GB2419835A - Method of diffusion bonding - Google Patents

Method of diffusion bonding Download PDF

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Publication number
GB2419835A
GB2419835A GB0424601A GB0424601A GB2419835A GB 2419835 A GB2419835 A GB 2419835A GB 0424601 A GB0424601 A GB 0424601A GB 0424601 A GB0424601 A GB 0424601A GB 2419835 A GB2419835 A GB 2419835A
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GB
United Kingdom
Prior art keywords
workpieces
article
vacuum bag
tooling
tooling member
Prior art date
Legal status (The legal status 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 status listed.)
Withdrawn
Application number
GB0424601A
Other versions
GB0424601D0 (en
Inventor
Wayne Eric Voice
Xinhua Wu
Michael Loretto
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce PLC
Original Assignee
Rolls Royce PLC
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 Rolls Royce PLC filed Critical Rolls Royce PLC
Priority to GB0424601A priority Critical patent/GB2419835A/en
Publication of GB0424601D0 publication Critical patent/GB0424601D0/en
Publication of GB2419835A publication Critical patent/GB2419835A/en
Withdrawn legal-status Critical Current

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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
    • B22F7/06—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
    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
    • B23K20/021—Isostatic pressure welding
    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/20—Special methods allowing subsequent separation, e.g. of metals of high quality from scrap material
    • 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
    • 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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/001—Turbines
    • 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
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/14—Titanium or alloys thereof

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

A method of manufacturing an article (10, fig.3) comprising the steps of arranging a plurality of workpieces 12 into an abutting relationship and holding them in that position with a tooling member 14, enclosing the workpieces and tooling member in a vacuum bag 16, evacuating the vacuum bag, heating and applying pressure to the vacuum bag to diffusion bond the workpieces to form the article, and removing the vacuum bag and tooling member from the article. Preferably the method uses hot isostatic pressing to bond the workpieces. The surfaces of the tooling member may be coated with a stop off material such as boron nitride to prevent diffusion bonding between the member and the article. A powder may be arranged between the workpieces to aid diffusion bonding. Preferably, the article is a component of a gas turbine engine, the component being formed from Titanium or Titanium aluminide alloy.

