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
  • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
  • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
  • B22F7/04—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
• • 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
  • B22F3/10—Sintering only
  • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
• • 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
  • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than 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
  • 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
  • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
  • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
  • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
  • B22F7/064—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts using an intermediate powder layer
• • 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
  • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
  • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
  • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
  • B23P6/00—Restoring or reconditioning objects
  • B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
  • B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
• • 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
  • B22F3/10—Sintering only
  • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
  • B22F2003/1051—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding by electric discharge
• • 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
• • 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
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49316—Impeller making
  • Y10T29/49318—Repairing or disassembling
• • 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
  • Y10T428/12014—All metal or with adjacent metals having metal particles
  • Y10T428/12021—All metal or with adjacent metals having metal particles having composition or density gradient or differential porosity

Definitions

• the invention relates to a local process of reloading damaged thermomechanical part having undergone strong constraints of use, for example by corrosion, erosion or wear. It also relates to the parts produced by this method and applies more particularly, but not exclusively, to the turbine parts.
• the field of the invention is that of nickel-based superalloy refractory materials. These materials are capable of constituting thermomechanical parts, in particular gas turbine parts in the field of aeronautics, such as moving blades of stator or distributor, their platform, their foot or other equipment, particularly resistant to corrosion and oxidation.
• one solution is to bring the material, in solid form, at the area to be recharged.
• the material is then in preforms cut from plate, or ribbon, made from a mixture of superalloy powders and solder raised to high temperature in a suitable oven.
• This mixture is thus sintered because of the low melting point eutectics generated by the mixing of the powders.
• the "sintered" thus obtained are then docked on the areas of the part to be repaired, previously cleaned, and the whole is brought to temperature. Diffusion-soldering phenomena then occur and the sinter is soldered to the surface of the workpiece.
• the sintered plate is cut with a water jet to form plane preforms of 2D two-dimensional configuration.
• a remission to the profile of the piece is performed by machining the planar areas to give it a geometry close to the original geometry and thus confer the proper aerodynamic properties.
• This method involves the presence of solder powder, so melting elements distributed throughout the thickness of the sintered.
• the presence of melting elements has a negative impact on thermomechanical performance.
• the invention aims to overcome the disadvantages of the state of the art by proposing to achieve a simple, fast and efficient sintered accurate three-dimensional (3D) shape substantially similar to that of the original part.
• the invention involves a flash sintering produced by SPS technology (initials of "Spark Plasma Sintering", that is to say “plasma sintering plasma” in English terminology).
• the SPS technology combines, simultaneously, the application of a high uniaxial pressure and high intensity DC pulses causing an almost immediate and uniform temperature rise.
• This technology is known in the field of powder metallurgy which allows, by agglomeration and compaction, to manufacture metal parts or metal oxides from powders.
• the implementation of SPS flash technology makes it possible to manufacture parts with particular and controllable microstructures.
• the present invention relates to a method of local reloading thermomechanical room superalloy.
• the method consists, in a preparatory step, of producing a mold in a flash-sintered SPS enclosure matrix, the mold having an imprint-like shape of at least a part of the reloading of the damaged part, to be introduced into the mold at least one layer of solder powder and at least one layer of superalloy powder constituting a multilayer assembly.
• this sintering step produces a preform having composition gradients in the multilayer assembly, with a braze face capable of being joined together on the part to be recharged and a superalloy material (6s) appearing on the surface of the preform.
• the flash sintering cycle is adjusted in temperature, pressure and time with a rise in temperature of at least 600 ° C / min, a temperature bearing substantially between 1000 and 2000 ° C and a pressure bearing substantially between 10 and 100 MPa.
• the mold has a shape corresponding to an impression of the entire original part.
• the superalloy layer forms by diffusion, during the sintering step, an anchorage of material continuum with the part to be recharged.
• the solder face of the preform thus produced can be brought into contact with the area of the part to be recharged. Then, by heating the preform and the contiguous piece in a suitable furnace at a temperature at least equal to the solder melting temperature, the solder face is anchored by diffusion of the solder melts into the coin to be recharged. . The mechanical reduction of the room in the recharged area is then substantially reduced or eliminated.
