EP2643113B1 - Method for the near net shape manufacture of high temperature resistant jet engine components - Google Patents

Method for the near net shape manufacture of high temperature resistant jet engine components Download PDF

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Publication number
EP2643113B1
EP2643113B1 EP11788791.9A EP11788791A EP2643113B1 EP 2643113 B1 EP2643113 B1 EP 2643113B1 EP 11788791 A EP11788791 A EP 11788791A EP 2643113 B1 EP2643113 B1 EP 2643113B1
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EP
European Patent Office
Prior art keywords
binder
intermetallic phase
point part
component
low melting
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Not-in-force
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EP11788791.9A
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German (de)
French (fr)
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EP2643113A1 (en
Inventor
Dan Roth-Fagaraseanu
Alexander Schult
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Rolls Royce Deutschland Ltd and Co KG
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Rolls Royce Deutschland Ltd and Co KG
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    • 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

  • the invention relates to a method for near net shape production of high-temperature engine components with geometrically complex structure by metal powder injection molding.
  • MIM Metal Injection Molding
  • a metal powder is first mixed with a binder of thermoplastics and waxes to form a flowable material (feedstock), which is injected into a mold by means of an extruder in a conventional injection molding process.
  • feedstock a flowable material
  • a so-called green part is available, from which an open-pore molding, the so-called brown part, is formed by thermal or chemical dissolution of the binder.
  • the open-pored brown part is compacted and given its final shape and has due to the remaining low porosity with the solid material on matching strength values.
  • the WO 2008/055594 A1 describes a cylinder crankcase for a motor vehicle, in which an infiltration body is formed from an inductively welded, open-pore shaped body.
  • the inductively welded, open-pore shaped body is infiltrated with a light metal melt.
  • the porosity of the inductively welded, open-pore shaped body is set by placeholders, which are gasified during the inductive welding.
  • a method for producing a composite material by means of metal powder injection in which a binder contained in the green compact is completely removed and the resulting openings are then infiltrated in a liquid with particles which may be alumina. After incorporation of the particles, the resulting part is sintered.
  • the invention has for its object to provide a cost-effective method for near-net-shape production of high-temperature engine components with geometrically complex structure.
  • the basic idea of the invention is that a high-melting part of an intermetallic phase which is present as metal powder is mixed with a binder and from the feedstock thus formed by metal powder injection molding a substantially corresponding to the final contour Green part is made, is infiltrated in its after removal of the binder remaining pores of the low-melting part of the intermetallic phase, wherein the brown part thus produced is subjected to a specific depending on the metallic phases used heat treatment to produce the intermetallic phase.
  • the binder used is a polymeric two-component binder, wherein the first binder component is dissolved out of the green part produced by metal powder injection molding chemically, catalytically or thermally and the second binder component is thermally removed on infiltration of the low-melting metallic part.
  • the proportion of the low-melting part of the intermetallic phase is variable and determined by the proportion of the pores after complete debindering of the green part.
  • the proportion of pores and thus the proportion of the infiltrated low-melting part in the intermetallic phase is determined by adjusting the mixing ratio between the metal powder and the two-component binder.
  • the infiltration of the molten, low-melting part of the intermetallic phase takes place in the open-pore brown part after the "squeeze-casting process under pressure.
  • the brown part after the infiltration of the low-melting part and before the intermetallic phase-generating heat treatment can be mechanically processed.
  • an iron powder is produced (step 1) which is mixed with a two-component polymeric binder (step 2).
  • step 3 From the iron powder binder mixture, the so-called granular feedstock, a green part is produced by means of a screw press in a conventional spraying process (step 3), from which after cooling, solidification and demolding the first component of the polymeric binder is dissolved out (step 4).
  • the removal of the first component of the binder can be carried out chemically, catalytically and / or thermally.
  • an open-pore brown part consisting of the high-melting metallic phase and the first component of the binder is provided, which has a certain porosity which can be adjusted as a function of the binder fraction.
  • a low-melting metallic phase-in this case aluminum-infiltrates into the cavities of the brown part, while the second component of the binder is thermally removed from the brown part (step 5).
  • the volume ratio between the high-melting metallic phase (iron) and the low-melting metallic phase (aluminum) is set by the respective porosity of the brown part.
  • step 6 a machining of the infiltrated brown part which can be carried out in a simple manner at this time can be carried out.
  • step 7 the component corresponding to the final shape is subjected to a heat treatment to form an iron and aluminum intermetallic phase (step 7), so that a metal-injection molded geometrically complex and high-temperature resistant component, for example a turbine blade for a gas turbine engine, is now available.

Description

Die Erfindung betrifft ein Verfahren zur endkonturnahen Fertigung von hochtemperaturbeständigen Triebwerksbauteilen mit geometrisch komplexer Struktur durch Metallpulverspritzgießen.The invention relates to a method for near net shape production of high-temperature engine components with geometrically complex structure by metal powder injection molding.

