WO2005030417A1 - Procede de production de composants - Google Patents

Procede de production de composants Download PDF

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Publication number
WO2005030417A1
WO2005030417A1 PCT/DE2004/001872 DE2004001872W WO2005030417A1 WO 2005030417 A1 WO2005030417 A1 WO 2005030417A1 DE 2004001872 W DE2004001872 W DE 2004001872W WO 2005030417 A1 WO2005030417 A1 WO 2005030417A1
Authority
WO
WIPO (PCT)
Prior art keywords
sintering
another
during
molded
injection molding
Prior art date
Application number
PCT/DE2004/001872
Other languages
German (de)
English (en)
Inventor
Gerhard Andrees
Josef Kranzeder
Max Kraus
Raimund Lackermeier
Original Assignee
Mtu Aero Engines Gmbh
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 Mtu Aero Engines Gmbh filed Critical Mtu Aero Engines Gmbh
Priority to US10/572,765 priority Critical patent/US20070202000A1/en
Priority to DE502004003171T priority patent/DE502004003171D1/de
Priority to EP04786170A priority patent/EP1663554B1/fr
Publication of WO2005030417A1 publication Critical patent/WO2005030417A1/fr

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
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy

Definitions

  • the invention relates to a method for producing components, preferably a gas turbine, according to the preamble of patent claim 1.
  • the most important materials used today for aircraft engines or other gas turbines are titanium alloys, nickel alloys (also called super alloys) and high-strength steels.
  • the high-strength steels are used for shaft parts, gear parts, compressor housings and turbine housings. Titanium alloys are typical materials for compressor parts. Nickel alloys are suitable for the hot parts of the aircraft engine.
  • Powder-metallurgical injection molding has proven itself in the manufacture or manufacture of precision components from metallic or ceramic powders. Powder-metallurgical injection molding is related to plastic injection molding and is also known as metal mold injection or metal injection molding (MIM). Powder-metallurgical injection molding can be used to manufacture components that achieve almost the full density and approx. 95% of the static strength of forged parts. The reduced dynamic strength compared to forged parts can be compensated for by suitable material selection.
  • MIM metal mold injection or metal injection molding
  • a powder preferably a metal powder, hard metal powder or ceramic powder
  • a binder and optionally a plasticizer to form a homogeneous mass becomes.
  • Shaped bodies are produced from this homogeneous mass by injection molding.
  • the injection molded moldings already have the geometric shape of the component to be produced, but their volume is increased by the volume of the binder and plasticizer added.
  • the binder and plasticizer are removed from the injection molded moldings in a debinding process. Subsequently, the shaped body is compressed or shrunk to form the finished component during the sintering.
  • the volume of the molded body decreases, whereby it is crucial that the dimensions of the molded part must shrink uniformly in all three spatial directions.
  • the volume shrinkage is between 30% and 60% depending on the binder and plasticizer content.
  • powder metallurgical injection molding is usually carried out in such a way that each molded body is subjected to the debinding process and then sintered for itself. If necessary, only after the actual powder metallurgy injection molding are several components manufactured by powder metallurgy injection molding connected to one another using suitable joining methods. With the powder metallurgical injection molding processes known from the prior art, the production of components with a complex, three-dimensional shape is therefore only possible to a limited extent.
  • the present invention is based on the problem of proposing a novel method for producing components.
  • a plurality of moldings are connected to one another during the sintering by a diffusion process in order to produce a component.
  • the molded bodies to be connected to one another are brought into surface contact, at least during the sintering, on sections of the molded bodies to be connected, preferably into a form-fitting surface contact, pressure being exerted on the components to be connected during the sintering and during the simultaneous diffusion process Shaped body is exercised.
  • the method according to the invention is used in particular for producing blades or blade segments from a plurality of blades of an aircraft engine, these blades or blade segments being made of a nickel-based alloy or also a titanium-based alloy.
  • Fig. 1 a block diagram to illustrate the individual process steps in powder metallurgical injection molding
  • FIG. 2 shows a cross section through two molded bodies to be connected to one another with the aid of the method according to the invention
  • the present invention relates to the production of components, preferably a gas turbine, in particular an aircraft engine, by powder-metallurgical injection molding (PM). Powder metallurgical injection molding is also known as metal injection molding (MIM).
  • PM powder-metallurgical injection molding
  • MIM metal injection molding
  • a metal powder, hard metal powder or ceramic powder is provided in a first step 10.
  • a binder and optionally a plasticizer are provided in a second step 11.
  • the metal powder provided in process step 10 and the binder and plasticizer provided in process step 11 are mixed in process step 12 so that a homogeneous mass is formed.
  • the volume proportion of the metal powder in the homogeneous mass is preferably between 40% and 70%.
  • the proportion of binder and plasticizer in the homogeneous mass fluctuates approximately between 30% and 60%.
  • This homogeneous mass of metal powder, binder and plasticizer is further processed in the sense of step 13 by injection molding. Moldings are manufactured during injection molding. These moldings already have all the typical features of the components to be produced. In particular, the shaped bodies have the geometric shape of the component to be manufactured. However, they have a volume increased by the binder content and plasticizer content.
  • Process step 14 the binder and the plasticizer are expelled from the moldings.
  • Process step 14 can also be referred to as the final binding process. Binding agents and plasticizers can be driven out in different ways. This is usually done by fractional, thermal decomposition or evaporation. Another possibility is to suck out the thermally liquefied binding and plasticizing agents by capillary forces, by sublimation or by solvents.
  • the shaped bodies are sintered in the sense of step 15.
  • the Shaped body compressed to the components with the final, geometric properties. Accordingly, the shaped bodies shrink during sintering, the dimensions of the shaped bodies having to shrink uniformly in all three spatial directions.
  • the linear shrinkage is between 10% and 20% depending on the binder content and plasticizer content.
  • step 16 the finished component is present, which is represented by step 16 in FIG. 1.
  • the component can still be subjected to a finishing process in the sense of step 17.
  • the finishing process is optional.
  • a ready-to-install component can already be present immediately after sintering.
  • the component is formed from a plurality of moldings, the moldings being connected to one another by a diffusion process during powder-metallurgical injection molding.