Description

A METHOD OF MANUFACTURING ARTICLES BY DIFFUSION BONDING
The present invention relates to a method of manufacturing articles by diffusion bonding and in particular relates to a method of manufacturing articles by hot isostatic diffusion bonding.
Metal articles, or components, are generally manufactured by machining a block of wrought metal, by casting metal or by hot pressing powder metal.
However, the machining of an article from a block of wrought metal is relatively expensive in terms of material wastage, scrap rate and machining time, but the mechanical properties are relatively good. Casting of an article is relatively cheap, but the mechanical properties of the article are relatively poor. Hot pressing to consolidate powder metal is best directed towards relatively large complex articles in order to make the process economical.
Accordingly the present invention seeks to provide a novel method of manufacturing complex moderately sized articles, or components, typically of the order of 400mm section, which overcomes the above-mentioned problems.
Accordingly the present invention provides a method of manufacturing an article comprising the steps of (a) forming each one of a plurality of workpieces into a simple shape, (b) arranging the formed workpieces into a predetermined abutting relationship and providing at least one tooling member to hold the formed workpieces in the predetermined abutting relationship, (c) enclosing the plurality of formed workpieces and the at least one tooling member in a vacuum bag, (d) evacuating the vacuum bag, (e) heating and applying pressure to the vacuum bag and the enclosed plurality of formed workpieces and at least one tooling member to diffusion bond the formed workpieces together to form the article, (f) removing the vacuum bag from the article and the at least one tooling member (g) removing the at least one tooling member from the article.
Preferably step (a) comprises machining at least one of the workpieces.
Preferably the at least one tooling member is strong and non-deformable such that it is reusable.
Preferably step (b) comprises providing a stop off material on the surfaces of the at least one tooling member to prevent diffusion bonding between the at least one tooling member and the plurality of workpieces.
Preferably step (b) comprises providing a plurality of tooling members.
Preferably step (b) comprises providing a stop off material on the surfaces of the tooling members to prevent diffusion bonding between the tooling members and the plurality of workpieces and to prevent diffusion bonding between the tooling members.
Preferably the stop off material comprises boron nitride.
Preferably the at least one tooling member comprises a material having a different thermal expansion coefficient than the plurality of workpieces such that the at least one tooling member and the plurality of workpieces disengage during cooling.
Preferably the vacuum bag comprises a steel bag, more preferably a mild steel bag.
Preferably step (e) comprises hot isostatic pressing.
Preferably step (f) comprises peeling off the vacuum bag or dissolving the vacuum bag in an acid.
At least one of the workpieces may be formed by hot pressing a powder.
Preferably a powder is arranged between the metal workpieces to aid diffusion bonding of the workpieces.
At least one of the workpieces may have a different composition to the other workpieces to produce a functionally graded article in which different portions of the article have different properties, e.g. one workpiece has higher ductility and lower temperature capability or corrosion resistance than another workpiece.
Preferably the workpieces are metal workpieces.
Preferably the metal workpieces are wrought metal workpieces.
Preferably the metal workpieces comprise a titanium alloy or a titanium aluminide alloy. However, the metal workpieces may comprise other suitable metals or alloys.
Preferably the article is a component of a gas turbine engine.
Preferably the article is a compressor blade, a compressor vane, a compressor casing, a fan blade, a fan outlet guide vane or a fan casing.
The present invention will be more fully described by way of example with reference to the accompanying drawings in which:- Figure 1 shows a schematic cross-sectional view through a plurality of workpieces and a plurality of tooling members used in a method of manufacturing an article according to the present invention.
Figure 2 shows a schematic cross-sectional view through the plurality of workpieces and the plurality of tooling members used in a method of manufacturing an article according to the present invention after diffusion bonding.
Figure 3 shows a schematic cross-sectional view through a plurality of workpieces and tooling members used in a method of manufacturing an article according to the present invention after the removing of the tooling members from the article.
A method of manufacturing a metal article 10 according to the present invention is shown with reference to figures 1 to 3. The method of manufacturing a metal article 10 comprises forming each one of a plurality of metal workpieces 12, preferably wrought metal workpieces, into a simple shape. Each individual metal workpiece 12 generally has a different shape and dimensions to the other metal workpieces 12, but some of the metal workpieces 12 may have the same shape and dimensions.
The formed metal workpieces 12 are arranged into a predetermined abutting relationship, to define the shape of the finished article 10, and at least one tooling member 14 is provided to hold the formed metal workpieces 12 in the predetermined abutting relationship as shown in figure 1.
The plurality of formed metal workpieces 12 and the at least one tooling member 14 are enclosed by a vacuum bag (16), as shown in figure 1. The vacuum bag 16 is sealed and evacuated.
The vacuum bag 16 and the enclosed plurality of formed metal workpieces 12 and tooling members 14 are then placed in a HIP, hot isostatic pressing, vessel and heat and pressure are applied to the vacuum bag 16 and the enclosed plurality of formed metal workpieces 12 and at least one tooling member 14 to diffusion bond the formed metal workpieces 14 together to form the article 10, as shown in figure 2. The formed metal workpieces 14 are hot isostatically pressed to diffusion bond them together. The temperature and pressure in the HIP vessel are reduced to ambient and then the vacuum bag 16, article 10 and the at least one tooling member 14 are removed from the HIP vessel.
The vacuum bag 16 is removed from the article 10 and the at least one tooling member 14 and then the at least one tooling member 14 is removed from the article 10, as shown in figure 3.
The metal workpieces 12 are preferably wrought metal workpieces which are subsequently formed by machining to the simple shapes required, for example by milling, grinding, cutting, laser cutting, water jet cutting, electrodischarge machining, electrochemical machining etc. However one or more of the metal workpieces 12 may be formed by hot pressing of a metal powder.
The at least one tooling member 14 is strong and non- deformable such that it is reusable to make other articles by the same manufacturing process.
Generally, for complex shaped articles 10, it is necessary to provide a plurality of tooling members 14 to hold the metal workpieces 12 in the predetermined abutting relationship.
A stop off material is applied on the surfaces of the at least one tooling member 14 to prevent diffusion bonding between the at least one tooling member 14 and the plurality of workpieces 12. If more than one tooling member 14 is used it may be necessary to provide a stop off material on the surfaces of the tooling members 14 to prevent diffusion bonding between the tooling members 14 and the plurality of workpieces 12 and also to prevent diffusion bonding between the tooling members 14 if some of the tooling members 14 are in adjacent abutting relationship.
Preferably the stop off material comprises boron nitride, but other suitable stop off materials may be used.
The at least one tooling member 14 comprises a material having a different, e.g. greater, thermal expansion coefficient than the plurality of workpieces 12 such that the at least one tooling member 14 and the plurality of workpieces 12 of the article 10 disengage during cooling of the article 10 after the metal workpieces 12 have been diffusion bonded together due to differential thermal contraction. The article 10 is designed such that the at least one tooling member 14 can be physically removed after diffusion bonding of the metal workpieces 12.
The vacuum bag 16 comprises a steel bag, more preferably a mild steel bag.
The vacuum bag 16 is removed from the article 10 and the at least one tooling member 14 by peeling off the vacuum bag 16 or by dissolving the vacuum bag 16 in a
suitable acid.
A metal powder may be arranged between the metal workpieces 12 to aid diffusion bonding of the metal workpieces 12. The metal powder breaks up oxide surface layers to aid diffusion bonding. This is particularly suitable for metal workpieces 12 comprising metals or alloys which are difficult to diffusion bond.
At least one of the metal workpieces 12 may have a different composition to the other metal workpieces 12 to produce a functionally graded article 10 in which different portions of the article 10 have different properties. For example one metal workpiece 12 may have higher ductility and lower temperature capability or corrosion resistance than another metal workpiece 12.
The metal workpieces 12 may comprise a titanium alloy or a titanium aluminide alloy. However, the metal workpieces 12 may comprise other suitable metals or alloys.
The article 10 may be a component of a gas turbine engine. The article 10 may be a compressor blade, a compressor vane, a compressor casing, a fan blade, a fan outlet guide vane or a fan casing.
The advantage of the present invention is that the method of manufacturing an article is cheaper and simpler for moderately sized articles, typically of the order of 400mm section, with wrought material properties. The diffusion bond is as strong as the parent material of the metal workpieces.
The present invention may also be applicable to larger sized articles or smaller sized components.
Although the present invention has been described with reference to manufacturing an article from metal workpieces, it may possible to manufacture an article from ceramic workpieces or composite workpieces in a similar manner using at least one tooling member and a vacuum bag.

