produced by means of powder-metallurgical manufacturing processes. More precisely, the invention relates to manufacturing components including internal concaves and channels.
  • the manufacturing method thereby comprises typically the following main steps: o 1. Manufacturing a gas-atomized powder.
  • Hot-isostatic pressing by means of temperature and pressure (e.g. for steels typically T 1100 - 1200°, pressure 100 - 120 MPa and time 1 - 4 h).
  • the capsule die is manufactured as over-sized, in order to take into account0 the volumetric change of the encapsulated powder when the gas-atomized powder is consolidated.
  • the density is 60-70 % of the theoretical density, in other words, the capsule can contract significantly when the powder is consolidated into the density of 100 %.
  • Control of the dimensional changes taking place, when the powder is consolidated, is essential for achieving the dimensional accuracy of the5 products and naturally it has an essential influence on the production costs due to the amount of tooling allowances and the need for machining.
  • a powder metallurgic method using hot isostatic pressing is also applicable for manufacturing products having internal channels and cavities, e.g. for heating and cooling of components.
  • Cavities and channels can be manufactured by making into the powder capsule a capsule corresponding with the desired channel and cavity structure and by filling with powder the space between the capsule surrounding the whole structure and the capsule forming the channel and cavity.
  • the accuracy of the location of these channels is in general critical with respect to the heating or cooling of the components and, in addition, it can have influence on the mechanical reliability of the structure.
  • One alternative that has been used to some extent is to use solid basic materials, the joint surfaces of which are confronted against each other accurately.
  • the joint surfaces are placed in the surrounding capsule so that the pressure in the hot isostatic pressing presses the surfaces against each other, thus providing a diffusion bonding.
  • the surfaces of the solid pieces to be joined must be well finished, especially clean and even, to ensure an adequate quality of the bonding.
  • the temperature and pres- sure of the hot isostatic pressing must be increased and the time prolonged compared with a powder metallurgic bonding, in order to ensure the good quality of the bonding.
  • even the smallest impurities of the joint surfaces or moving of the surfaces during the hot isostatic pressing can prevent the bonding or weaken its quality significantly.
  • the component is manufactured so, that substantially solid, preformed pieces produced by forging, casting or machining are used, and material in powder form, in an encapsulated space, is used for the joint surfaces of the solid pieces to be joined by isostatic pressing, More precisely, the method in accordance with the invention is characterized in by what has been stated in the characterizing part of Claim 1.
  • Figures la - lc show examples of embodiments of the method in accordance with the invention.
  • Figure la shows one embodiment of an application of the method in accordance with the invention.
  • the joint area of the solid pieces 1, 1' and 1" has been sealed with gas-tight welds 3 and a capsule plate 4.
  • the area formed in that way has been filled with powder material 2.
  • the welds between the joint surfaces have been partly made directly between the solid pieces.
  • the gas tightness is a precondition for using the hot isostatic pressing.
  • the powder has been consolidated by means of pres- sure and/or temperature, like for example by hot isostatic pressing.
  • the capsule plates and welds connected thereto can remain in the component or they can be removed for example by machining and in certain cases by acid etching.
  • the amount of powder to be used in the joint has been minimized.
  • the area formed into the jointing point of the solid pieces 1, 1' and 1" has been filled with powder 2 and solid material 5 in order to minimize the amount of the powder material.
  • the joint area is sealed gas tightly by means of gas tight welds 3 and a capsule plate 4.
  • the requirements for the dimensional accuracy of the joint surfaces are not as big as when using only solid materials.
  • the oxide films of the junctions of the powder and solid material are efficiently broken, thus providing a more reliable and better joint compared with the solid-solid-joint.
  • the amount of the powder to be used is very much limited only at the junctions of the pieces to be joined, the dimensional changes caused by the contraction of the powder are not big, whereby more accurate dimensions are achieved after the hot isostatic pressing, than by using as basic material a capsule totally filled with powder or powder encapsulated on the surface of the solid material.
  • the capsule surrounding the joint surfaces can be (I) welded to the solid materials at both sides of the joint, (II) the whole interior of the concave or the channel can be encapsulated and (III) in addition, gas-tight capsules can be manufactured between the solid materials, said capsules transmitting the isostatic gas pressure to the joint surface and consolidating the powder between the joint surfaces.
  • Components having more accurate dimensions can be manufactured by means of the method in accordance with the present invention, than by using materials manufactured by means of powder only or by using powder encapsulated into the surface of the solid material for sealing the internal concaves,
  • the joints in the components are mainly free of welding joints; welding joints can be left to the gas tight welds surrounding the joint surfaces inside the component, but they form only a small part of the load bearing cross surface, and in addition, eventual welding mistakes not opening to the surface are closed during the hot isostatic pressing.

Landscapes

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

Abstract

A method for manufacturing metallic components including internal channels and concaves, the pre-blanks in said methods being produced of solid materials being attached to each other with a powder metallurgic method.

