WO2009115821A1 - Net-shape or near net-shape powder isostatic pressing process - Google Patents

Net-shape or near net-shape powder isostatic pressing process Download PDF

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Publication number
WO2009115821A1
WO2009115821A1 PCT/GB2009/000757 GB2009000757W WO2009115821A1 WO 2009115821 A1 WO2009115821 A1 WO 2009115821A1 GB 2009000757 W GB2009000757 W GB 2009000757W WO 2009115821 A1 WO2009115821 A1 WO 2009115821A1
Authority
WO
WIPO (PCT)
Prior art keywords
insert
powder
containment
net
mould
Prior art date
Application number
PCT/GB2009/000757
Other languages
French (fr)
Inventor
Geoffrey Frederick Archer
Original Assignee
Advanced Interactive Materials Science Limited
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 Advanced Interactive Materials Science Limited filed Critical Advanced Interactive Materials Science Limited
Priority to US12/736,207 priority Critical patent/US20110033725A1/en
Priority to BRPI0909088A priority patent/BRPI0909088A2/en
Priority to ES09721920.8T priority patent/ES2530092T3/en
Priority to EA201001527A priority patent/EA019527B1/en
Priority to EP09721920.8A priority patent/EP2262599B1/en
Priority to CN2009801098127A priority patent/CN102026752A/en
Priority to MX2010010146A priority patent/MX2010010146A/en
Publication of WO2009115821A1 publication Critical patent/WO2009115821A1/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
    • 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 750mm, 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 10mm 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 750mm, 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 2m, 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 6mm to 10mm 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 2m 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 Im and a radius of 50mm 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.

Abstract

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 750mm, 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 can 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, such as a canister or a sprayed coating. The insert can be a metallic insert of a material, such as copper, that is subsequently removable by chemical etching. The insert can be coated with a material that is amenable to removal by etching, and to enable the insert to be extracted. A metallic insert can be coated with a 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.

Description

NET-SHAPE OR NEAR NET-SHAPE POWDER ISOSTATIC
PRESSING PROCESS
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 750mm, 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 10mm can be machined.
We consider that it would be of advantage in certain circumstances to provide a bore of accurate dimensions extending lengthwise through a component of length approximately 2m, the component desirably being produced from a powder by a hot isostatic pressing process so as to provide hard wearing properties.
According to one aspect of the invention 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 750mm, 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. As is well known, 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
Preferably 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.
In suitable cases 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.
Preferably 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. In one preferred embodiment a copper rod, of a diameter in the range of 6 to 10 mm for example and of length greater than 2m, 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 Al2O3 applied by vapour phase deposition or by high velocity spraying. Alternatively, the diffusion barrier may be created by applying boron nitride as an aqueous solution by spraying.
In a second embodiment a preformed metal tube, of 6mm to 10mm 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.
During consolidation 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.
Example
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 2m 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 Im and a radius of 50mm 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.