  • the component to be manufactured can be composed of two shaped bodies, the two shaped bodies being connected to one another during the sintering by the diffusion process. It is also possible to connect a larger number of shaped bodies to one component during the sintering.
  • the shaped bodies are brought into surface contact at sections or surface areas thereof to be connected to one another.
  • a pressure is exerted on the touching shaped bodies or the touching sections of the shaped bodies during the diffusion process.
  • the surface contact between the molded bodies to be connected to one another and the application of pressure thereon takes place at least during the sintering.
  • the diffusion process therefore takes place during sintering.
  • the surface contact and the pressure on the molded bodies that are in contact and to be connected to one another already during a pre-sintering and / or during the debinding process are also possible to apply the surface contact and the pressure on the molded bodies that are in contact and to be connected to one another already during a pre-sintering and / or during the debinding process.
  • the preferred procedure is that the surface contact is already provided during the debinding process and during the pre-sintering as well as during the actual sintering, but the pressure is only exerted on the shaped bodies during the actual sintering.
  • the pre-sintering takes place between the debinding process and the actual sintering, wherein during the pre-sintering there is still no noticeable shrinkage process of the molded bodies to be joined together.
  • the molded bodies are brought into a form-fitting surface contact. This is explained below with reference to FIGS. 2 to 4.
  • FIG. 2 shows two molded bodies 18 and 19 to be connected to one another during powder metallurgical injection molding via a diffusion process.
  • the molded bodies 18 and 19 touch one another at sections or surface regions 20 and 21.
  • the surface region 20 is the Shaped body 18 is wedge-shaped in cross section.
  • This wedge-shaped surface area 20 of the molded body 18 engages in a form-fitting manner in the correspondingly formed surface area 21 of the molded body 19.
  • the surface area 21 of the molded body 19 accordingly forms a wedge-shaped groove in cross section.
  • FIG. 3 shows an alternative embodiment of two molded bodies 22 and 23 to be connected to one another. Also in the exemplary embodiment in FIG. 3, surface regions 24 and 25 of the molded bodies 22 and 23 to be connected to one another are in positive contact. For this purpose, a projection with a trapezoidal cross section is formed on the surface area 25 of the molded body 23, which engages in a correspondingly formed recess in the surface area 24 of the molded body 22.
  • FIG. 4 shows another possible embodiment of two molded bodies 26 and 27 to be connected to one another.
  • surface regions 28 and 29 of the two molded bodies 26 and 27 to be connected to one another are again in positive contact with one another, in contrast to the exemplary embodiment according to FIG. 3 in the exemplary embodiment according to FIG. 4, the projection or the recess in the area of the sections or the surface areas 28 and 29 is not trapezoidal in cross section, but rather rectangular in cross section.
  • the molded bodies 18 and 19 or 22 and 23 to be connected to one another are arranged laterally next to one another, in the exemplary embodiment in FIG. 4 the molded bodies 26 and 27 are positioned one above the other.
  • the positive connection between the molded bodies to be connected to one another during the sintering by the diffusion process improves the dimensional accuracy of the component to be produced.
  • the molded bodies to be connected to one another in the sense of the present invention can be designed identically both with regard to their material composition and / or with regard to their shrinkage properties, and can also have different properties in this regard. If the material compositions and the shrinking properties of the molded articles to be connected to one another are identical, a uniform shrinkage process occurs for the molded articles to be connected to one another during sintering.
  • shaped bodies with different shrinkage properties in the sense of the present invention can also be connected to one another via the diffusion process during sintering. It is also within the meaning of the present invention to sinter a molded article with a larger shrinkage amount during sintering onto a molded article with a smaller shrinkage amount. In the exemplary embodiments shown in FIGS. 2 to 4, this would mean that the shaped bodies 19, 22 and 26 have a larger amount of shrinkage and thus shrink more than the shaped bodies 18, 23 and 27.
  • Shaped bodies with different shrinkage properties can be provided by using shaped bodies with different material compositions.
  • molded bodies can be used which are formed from different metal powders and thus different metal alloys. Shaped bodies made of different metal powders which are connected, it must be ensured that the sintering temperature or diffusion temperature of the metal powder is of the same order of magnitude, so that the shrinkage of the shaped bodies also takes place at the same time.
  • the material composition for providing shaped articles with different shrinkage properties can also be changed by varying the type and extent of the binder. Different shrinkage properties can also be achieved with the same material composition by pre-sintering moldings with the same material composition.
  • Another alternative of the present invention is to compensate for the different shrinkage behavior when using shaped bodies with different shrinkage behavior in that the shaped bodies are processed by an upstream pre-sintering process before the actual sintering.
  • the different shrinkage behavior of the molded bodies to be connected to one another can be compensated for so that the shrinkage behavior of the molded bodies is matched to one another during the actual sintering.
  • the different shrinkage behavior can be compensated for by the fact that the shaped bodies, which consist, for example, of different metal powders, also differ in terms of their binders and optionally plasticizers or in terms of their percentage composition of metal powder, binders and optionally plasticizers.
  • This also makes it possible to compensate for the different shrinkage behavior if, for example, molded articles made of different metal powders are to be joined together.
  • the sintering temperature or diffusion temperature of the material compositions of the shaped bodies is of the same order of magnitude, so that the shrinkage of the shaped bodies also takes place at the same time.
  • the surfaces thereof touching one another can have a coating.
  • This coating then forms what is known as a sintering aid, which can be applied as a film or as a slip material or slip layer to the surface regions of the moldings to be brought into surface contact.
  • This coating which enhances the diffusion effect, can be applied to at least one of the surface areas or sections to be connected to one another or also to both or all sections to be connected to one another.
  • the sintering can also be carried out under a special gas atmosphere which supports the diffusion effect.
  • the method according to the invention is particularly suitable for producing components of a gas turbine, in particular an aircraft engine. It is within the scope of the present invention to manufacture blades or blade segments or rotors with integral blading - so-called blisks (B