Ein bekanntes Verfahren zur endabmessungsnahen Herstellung von geometrisch kompliziert ausgebildeten Bauteilen ist das auch als MIM-Verfahren (Metal Injection Moulding) bezeichnete Metallpulverspritzgießen. Beim Metallpulverspritzgießen wird zunächst ein Metallpulver mit einem Binder aus thermoplastischen Kunststoffen und Wachsen zu einem fließfähigen Werkstoff (Feedstock) vermischt, der in einem herkömmlichen Spritzgießprozess mit Hilfe eines Extruders in eine Form gespritzt wird. Nach dem Abkühlen, Erstarren und Entformen steht ein sogenanntes Grünteil zur Verfügung, aus dem durch thermisches oder chemisches Herauslösen des Binders ein offenporiges Formteil, das sogenannte Braunteil, entsteht. In einem anschließenden Sinterprozess wird das offenporige Braunteil verdichtet und erhält seine endgültige Form und weist aufgrund der verbleibenden geringen Restporosität mit dem Vollmaterial übereinstimmende Festigkeitswerte auf. Um auch hochtemperaturbeständige Triebwerksbauteile, zum Beispiel Turbinenschaufeln, endkonturnah herstellen zu können, wurde bereits vorgeschlagen, ein aus einer intermetallischen Phase bestehendes Pulver zu erzeugen und in der oben geschilderten Art für das Metallpulverspritzen einzusetzen. Die Herstellung intermetallischer Phasen und eines daraus erzeugten Pulvers zur Anwendung beim Metallpulverspritzgießen ist jedoch mit einem hohen Fertigungs- und Kostenaufwand verbunden.A well-known method for near-net-shape production of geometrically complicated components is also known as MIM (Metal Injection Molding) metal injection molding. In metal powder injection molding, a metal powder is first mixed with a binder of thermoplastics and waxes to form a flowable material (feedstock), which is injected into a mold by means of an extruder in a conventional injection molding process. After cooling, solidification and demolding, a so-called green part is available, from which an open-pore molding, the so-called brown part, is formed by thermal or chemical dissolution of the binder. In a subsequent sintering process, the open-pored brown part is compacted and given its final shape and has due to the remaining low porosity with the solid material on matching strength values. In order to produce high-temperature-resistant engine components, for example turbine blades, close to the final contour, it has already been proposed to produce a powder consisting of an intermetallic phase and to use it in the above-described manner for metal powder spraying. However, the production of intermetallic phases and a powder produced therefrom for use in metal powder injection molding is associated with a high manufacturing and cost.

Die WO 2008/055594 A1 beschreibt ein Zylinderkurbelgehäuse für ein Kraftfahrzeug, bei dem ein Infiltrationskörper aus einem induktiv verschweißten, offenporigen Formkörper gebildet ist. Der induktiv verschweißte, offenporige Formkörper wird mit einer Leichtmetallschmelze infiltriert. Die Porosität des induktiv verschweißten, offenporigen Formkörpers wird durch Platzhalter eingestellt, die während der induktiven Verschweißung vergast werden.The WO 2008/055594 A1 describes a cylinder crankcase for a motor vehicle, in which an infiltration body is formed from an inductively welded, open-pore shaped body. The inductively welded, open-pore shaped body is infiltrated with a light metal melt. The porosity of the inductively welded, open-pore shaped body is set by placeholders, which are gasified during the inductive welding.

Aus der WO 2008/095080 A1 ist ein Verfahren zum Herstellen eines Kompositmaterials mittels Metallpulverspritzens bekannt, bei dem ein im Grünling enthaltener Binder vollständig entfernt und die dabei entstehenden Öffnungen anschließend in einer Flüssigkeit mit Partikeln infiltriert werden, bei denen es sich um Aluminiumoxid handeln kann. Nach Einlagerung der Partikel wird das entstandene Teil gesintert.From the WO 2008/095080 A1 For example, a method for producing a composite material by means of metal powder injection is known in which a binder contained in the green compact is completely removed and the resulting openings are then infiltrated in a liquid with particles which may be alumina. After incorporation of the particles, the resulting part is sintered.

Der Erfindung liegt die Aufgabe zugrunde, ein kostengünstiges Verfahren zur endkonturnahen Fertigung von hochtemperaturbeständigen Triebwerksbauteilen mit geometrisch komplexer Struktur anzugeben.The invention has for its object to provide a cost-effective method for near-net-shape production of high-temperature engine components with geometrically complex structure.

Erfindungsgemäß wird die Aufgabe mit einem Verfahren gemäß den Merkmalen des Patentanspruchs 1 gelöst.According to the invention the object is achieved by a method according to the features of patent claim 1.