Claims

1. A method of producing a net or near net- shape component from metal powder comprising 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 750mm, 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.
2. The method of claim 1 in which the mould is 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.
3. The method of claim 2 in which the containment is a canister.
4. The method of claim 2 in which the containment is a sprayed coating.
5. The method of claim 1 or claim 2 in which 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.
6. The method of any one of the preceding claims in which the insert is a metallic insert of a material that is subsequently removable by chemical etching.
7. The method of claim 6 in which the insert comprises copper.
8. The method of claim 7 in which the chemical etching is assisted by electrolytic reaction.
9. The method of any one of the preceding claims in which the insert is coated with a material that is amenable to removal by etching, and comprising the steps of releasing the insert by etching the coating, and then extracting the insert.
10. The method of any one of the claims 6 to 9 in which the metallic insert is coated with a material that provides a diffusion barrier to prevent the material of the insert from diffusing by atomic diffusion into the powder being consolidated during HlPing.
11. The method of claim 10 in which the diffusion barrier comprises Al2O3 applied by vapour phase deposition.
12. The method of claim 10 in which the diffusion barrier comprises Al2O3 applied by high velocity spraying.
13. The method of claim 10 in which the diffusion barrier is created by applying boron nitride as an aqueous solution by spraying.
14. The method of claim 1 in which the insert is produced by taking a copper rod, of a diameter in the range of 6 to 10 mm and of length greater than 2m, bending the copper rod into a helix of the required dimensions, and then holding the helical rod in position in a powder containment prior to filling the containment with powder, the containment enclosing the powder, rod and former, and then consolidating the powder by solid state diffusion using a HIPing method.
15. The method of claim 1 in which the insert is produced by taking a preformed metal tube, of 6mm to 10mm diameter, filling the tube with ceramic particles, and bending the filled tube to a helical shape, placing the helical filled tube within the powder containment prior to filling the containment with powder, holding the tube in position with formers compatible with the finally consolidated powder, providing a containment encompassing the metallic and/or cermet/MMC powder, and then consolidating the contained material by solid state diffusion using a HIPing method.
16. The method of claim 15 comprising removing the ceramic particles mechanically by a vibration technique to leave a clean hole through the finished component.
17. A net or near net-shape component produced by the method of any one of the preceding claims.
PCT/GB2009/000757 2008-03-20 2009-03-20 Net-shape or near net-shape powder isostatic pressing process WO2009115821A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
US12/736,207 US20110033725A1 (en) 2008-03-20 2009-03-20 Net-shape or near net-shape powder isostatic pressing process
BRPI0909088A BRPI0909088A2 (en) 2008-03-20 2009-03-20 isostatic powder pressing process near final or final shape
ES09721920.8T ES2530092T3 (en) 2008-03-20 2009-03-20 Isostatic pressing process of finished or almost finished powder
EA201001527A EA019527B1 (en) 2008-03-20 2009-03-20 Net-shape or near net-shape powder isostatic pressing process
EP09721920.8A EP2262599B1 (en) 2008-03-20 2009-03-20 Net-shape or near net-shape powder isostatic pressing process
CN2009801098127A CN102026752A (en) 2008-03-20 2009-03-20 Net-shape or near net-shape powder isostatic pressing process
MX2010010146A MX2010010146A (en) 2008-03-20 2009-03-20 Net-shape or near net-shape powder isostatic pressing process.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0805242.5 2008-03-20
GBGB0805242.5A GB0805242D0 (en) 2008-03-20 2008-03-20 Net-shape or near net-shape powder isostatic pressing process

Publications (1)

Publication Number Publication Date
WO2009115821A1 true WO2009115821A1 (en) 2009-09-24

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2009/000757 WO2009115821A1 (en) 2008-03-20 2009-03-20 Net-shape or near net-shape powder isostatic pressing process

Country Status (9)

Country Link
US (1) US20110033725A1 (en)
EP (1) EP2262599B1 (en)
CN (1) CN102026752A (en)
BR (1) BRPI0909088A2 (en)
EA (1) EA019527B1 (en)
ES (1) ES2530092T3 (en)
GB (1) GB0805242D0 (en)
MX (1) MX2010010146A (en)
WO (1) WO2009115821A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011077150A3 (en) * 2009-12-23 2011-09-22 Advanced Interactive Materials Science Limited Improvements in or relating to hot isostatic pressing

Families Citing this family (6)

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Publication number Priority date Publication date Assignee Title
CN102366836B (en) * 2011-10-25 2013-08-14 航天材料及工艺研究所 Production method of high-performance titanium alloy blind pipe
CN103586468B (en) * 2013-11-08 2015-04-15 中国航空工业集团公司北京航空材料研究院 TiAl alloy powder near-net-shaping method
CN104972114A (en) * 2014-04-25 2015-10-14 华中科技大学 Hot isostatic pressing integrated forming method of complex part with special functional layer
JP6417586B2 (en) * 2014-08-25 2018-11-07 セイコーエプソン株式会社 Modeling method and model
CN105458265B (en) * 2015-11-14 2018-07-31 华中科技大学 A kind of hot isostatic pressing use control pattern core, its manufacturing method and its application of recyclable reuse
CN108421980B (en) * 2018-03-16 2019-07-19 华中科技大学 A kind of hot isostatic pressing manufacturing process based on increasing material manufacturing

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Cited By (5)

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Publication number Priority date Publication date Assignee Title
WO2011077150A3 (en) * 2009-12-23 2011-09-22 Advanced Interactive Materials Science Limited Improvements in or relating to hot isostatic pressing
CN103068505A (en) * 2009-12-23 2013-04-24 高级交互材料科学有限公司 Improvements in or relating to hot isostatic pressing
US9095902B2 (en) 2009-12-23 2015-08-04 Advanced Interactive Materials Science Limited Hot isostatic pressing
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Also Published As

Publication number Publication date
BRPI0909088A2 (en) 2015-09-29
CN102026752A (en) 2011-04-20
EP2262599A1 (en) 2010-12-22
GB0805242D0 (en) 2008-04-30
EP2262599B1 (en) 2014-11-12
ES2530092T3 (en) 2015-02-26
MX2010010146A (en) 2010-10-20
EA019527B1 (en) 2014-04-30
US20110033725A1 (en) 2011-02-10
EA201001527A1 (en) 2011-04-29

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