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé de production de composants, de préférence d'une turbine à gaz, en particulier d'un propulseur d'avion, ce procédé faisant appel au moulage par injection de poudre métallique. Lors du moulage par injection de poudre métallique, on mélange d'abord une poudre métallique avec un liant de façon à obtenir une masse homogène, et ensuite on réalise, par moulage par injection de cette masse homogène, au moins un corps moulé, le ou chaque corps moulé étant alors soumis à un processus de déliantage. Enfin, le ou chaque corps moulé est comprimé par frittage pour former au moins un composant présentant les caractéristiques géométriques voulues. Selon l'invention, lors du frittage, pour la production d'un composant, plusieurs corps moulés sont assemblés par un procédé de diffusion. De préférence, les corps moulés à assembler sont, au moins pendant le frittage, mis en contact superficiel au niveau de leurs parties à assembler, de préférence en contact superficiel avec liaison de forme, une pression étant exercée, pendant le frittage, sur les corps moulés à assembler.
PCT/DE2004/001872 2003-09-22 2004-08-24 Procede de production de composants WO2005030417A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US10/572,765 US20070202000A1 (en) 2004-08-24 2004-08-24 Method For Manufacturing Components
DE502004003171T DE502004003171D1 (de) 2003-09-22 2004-08-24 Verfahren zur herstellung von bauteilen einer gastubine
EP04786170A EP1663554B1 (fr) 2003-09-22 2004-08-24 Procede de production de composants d'une turbine à gaz

