WO2005049251A1 - Method for making inner channels of a component - Google Patents

Method for making inner channels of a component Download PDF

Info

Publication number
WO2005049251A1
WO2005049251A1 PCT/FI2004/050170 FI2004050170W WO2005049251A1 WO 2005049251 A1 WO2005049251 A1 WO 2005049251A1 FI 2004050170 W FI2004050170 W FI 2004050170W WO 2005049251 A1 WO2005049251 A1 WO 2005049251A1
Authority
WO
WIPO (PCT)
Prior art keywords
powder
mould
isostatic pressing
cavity mould
hot isostatic
Prior art date
Application number
PCT/FI2004/050170
Other languages
French (fr)
Inventor
Arttu Laitinen
Original Assignee
Metso Powdermet Oy
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 Metso Powdermet Oy filed Critical Metso Powdermet Oy
Publication of WO2005049251A1 publication Critical patent/WO2005049251A1/en

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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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds
    • 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
    • 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
    • B22F2998/10—Processes characterised by the sequence of their steps

Definitions

  • the object of this invention is a method for making inner channels or cavities to a component made of powder using a hot isostatic pressing.
  • the hot isostatic pressing can be used to compress powder, usually a metal powder, into a solid component.
  • the compression is usually carried out by using a mould made of thin metal plate, that is a so called capsule, which is filled with powder, vacuumed and placed into an autoclave in a high temperature and pressure.
  • the capsule can be so formed that it resembles the actual object, then it is a so called near net shape (NNS) manufacturing.
  • the gas typically argon
  • the pressure of the gas is not necessarily enough to prevent the effects shaping the cross section profile of the material surrounding the channel.
  • the risks of the manufacturing are linked to that in the method in question the inner channels must be in connection to the outer side of the capsule and making of welds of the gas tight connection tubes is difficult.
  • the aim of this invention is to produce a method for manufacturing a powder made component, where the effects caused by the hot isostatic pressing to the cross section profile of the inner channels are minimized and to minimize the risks relating to the manufacturing of an object, such as the difficult welding joints.
  • the inner channels are made so that a) the moulds used to form the inner channels of a component are filled with a first powder, preferably a ceramic powder and placed inside of the actual capsule, or b) a piece is made which is formed like the cavity and made of a solid material, preferably a copper-nickel alloy and placed inside the actual capsule.
  • the actual capsule in turn is filled with a second powder, that is a mould powder, which typically is a metal powder.
  • it is essential that these materials, the first powder or the solid material and the second powder differ from each other, preferably the difference is either in the different sintrating temperatures of the powder or in the different melting temperatures of the materials.
  • the first powder is removed mechanically from the inner channels or b) the solid mould core material is melt from the inner channels. After this, a second hot isostatic pressing is performed, where the mould powder densities further.
  • Figure 1 depicts the ceramic filled inner channels which are used for making inner channels and placed inside the actual capsule
  • Figure 2 depicts a component to be produced after the hot isostatic pressing, and where there is depicted the openings which are used for removing the ceramic powder after the first hot isostatic pressing.
  • a mould 2 of the desired inner channel is placed, which is manufactured preferably from a metal plate.
  • These moulds of the inner channels are filled with a powder, preferably a ceramic powder, e.g. aluminium oxide (AL 2 O 3 ) which differs from the actual mould powder.
  • the inner channel parts which are filled with ceramic, can be either separately vacuumed and closed or a hole can be left to them, when they get vacuumed during vacuuming of the actual article. In the later case care must be taken that the ceramic powder of the inner channels and the mould powder used to fill the actual capsule, typically a metal powder, do not mix.
  • the parameters for the first compression that is the temperature (e.g. 1000-1300 °C), the pressure (e.g. 100-150 Mpa) and the time are so chosen that the mould powder in the capsule compresses almost to a full density (typically >92%, which is a typical bound density of a powder, after which the porosity through the structure is removed) but the ceramic powder used for the inner channels stays loose.
  • Fig. 2 is depicted the component to be manufatured after a hot isostatic pressing, and there is also depicted the openings 3 which are used to remove the ceramic powder after a first hot isostatic pressing.
  • the capsule is taken again to the hot isostatic pressing, where the used parameters, i.e temperature, pressure and time are so chosen that the desired density in the mould powder is achieved.
  • the article which can be e.g. a valve, is ready for follow-up processing that is typically thermal processing and machining.
  • the main features of the processing are the same as in the above mentioned example but the parameters of the first hot isostatic pressing are so chosen that the solid mould does not melt during the processing.
  • the first hot isostatic pressing holes are made to the capsule and the solid moulds are removed by melting in an oven whose temperature is higher than the melting temperature of the solid moulds but lower than melting temperatures of the second powder and the capsule material.
  • a second hot isostatic pressing is performed, whose parameters are so chosen that the second powder achieves a full density.