Vorteilhafte Weiterbildungen der Erfindung sind Gegenstand der Unteransprüche.Advantageous developments of the invention are the subject of the dependent claims.

Der Grundgedanke der Erfindung besteht darin, dass ein als Metallpulver vorliegender hoch schmelzender Teil einer intermetallischen Phase mit einem Binder vermischt und aus dem so gebildeten Feedstock durch Metallpulverspritzen ein im Wesentlichen der Endkontur entsprechendes Grünteil gefertigt wird, in dessen nach Herauslösen des Binders verbleibende Poren der niedrig schmelzende Teil der intermetallischen Phase infiltriert wird, wobei das so erzeugte Braunteil einer in Abhängigkeit von den eingesetzten metallischen Phasen spezifischen Wärmebehandlung zur Erzeugung der intermetallischen Phase unterzogen wird.The basic idea of the invention is that a high-melting part of an intermetallic phase which is present as metal powder is mixed with a binder and from the feedstock thus formed by metal powder injection molding a substantially corresponding to the final contour Green part is made, is infiltrated in its after removal of the binder remaining pores of the low-melting part of the intermetallic phase, wherein the brown part thus produced is subjected to a specific depending on the metallic phases used heat treatment to produce the intermetallic phase.

Dadurch ist es möglich, hochtemperaturbeständige und leichte Triebwerksbauteile mit geometrisch komplizierter Struktur, wie zum Beispiel Turbinenschaufeln, kosteneffizient aus Hochleistungswerkstoffen herzustellen.This makes it possible to produce high temperature resistant and lightweight engine components with geometrically complicated structure, such as turbine blades, cost-effectively from high performance materials.

Erfindungsgemäß wird als Binder ein polymerer Zweikomponentenbinder verwendet, wobei die erste Binderkomponente aus dem durch Metallpulverspritzgießen erzeugten Grünteil chemisch, katalytisch oder thermisch herausgelöst wird und die zweite Binderkomponente beim Infiltrieren des niedrig schmelzenden metallischen Teils thermisch entfernt wird.According to the invention, the binder used is a polymeric two-component binder, wherein the first binder component is dissolved out of the green part produced by metal powder injection molding chemically, catalytically or thermally and the second binder component is thermally removed on infiltration of the low-melting metallic part.

In weiterer Ausbildung der Erfindung ist der Anteil des niedrig schmelzenden Teils der intermetallischen Phase variabel und durch den Anteil der Poren nach dem vollständigen Entbindern des Grünteils bestimmt.In a further embodiment of the invention, the proportion of the low-melting part of the intermetallic phase is variable and determined by the proportion of the pores after complete debindering of the green part.

Der Anteil der Poren und damit der Anteil des infiltrierten niedrig schmelzenden Teils in der intermetallischen Phase wird durch die Einstellung des Mischungsverhältnisses zwischen dem Metallpulver und dem Zweikomponentenbinder bestimmt.The proportion of pores and thus the proportion of the infiltrated low-melting part in the intermetallic phase is determined by adjusting the mixing ratio between the metal powder and the two-component binder.

In weiterer Ausbildung der Erfindung erfolgt die Infiltration des schmelzflüssigen, niedrig schmelzenden Teils der intermetallischen Phase in das offenporige Braunteil nach dem "Squeeze-Casting-Verfahren unter Druck.In a further embodiment of the invention, the infiltration of the molten, low-melting part of the intermetallic phase takes place in the open-pore brown part after the "squeeze-casting process under pressure.

In weiterer Ausbildung der Erfindung kann das Braunteil nach der Infiltration des niedrig schmelzenden Teils und noch vor der die intermetallische Phase erzeugenden Wärmebehandlung mechanisch bearbeitet werden.In a further embodiment of the invention, the brown part after the infiltration of the low-melting part and before the intermetallic phase-generating heat treatment can be mechanically processed.

Eine Ausführungsform der Erfindung wird in Verbindung mit dem beigefügten Verfahrensablaufschema nachfolgend am Beispiel der Herstellung einer Turbinenschaufel, die aus einer auf Eisen und Aluminium basierenden intermetallischen Phase besteht, näher erläutert.An embodiment of the invention will be further described in connection with the attached process flow diagram, using as an example the manufacture of a turbine blade consisting of an iron and aluminum based intermetallic phase.