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10343782.7 2003-09-22
DE10343782A DE10343782A1 (de) 2003-09-22 2003-09-22 Verfahren zur Herstellung von Bauteilen

Publications (1)

Publication Number Publication Date
WO2005030417A1 true WO2005030417A1 (fr) 2005-04-07

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ID=34306008

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/DE2004/001872 WO2005030417A1 (fr) 2003-09-22 2004-08-24 Procede de production de composants

Country Status (3)

Country Link
EP (1) EP1663554B1 (fr)
DE (2) DE10343782A1 (fr)
WO (1) WO2005030417A1 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1721699A1 (fr) * 2005-05-05 2006-11-15 General Electric Company Méthode de fabrication d'aubes de turbine utilisant le frittage d'une poudre métallique par micro ondes
WO2006122518A2 (fr) * 2005-05-18 2006-11-23 Schaeffler Kg Anneau de roulement destine en particulier a des roulements soumis a de fortes contraintes dans des reacteurs d'avions, et procede de realisation
WO2007098739A1 (fr) * 2006-03-03 2007-09-07 Mtu Aero Engines Gmbh Procédé de fabrication d'un segment d'étanchéité et segment d'étanchéité à utiliser dans des composants de turbine et de compresseur
GB2448031A (en) * 2007-03-26 2008-10-01 Gen Electric Metal Injection Moulding Process for Bimetalllic Applications and Airfoils
WO2009012556A1 (fr) * 2007-07-24 2009-01-29 Pratt & Whitney Canada Corp. Procédé de fabrication de collier flottant d'injecteur de carburant
EP2233232A1 (fr) * 2009-03-20 2010-09-29 Pratt & Whitney Canada Corp. Procédé de réunion de pièces moulée par injection de poudre
FR2944724A1 (fr) * 2009-04-24 2010-10-29 Snecma Procede de fabrication d'un ensemble comprenant une pluralite d'aubes montees dans une plateforme
US9970318B2 (en) 2014-06-25 2018-05-15 Pratt & Whitney Canada Corp. Shroud segment and method of manufacturing

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013004807B4 (de) 2013-03-15 2018-12-20 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zur Herstellung von gesinterten Bauteilen
DE102013207440A1 (de) * 2013-04-24 2014-10-30 Bosch Mahle Turbo Systems Gmbh & Co. Kg Verfahren zur Herstellung eines Hebels einer variablen Turbinengeometrie