Abstract

The object of this invention is a method for manufacturing a component made of powder, which component is equipped with inner channels or with other inner cavities. In the method moulds are used which are placed inside the actual capsule, inside of which in the first hot isostatic pressing the powder remains easily removable. After removing a second hot isostatic pressing is performed, where the component achieves it's final density. The aim of the invention is to produce a method for manufacturing a component made of powder, where the effects of forming the cross section profiles of the channels caused by the hot isostatic pressing can be reduced and to minimize the difficulties during manufacturing of the article, such as difficult weld joints.

Description

Method for making inner channels of a component
The object of this invention is a method for making inner channels or cavities to a component made of powder using a hot isostatic pressing.
The hot isostatic pressing (HIP) can be used to compress powder, usually a metal powder, into a solid component. The compression is usually carried out by using a mould made of thin metal plate, that is a so called capsule, which is filled with powder, vacuumed and placed into an autoclave in a high temperature and pressure. The capsule can be so formed that it resembles the actual object, then it is a so called near net shape (NNS) manufacturing.
It is previously known to make the inner channels using hot isostatic pressing so that the pressure enters into the channels inside the object. The defects in this technique are that the cross section dimensions of the channel change during the compression and that several welding joints cause risks during manufacturing.
Although the gas, typically argon, which is used in the compression enters during the hot isostatic pressing into the channels, the pressure of the gas is not necessarily enough to prevent the effects shaping the cross section profile of the material surrounding the channel. The risks of the manufacturing are linked to that in the method in question the inner channels must be in connection to the outer side of the capsule and making of welds of the gas tight connection tubes is difficult.
Also a previously known methdod is disclosed in publication US3996048, where there is used tubes filled with a ceramic to build up inner channels. The difference to the present invention is that in the mentioned patent only one comperssion with the hot isostatic pressing is used and that the ceramic is removed after the compression by leaching with acid or alkali solution.
The aim of this invention is to produce a method for manufacturing a powder made component, where the effects caused by the hot isostatic pressing to the cross section profile of the inner channels are minimized and to minimize the risks relating to the manufacturing of an object, such as the difficult welding joints. In a method according to the invention the inner channels are made so that a) the moulds used to form the inner channels of a component are filled with a first powder, preferably a ceramic powder and placed inside of the actual capsule, or b) a piece is made which is formed like the cavity and made of a solid material, preferably a copper-nickel alloy and placed inside the actual capsule. The actual capsule in turn is filled with a second powder, that is a mould powder, which typically is a metal powder. According to the invention it is essential that these materials, the first powder or the solid material and the second powder, differ from each other, preferably the difference is either in the different sintrating temperatures of the powder or in the different melting temperatures of the materials.
When the actual capsule is filled with a mould powder, vacuumed and closed gas tightly, a first hot isostatic pressing is performed to the capsule in the autoclave.
After the first compression through the openings which are left to the capsule either a) the first powder is removed mechanically from the inner channels or b) the solid mould core material is melt from the inner channels. After this, a second hot isostatic pressing is performed, where the mould powder densities further.
In the following the invention is disclosed in more detail while referring to the attached drawings, where
Figure 1 depicts the ceramic filled inner channels which are used for making inner channels and placed inside the actual capsule, and
Figure 2 depicts a component to be produced after the hot isostatic pressing, and where there is depicted the openings which are used for removing the ceramic powder after the first hot isostatic pressing.
In Fig. 1 inside the actual manufacturing capsule 1 , which is used for manufacturing a component from powder, a mould 2 of the desired inner channel is placed, which is manufactured preferably from a metal plate. These moulds of the inner channels are filled with a powder, preferably a ceramic powder, e.g. aluminium oxide (AL2O3) which differs from the actual mould powder.
When the powders are placed the article is vacuumed. The inner channel parts, which are filled with ceramic, can be either separately vacuumed and closed or a hole can be left to them, when they get vacuumed during vacuuming of the actual article. In the later case care must be taken that the ceramic powder of the inner channels and the mould powder used to fill the actual capsule, typically a metal powder, do not mix.
After this a first hot isostatic pressing is performed. The parameters for the first compression, that is the temperature (e.g. 1000-1300 °C), the pressure (e.g. 100-150 Mpa) and the time are so chosen that the mould powder in the capsule compresses almost to a full density (typically >92%, which is a typical bound density of a powder, after which the porosity through the structure is removed) but the ceramic powder used for the inner channels stays loose.
Because the ceramic powder remains loose it can be easily removed by making holes to the capsule, through which the ceramic powder is removed from the inner channels. In Fig. 2 is depicted the component to be manufatured after a hot isostatic pressing, and there is also depicted the openings 3 which are used to remove the ceramic powder after a first hot isostatic pressing.
After this the capsule is taken again to the hot isostatic pressing, where the used parameters, i.e temperature, pressure and time are so chosen that the desired density in the mould powder is achieved. After the second compression the article, which can be e.g. a valve, is ready for follow-up processing that is typically thermal processing and machining.
If instead of a first powder is used a mould made of solid material, the main features of the processing are the same as in the above mentioned example but the parameters of the first hot isostatic pressing are so chosen that the solid mould does not melt during the processing. After the first hot isostatic pressing holes are made to the capsule and the solid moulds are removed by melting in an oven whose temperature is higher than the melting temperature of the solid moulds but lower than melting temperatures of the second powder and the capsule material. After removing the moulds a second hot isostatic pressing is performed, whose parameters are so chosen that the second powder achieves a full density.