Claims (22)

  1. Claims: - 1. A method of manufacturing an article comprising the steps of
    (a) forming each one of a plurality of workpieces into a simple shape, (b) arranging the formed workpieces into a predetermined abutting relationship and providing at least one tooling member to hold the formed workpieces in the predetermined abutting relationship, (c) enclosing the plurality of formed workpieces and the at least one tooling member in a vacuum bag, (d) evacuating the vacuum bag, (e) heating and applying pressure to the vacuum bag and the enclosed plurality of formed workpieces and at least one tooling member to diffusion bond the formed workpieces together to form the article, (f) removing the vacuum bag from the article and the at least one tooling member (g) removing the at least one tooling member from the article.
  2. 2. A method as claimed in claim 1 wherein step (a) comprises machining at least one of the workpieces.
  3. 3. A method as claimed in claim 1 or claim 2 wherein the at least one tooling member is strong and non-deformable such that it is reusable.
  4. 4. A method as claimed in any of claims 1 to 3 wherein step (b) comprises providing a stop off material on the surfaces of the at least one tooling member to prevent diffusion bonding between the at least one tooling member and the plurality of workpieces.
  5. 5. A method as claimed in any of claims 1 to 4 wherein step (b) comprises providing a plurality of tooling members.
  6. 6. A method as claimed in claim 5 wherein step (b) comprises providing a stop off material on the surfaces of the tooling members to prevent diffusion bonding between the tooling members and the plurality of workpieces and to prevent diffusion bonding between the tooling members.
  7. 7. A method as claimed in claim 4 or claim 6 wherein the stop off material comprises boron nitride.
  8. 8. A method as claimed in any of claims 1 to 7 wherein the at least one tooling member comprises a material having a different thermal expansion coefficient than the plurality of workpieces such that the at least one tooling member and the plurality of workpieces disengage during cooling.
  9. 9. A method as claimed in any of claims 1 to 8 wherein the vacuum bag comprises a steel bag.
  10. 10. A method as claimed in claim 9 wherein the vacuum bag comprises a mild steel bag.
  11. 11. A method as claimed in any of claims 1 to 10 wherein step (f) comprises peeling off the vacuum bag or dissolving the vacuum bag in an acid.
  12. 12. A method as claimed in any of claims 1 to 11 wherein step (e) comprises hot isostatic pressing.
  13. 13. A method as claimed in any of claims 1 to 12 wherein the at least one of the workpieces is formed by hot pressing a powder.
  14. 14. A method as claimed in any of claims 1 to 13 wherein a powder is arranged between the workpieces to aid diffusion bonding of the workpieces.
  15. 15. A method as claimed in any of claims 1 to 14 wherein at least one of the workpieces has a different composition to the other workpieces to produce a functionally graded article in which different portions of the article have different properties.
  16. 16. A method as claimed in claim 15 wherein one workpiece has higher ductility and lower temperature capability or corrosion resistance than another workpiece.
  17. 17. A method as claimed in any of claims 1 to 16 wherein the workpieces are metal workpieces.
  18. 18. A method as claimed in claim 17 wherein the metal workpieces are wrought metal workpieces.
  19. 19. A method as claimed in claim 17 or claim 18 wherein the metal workpieces comprise a titanium alloy or a titanium aluminide alloy.
  20. 20. A method as claimed in any of claims 1 to 19 wherein the article is a component of a gas turbine engine.
  21. 21. A method as claimed in claim 20 wherein the article is a compressor blade, a compressor vane, a compressor casing, a fan blade, a fan outlet guide vane or a fan casing.
  22. 22. A method of manufacturing an article substantially as hereinbefore described with reference to the accompanying drawings.
GB0424601A 2004-11-06 2004-11-06 Method of diffusion bonding Withdrawn GB2419835A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0424601A GB2419835A (en) 2004-11-06 2004-11-06 Method of diffusion bonding