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4813823A (en) * 1986-01-18 1989-03-21 Fried. Krupp Gesellschaft Mit Beschrankter Haftung Drilling tool formed of a core-and-casing assembly
US5487773A (en) * 1991-10-18 1996-01-30 Fujitsu Limited Process for producing sintered body and magnet base
EP0995525A1 (fr) * 1998-05-07 2000-04-26 Injex Corporation Procede pour realiser un produit fritte
DE10053199A1 (de) * 1999-10-28 2001-05-03 Denso Corp Verfahren zur Herstellung eines Preßlings aus Metallverbundwerkstoff

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4813823A (en) * 1986-01-18 1989-03-21 Fried. Krupp Gesellschaft Mit Beschrankter Haftung Drilling tool formed of a core-and-casing assembly
US5487773A (en) * 1991-10-18 1996-01-30 Fujitsu Limited Process for producing sintered body and magnet base
EP0995525A1 (fr) * 1998-05-07 2000-04-26 Injex Corporation Procede pour realiser un produit fritte
DE10053199A1 (de) * 1999-10-28 2001-05-03 Denso Corp Verfahren zur Herstellung eines Preßlings aus Metallverbundwerkstoff

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7282681B2 (en) 2005-05-05 2007-10-16 General Electric Company Microwave fabrication of airfoil tips
EP1721699A1 (fr) * 2005-05-05 2006-11-15 General Electric Company Méthode de fabrication d'aubes de turbine utilisant le frittage d'une poudre métallique par micro ondes
US7685711B2 (en) 2005-05-05 2010-03-30 Thomas Joseph Kelly Microwave fabrication of airfoil tips
US7857518B2 (en) 2005-05-18 2010-12-28 Schaeffler Kg Antifriction bearing race, particularly for highly stressed antifriction bearings in aircraft power units
WO2006122518A2 (fr) * 2005-05-18 2006-11-23 Schaeffler Kg Anneau de roulement destine en particulier a des roulements soumis a de fortes contraintes dans des reacteurs d'avions, et procede de realisation
WO2006122518A3 (fr) * 2005-05-18 2007-01-04 Schaeffler Kg Anneau de roulement destine en particulier a des roulements soumis a de fortes contraintes dans des reacteurs d'avions, et procede de realisation
WO2007098739A1 (fr) * 2006-03-03 2007-09-07 Mtu Aero Engines Gmbh Procédé de fabrication d'un segment d'étanchéité et segment d'étanchéité à utiliser dans des composants de turbine et de compresseur
GB2448031A (en) * 2007-03-26 2008-10-01 Gen Electric Metal Injection Moulding Process for Bimetalllic Applications and Airfoils
WO2009012556A1 (fr) * 2007-07-24 2009-01-29 Pratt & Whitney Canada Corp. Procédé de fabrication de collier flottant d'injecteur de carburant
EP2233232A1 (fr) * 2009-03-20 2010-09-29 Pratt & Whitney Canada Corp. Procédé de réunion de pièces moulée par injection de poudre
US10226818B2 (en) 2009-03-20 2019-03-12 Pratt & Whitney Canada Corp. Process for joining powder injection molded parts
US11383299B2 (en) 2009-03-20 2022-07-12 Pratt & Whitney Canada Corp. Process for joining powder injection molded parts
FR2944724A1 (fr) * 2009-04-24 2010-10-29 Snecma Procede de fabrication d'un ensemble comprenant une pluralite d'aubes montees dans une plateforme
US9970318B2 (en) 2014-06-25 2018-05-15 Pratt & Whitney Canada Corp. Shroud segment and method of manufacturing

Also Published As

Publication number Publication date
EP1663554B1 (fr) 2007-03-07
DE502004003171D1 (de) 2007-04-19
EP1663554A1 (fr) 2006-06-07
DE10343782A1 (de) 2005-04-14

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