Description

PULNER METALLURGICAL COMPONENT PRODUCTION
The present invention is related to manufacturing components produced by means of powder-metallurgical manufacturing processes. More precisely, the invention relates to manufacturing components including internal concaves and channels.
j Background of the Invention
It is well known in the art to produce high-class components having almost the final dimensions by means of powder metallurgic manufacturing methods by using hot-isostatic pressing (HIP). The manufacturing method thereby comprises typically the following main steps: o 1. Manufacturing a gas-atomized powder.
2. Designing and manufacturing a sheet metal capsule by means of sheet metal forming, cutting and welding techniques.
3. Filling the capsule with the powder.
4. Evacuation of the capsule. s 5. Sealing of the capsule.
6. Hot-isostatic pressing by means of temperature and pressure (e.g. for steels typically T 1100 - 1200°, pressure 100 - 120 MPa and time 1 - 4 h).
7. Machining, heat treatment and inspection.
In the method, the capsule die is manufactured as over-sized, in order to take into account0 the volumetric change of the encapsulated powder when the gas-atomized powder is consolidated. Typically, in case of a gas-atomized powder, the density is 60-70 % of the theoretical density, in other words, the capsule can contract significantly when the powder is consolidated into the density of 100 %. Control of the dimensional changes taking place, when the powder is consolidated, is essential for achieving the dimensional accuracy of the5 products and naturally it has an essential influence on the production costs due to the amount of tooling allowances and the need for machining. A powder metallurgic method using hot isostatic pressing is also applicable for manufacturing products having internal channels and cavities, e.g. for heating and cooling of components. Cavities and channels can be manufactured by making into the powder capsule a capsule corresponding with the desired channel and cavity structure and by filling with powder the space between the capsule surrounding the whole structure and the capsule forming the channel and cavity. The accuracy of the location of these channels is in general critical with respect to the heating or cooling of the components and, in addition, it can have influence on the mechanical reliability of the structure.
In many cases it is, however, not possible to achieve a sufficient dimensional accuracy by means of the powder metallurgic technology alone, because the contraction of the powder is not sufficiently controlled or the starting density before consolidation is not homogenous enough for the controlled consolidation. In that case an alternative is to use in the component a solid basic material, in which that part of the powder is encapsulated, into which the channels and cavities are formed. Thus, the amount of the contracting powder is minimized and, in addition, the contracting can be controlled so that a better predictability of the consolidation can be achieved. Even in those cases the control of the dimensions in the most critical objects is not accurate enough, because for example when large surfaces are consolidated, the dimensional changes are too big.
One alternative that has been used to some extent is to use solid basic materials, the joint surfaces of which are confronted against each other accurately. The joint surfaces are placed in the surrounding capsule so that the pressure in the hot isostatic pressing presses the surfaces against each other, thus providing a diffusion bonding. In this method the surfaces of the solid pieces to be joined must be well finished, especially clean and even, to ensure an adequate quality of the bonding. In addition, typically, the temperature and pres- sure of the hot isostatic pressing must be increased and the time prolonged compared with a powder metallurgic bonding, in order to ensure the good quality of the bonding. On the other hand, even the smallest impurities of the joint surfaces or moving of the surfaces during the hot isostatic pressing can prevent the bonding or weaken its quality significantly.
Description of the Invention
In the method in accordance with the invention the component is manufactured so, that substantially solid, preformed pieces produced by forging, casting or machining are used, and material in powder form, in an encapsulated space, is used for the joint surfaces of the solid pieces to be joined by isostatic pressing, More precisely, the method in accordance with the invention is characterized in by what has been stated in the characterizing part of Claim 1.
The invention will be described in more detail in the following, with reference to the enclosed drawings, in which
Figures la - lc show examples of embodiments of the method in accordance with the invention.
Figure la shows one embodiment of an application of the method in accordance with the invention. In the figure, the joint area of the solid pieces 1, 1' and 1" has been sealed with gas-tight welds 3 and a capsule plate 4. The area formed in that way has been filled with powder material 2. In this embodiment the welds between the joint surfaces have been partly made directly between the solid pieces. The gas tightness is a precondition for using the hot isostatic pressing. After this the powder has been consolidated by means of pres- sure and/or temperature, like for example by hot isostatic pressing. The capsule plates and welds connected thereto can remain in the component or they can be removed for example by machining and in certain cases by acid etching.
In the embodiment shown in Figure lb, the embodiment of Figure la has been improved by replacing the gas tight welds that bond the solid pieces directly with each other by cap- sule plates 4' . This is a way to improve the gas tightness of these joints.
In the embodiment of Figure lc, the amount of powder to be used in the joint has been minimized. In the figure, the area formed into the jointing point of the solid pieces 1, 1' and 1" has been filled with powder 2 and solid material 5 in order to minimize the amount of the powder material. The joint area is sealed gas tightly by means of gas tight welds 3 and a capsule plate 4. With a solution in accordance with this embodiment, the changes in the volume and dimensional accuracy caused by the consolidation of the powder can be minimized.
Due to the use of powder materials, the requirements for the dimensional accuracy of the joint surfaces are not as big as when using only solid materials. In addition, due to the strong plastic deformation caused by the consolidation of the powder, the oxide films of the junctions of the powder and solid material are efficiently broken, thus providing a more reliable and better joint compared with the solid-solid-joint.
As the amount of the powder to be used is very much limited only at the junctions of the pieces to be joined, the dimensional changes caused by the contraction of the powder are not big, whereby more accurate dimensions are achieved after the hot isostatic pressing, than by using as basic material a capsule totally filled with powder or powder encapsulated on the surface of the solid material. For example the capsule surrounding the joint surfaces can be (I) welded to the solid materials at both sides of the joint, (II) the whole interior of the concave or the channel can be encapsulated and (III) in addition, gas-tight capsules can be manufactured between the solid materials, said capsules transmitting the isostatic gas pressure to the joint surface and consolidating the powder between the joint surfaces.
The following advantages, among others, can be achieved by the method of the invention:
(a) Components having more accurate dimensions can be manufactured by means of the method in accordance with the present invention, than by using materials manufactured by means of powder only or by using powder encapsulated into the surface of the solid material for sealing the internal concaves,
(b) More reliable joints can be achieved by means of the method in accordance with the present invention, than by connecting solid materials by hot isostatic pressing; in addition, the requirements for dimensional accuracy of the joint surfaces of the solid materials are not as big,
(c) The joints in the components are mainly free of welding joints; welding joints can be left to the gas tight welds surrounding the joint surfaces inside the component, but they form only a small part of the load bearing cross surface, and in addition, eventual welding mistakes not opening to the surface are closed during the hot isostatic pressing.