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0424601A GB2419835A (en) 2004-11-06 2004-11-06 Method of diffusion bonding

Publications (2)

Publication Number Publication Date
GB0424601D0 GB0424601D0 (en) 2004-12-08
GB2419835A true GB2419835A (en) 2006-05-10

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2459653A (en) * 2008-04-29 2009-11-04 Rolls Royce Plc Manufacture of an article by hot isostatic pressing
EP3486029A1 (en) * 2017-11-20 2019-05-22 HIPtec AS A method for manufacturing a metal based frame, and a metal based frame

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115301951A (en) * 2022-08-10 2022-11-08 中国航发北京航空材料研究院 Forming method of intermetallic compound structural part

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3940268A (en) * 1973-04-12 1976-02-24 Crucible Inc. Method for producing rotor discs
US4603801A (en) * 1984-07-24 1986-08-05 The Garrett Corporation Diffusion bonding of mechanically held components by hot isostatic pressure
US5184769A (en) * 1989-07-26 1993-02-09 Avco Corporation Tooling and method for consolidating a filamentary reinforced metal matrix composite
US5678164A (en) * 1994-08-24 1997-10-14 Societe Nationale D'etude Et De Construction De Moteurs D'aviation "Snecma" Process for obtaining a bladed circular metallic article
WO2001003876A1 (en) * 1999-07-14 2001-01-18 Swales Aerospace High temperature isostatic pressure bonding of hollow beryllium pressure vessels using a bonding flange

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3940268A (en) * 1973-04-12 1976-02-24 Crucible Inc. Method for producing rotor discs
US4603801A (en) * 1984-07-24 1986-08-05 The Garrett Corporation Diffusion bonding of mechanically held components by hot isostatic pressure
US5184769A (en) * 1989-07-26 1993-02-09 Avco Corporation Tooling and method for consolidating a filamentary reinforced metal matrix composite
US5678164A (en) * 1994-08-24 1997-10-14 Societe Nationale D'etude Et De Construction De Moteurs D'aviation "Snecma" Process for obtaining a bladed circular metallic article
WO2001003876A1 (en) * 1999-07-14 2001-01-18 Swales Aerospace High temperature isostatic pressure bonding of hollow beryllium pressure vessels using a bonding flange

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2459653A (en) * 2008-04-29 2009-11-04 Rolls Royce Plc Manufacture of an article by hot isostatic pressing
EP3486029A1 (en) * 2017-11-20 2019-05-22 HIPtec AS A method for manufacturing a metal based frame, and a metal based frame
WO2019097088A1 (en) * 2017-11-20 2019-05-23 Hiptec As A method for manufacturing a metal based frame, and a metal based frame
CN111356554A (en) * 2017-11-20 2020-06-30 海派克有限公司 Method for manufacturing a metal-based frame and metal-based frame
US11285537B2 (en) 2017-11-20 2022-03-29 Hiptec As Method for manufacturing a metal based frame, and a metal based frame

Also Published As

Publication number Publication date
GB0424601D0 (en) 2004-12-08

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