Aus dem hoch schmelzenden Teil der intermetallischen Phase, hier Eisen, wird ein Eisenpulver hergestellt (Schritt 1), das mit einem aus zwei Komponenten bestehenden polymeren Binder vermischt wird (Schritt 2). Aus dem Eisenpulver-Binder Gemisch, dem - als Granulat vorliegenden - sogenannten Feedstock, wird mithilfe einer Schneckenpresse in einem herkömmlichen Spritzverfahren ein Grünteil erzeugt (Schritt 3), aus dem nach dem Abkühlen, Erstarren und Entformen die erste Komponente des polymeren Binders herausgelöst wird (Schritt 4). Das Entfernen der ersten Komponente des Binders kann chemisch, katalytisch und/oder thermisch erfolgen. Im Ergebnis der teilweisen Entbinderung wird ein aus der hoch schmelzenden metallischen Phase und der ersten Komponente des Binders bestehendes offenporiges Braunteil bereitgestellt, das eine bestimmte - in Abhängigkeit von dem Binderanteil einstellbare - Porosität aufweist. In dem nachfolgenden Verfahrensschritt wird in einem modifizierten Druckgießverfahren, dem sogenannten "squeeze casting", in die Hohlräume des Braunteils unter hohem Druck eine niedrig schmelzende metallische Phase - hier: Aluminium - infiltriert und dabei die zweite Komponente des Binders thermisch aus dem Braunteil herausgelöst (Schritt 5). Das Volumenverhältnis zwischen der hoch schmelzenden metallischen Phase (Eisen) und der niedrig schmelzenden metallischen Phase (Aluminium) wird über die jeweilige Porosität des Braunteils eingestellt. Nach diesem Schritt kann, sofern erforderlich, eine zu diesem Zeitpunkt in einfacher Weise durchführbare mechanische Bearbeitung des infiltrierten Braunteils erfolgen (Schritt 6). Anschließend wird das der Endform entsprechende Bauteil einer Wärmebehandlung zur Bildung einer aus Eisen und Aluminium bestehenden intermetallischen Phase unterworfen (Schritt 7), so dass nun ein durch Metallpulverspritzgießen geometrisch komplex gestaltetes sowie hochtemperaturbeständiges Bauteil, beispielsweise eine Turbinenschaufel für ein Gasturbinentriebwerk, zur Verfügung steht.From the refractory portion of the intermetallic phase, here iron, an iron powder is produced (step 1) which is mixed with a two-component polymeric binder (step 2). From the iron powder binder mixture, the so-called granular feedstock, a green part is produced by means of a screw press in a conventional spraying process (step 3), from which after cooling, solidification and demolding the first component of the polymeric binder is dissolved out (step 4). The removal of the first component of the binder can be carried out chemically, catalytically and / or thermally. As a result of the partial debindering, an open-pore brown part consisting of the high-melting metallic phase and the first component of the binder is provided, which has a certain porosity which can be adjusted as a function of the binder fraction. In the subsequent process step, in a modified die casting process, the so-called "squeeze casting", a low-melting metallic phase-in this case aluminum-infiltrates into the cavities of the brown part, while the second component of the binder is thermally removed from the brown part (step 5). The volume ratio between the high-melting metallic phase (iron) and the low-melting metallic phase (aluminum) is set by the respective porosity of the brown part. After this step, if necessary, a machining of the infiltrated brown part which can be carried out in a simple manner at this time can be carried out (step 6). Subsequently, the component corresponding to the final shape is subjected to a heat treatment to form an iron and aluminum intermetallic phase (step 7), so that a metal-injection molded geometrically complex and high-temperature resistant component, for example a turbine blade for a gas turbine engine, is now available.

In der gleichen Art können auch andere aus einer intermetallischen Phase, beispielsweise auf der Basis von Nickel, Eisen, Titan und Aluminium gefertigte - hochtemperaturbeständige und leichte Bauteile mit geometrisch komplizierter Struktur bei geringem Materialaufwand effizient und kostengünstig hergestellt werden.In the same way other made of an intermetallic phase, for example on the basis of nickel, iron, titanium and aluminum - high temperature resistant and lightweight components with geometrically complicated structure can be produced efficiently and inexpensively with low material costs.

Claims (6)

  1. Method for near net shape manufacturing of high-temperature resistant engine components of geometrically complex structure by metal injection moulding, the engine components including an intermetallic phase of a high melting-point part and a low melting-point part, where the high melting-point part provided as a metal powder is mixed with a binder, and a green compact of the engine component is first produced by metal injection moulding, and a porous brown compact is created after removal of the binder, and subsequently the low melting-point part of the intermetallic phase is infiltrated into the pores of the brown compact in the molten state,
    characterized in that
    finally the brown compact such prepared is subjected to a heat treatment generating the intermetallic phase, and 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.
  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 the first binder component is removed chemically, catalytically and/ or thermally, and the second binder component is removed thermally.
EP11788791.9A 2010-11-25 2011-11-18 Method for the near net shape manufacture of high temperature resistant jet engine components Not-in-force EP2643113B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
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

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EP2643113A1 EP2643113A1 (en) 2013-10-02
EP2643113B1 true EP2643113B1 (en) 2016-11-16

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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

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US20130266469A1 (en) 2013-10-10
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DE102010061960A1 (en) 2012-05-31

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