Claims

1. A method for manufacturing metallic components including channels and concaves, wherein pre-blanks are produced of solid materials and metal powder is used between their joint surfaces, characterized in, that - the pre-blanks are joined together so, that the joint surfaces of the preformed blanks forming the internal concaves have been sealed gas-tightly, and when the powder between the components is consolidated effected by the temperature and/or pressure, the solid pre-blanks attach to each other, thus forming a ready component with concaves and channels.
2. A method in accordance with claim 1, characterized in, that the consolidation of the powder and the bonding is achieved by means of hot isostatic pressing caused by the simultaneously effecting isostatic and high temperature.
3. A method in accordance with claim 1 or 2, characterized in, that the hot isostatic pressing is performed in a temperature that is at least 60 % of the melting point of the material having the lowest melting point.
4. A method in accordance with any of the claims from 1 to 3, characterized in, that the hot isostatic pressing is performed in a pressure of at least 50 MPa.
5. A method in accordance with any of the claims from 1 to 4, characterized in, that the solid material and the material in powder form can be the same material or different materials.
PCT/FI2004/000408 2003-06-30 2004-06-30 Pulver metallurgical component production WO2005000504A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP04742151A EP1638718A1 (en) 2003-06-30 2004-06-30 Pulver metallurgical component production

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI20030980 2003-06-30
FI20030980A FI120230B (en) 2003-06-30 2003-06-30 A method for manufacturing metal components containing internal cavities and ducts

Publications (1)

Publication Number Publication Date
WO2005000504A1 true WO2005000504A1 (en) 2005-01-06

Family

ID=8566331

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/FI2004/000408 WO2005000504A1 (en) 2003-06-30 2004-06-30 Pulver metallurgical component production

Country Status (3)

Country Link
EP (1) EP1638718A1 (en)
FI (1) FI120230B (en)
WO (1) WO2005000504A1 (en)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1414413A (en) 1973-05-18 1975-11-19 Contour Saws Bimetal saw blade stock and method of making the same
US4537097A (en) * 1983-01-07 1985-08-27 Christensen, Inc. Method and apparatus for manufacturing cutting elements particularly for deep drilling
US4627958A (en) * 1983-12-27 1986-12-09 Gray Tool Company Densification of metal powder to produce cladding of valve interiors by isodynamic compression
US4748059A (en) * 1985-10-17 1988-05-31 Crucible Materials Corporation Assembly for producing extrusion-clad tubular product
US4933141A (en) * 1988-03-28 1990-06-12 Inco Alloys International, Inc. Method for making a clad metal product
EP1354653A1 (en) * 2002-04-16 2003-10-22 Delphi Technologies, Inc. Sinterbonded electric machine components

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1414413A (en) 1973-05-18 1975-11-19 Contour Saws Bimetal saw blade stock and method of making the same
US4537097A (en) * 1983-01-07 1985-08-27 Christensen, Inc. Method and apparatus for manufacturing cutting elements particularly for deep drilling
US4627958A (en) * 1983-12-27 1986-12-09 Gray Tool Company Densification of metal powder to produce cladding of valve interiors by isodynamic compression
US4748059A (en) * 1985-10-17 1988-05-31 Crucible Materials Corporation Assembly for producing extrusion-clad tubular product
US4933141A (en) * 1988-03-28 1990-06-12 Inco Alloys International, Inc. Method for making a clad metal product
EP1354653A1 (en) * 2002-04-16 2003-10-22 Delphi Technologies, Inc. Sinterbonded electric machine components

Also Published As

Publication number Publication date
FI20030980A (en) 2004-12-31
EP1638718A1 (en) 2006-03-29
FI20030980A0 (en) 2003-06-30
FI120230B (en) 2009-08-14

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