• the solder face of the preform thus produced is brought into contact with the area of the part to be recharged. Then, by heating the preform and the contiguous piece in a suitable furnace at a temperature at least equal to the solder melting temperature, the solder face is anchored by diffusion of the solder melts into the coin to be recharged. .
• a suitable furnace at a temperature at least equal to the solder melting temperature
• the metal protective layer consists of at least one matrix sheet of Ni, Pt, Hf, Y, Zr, Al, Si, Cu, Ag and / or Au composition, and / or of Ni-Al, Ni compositions -Pt-AI and / or Ni-AI-Zr.
• the thermal barrier is composed of zirconia stabilized at 6-8% by mass of Yttrine (thermal barrier of composition ZrO 2 - 6-8Y 2 O 3 ).
• the invention also relates to a thermomechanical part superalloy, in particular a turbine part, reloaded according to the above method from a flash sintering. The piece then has an anchorage on the part to be recharged by diffusion of material.
• FIG. 1 is a diagrammatic sectional view of an example of assembly of layers in an SPS matrix mold having an imprint shape corresponding to the original part;
• FIG. 3 is a diagrammatic sectional view of an exemplary assembly of layers in an SPS matrix mold having an imprint shape corresponding to the part reloading part;
• FIG. 4 a partial schematic sectional view of this assembly after flash sintering
• FIG. 1 illustrates a schematic view in vertical partial section of a mold 1 formed in a hollow cylindrical matrix chamber 1 1 in graphite of an SPS enclosure (not shown). Electrical voltage terminals "B” and compression “P” pistons are set to allow pressurization and pulsed current flow through the mold according to flash sintering cycles.
• This mold 1 has the impression shape corresponding to the original piece superalloy.
• the damaged part 2 is introduced into this mold after a cleaning of the external surface, in particular of the face 20 from which missing or eroded, corroded or oxidized part of the room.
• a layer of superalloy powder 31 a protective metal layer 32, consisting of platinum and aluminum sheets, and a thermal barrier 33, formed of a yttrine-stabilized zirconia ceramic powder of the formula ZrO 2 Y 2 O 3 .
• the layers or layers may be deposited on the damaged part 2 before their integration into the mold 1 or, alternatively, the assembly 3 may be injected into this mold from nozzles .
• the part and the assembly are arranged in a graphite sleeve 4 itself placed in the mold to allow the application of a localized pressure.
• the imposed current allows a very rapid temperature rise, for example of the order 600 ° C / min or more.
• This speed avoids the magnification of the grains during sintering and is therefore particularly suitable for the synthesis of nanomaterials.
• this speed also makes it possible to dose the diffusion: as illustrated in FIG. 2, the elaboration of the multilayer assembly 3 is preserved while favoring the appearance of compositional gradients G1 and G2 at the interface of the layers and strata 31 -32-33, and a continuous material anchoring between the sintered superalloy stratum 31 and the part to be recharged 2.
• the schematic sectional view illustrates another example of assembly of layers 6 in a mold 7 formed in the SPS matrix chamber 1 1.
• the mold 7 has an imprint shape corresponding to the refilling portion completing the damaged part to reconstruct the shape of the original part.
• the imprint is filled by successive deposits of layers and layers forming the assembly 6 or multilayer assembly: a layer of solder powder 60 - adapted to match the face of the part to be recharged - a layer of superalloy powder 61, a protective layer 62 consisting of sheets of compounds Ni- Al-Zr and a thermal barrier 63, formed of a yttrine-stabilized zirconia ceramic powder, of formula ZrO 2 Y 2 O 3 , and doped with gadolinium oxide Gd 2 O 3 .
• the sintering step performed under the conditions defined above makes it possible to obtain a preform 2a having composition gradients G3, G4 and G5 in the multilayer assembly 6, between the layers or strata 60-61 -62-63.
• the sintered solder layer 60 has an outer face 6b adapted to be secured to the damaged face of the part to be recharged and the superalloy material 6s appears on the surface of the preform 2a, in the solder face 6b.
• solder face 6b of the preform 2a is brought into contact with the complementary area of the part 2 to recharge, namely the face 20. Then, the preform 2a and the adjoining piece 2 are heated in a suitable oven at a temperature at least equal to the solder melting temperature, for example about 700 ° C for a silver solder. The solder face 6b is then anchored by diffusion of the melting elements of the solder into the part to be recharged 2 through its face 20.
• the invention is not limited to the examples described and shown.
• metal protection and thermal barrier layers can be added later in a subsequent deposition step on the entire part once reconstituted.
• the protective and heat-resistance layers are advantageously previously etched on the surface of the damaged part, and the sintering is carried out without these layers.
• the layers are then deposited and secured by sintering on the entire reconstituted part.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Materials Engineering (AREA)
• Physics & Mathematics (AREA)
• Optics & Photonics (AREA)
• Powder Metallurgy (AREA)
• Turbine Rotor Nozzle Sealing (AREA)
• Pressure Welding/Diffusion-Bonding (AREA)

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• 2011
  • 2011-03-07 FR FR1151832A patent/FR2972379B1/fr active Active
• 2012
  • 2012-03-06 CN CN201280011974.9A patent/CN103415365B/zh active Active
  • 2012-03-06 RU RU2013140968/02A patent/RU2598018C2/ru active
  • 2012-03-06 EP EP12720222.4A patent/EP2683509B1/fr active Active
  • 2012-03-06 JP JP2013557155A patent/JP6085256B2/ja active Active
  • 2012-03-06 BR BR112013022876A patent/BR112013022876A2/pt not_active Application Discontinuation
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