Claims

1. Method for manufacturing a component made of powder by a hot isostatic pressing, which component is equipped with inner channels or with other inner cavities, which method comprises the following steps: - manufacturing of a cavity mould with a desired size and shape; - placing the cavity mould inside a capsule in a way required by the desired cavity; - filling the capsule with a powder around the cavity mould; - vacuuming the capsule and closing gas tightly; - performing a hot isostatic pressing, where the powder around the cavity mould densities; - removing the cavity mould after the hot isostatic pressing, characterised in that a second hot isostatic pressing is performed where the powder outside the cavity mould densities further.
2. Method according to claim 1, characterised in that - in the manufacturing phase of the cavity mould the cavity mould with desired size and shape is filled with a first powder which differs from the powder outside the cavity mould, and the cavity mould is either closed powder tightly or it is vacuumed and closed gas tightly; - in the removing phase of the cavity mould the first powder is removed from the cavity mould.
3. Method according to claim 1, characterised in that the cavity mould is a mould made of a solid material and shaped like the cavity, that is a mould core.
4. Method according to claim 2, characterised in that the first powder is still in a powder form when it is removed.
5. Method according to claim 1, characterised in that the first powder or the solid mould core is removed using means which comprise chemical, mechanical and/or thermal means.
6. Method according to any of the preceding claims, characterised in that the first and the second powder differ from each other by their sintrating temperature.
7. Method according to any of the preceding claims, characterised in that the material of the solid mould core and the second powder differ from each other by their melting temperature.
8. Method according to any of the preceding claims, characterised in that after the first isostatic pressing the density of the second powder is at least 90 %.
9. Method according to claim 5, characterised in that after the first isostatic pressing the density of the second powder is 90-95 %.
10. Method according to any of the preceding claims, characterised in that the first powder is a ceramic powder and the second powder is a metal powder.
11. Method according to any of the preceding claims, characterised in that the component is a valve.
PCT/FI2004/050170 2003-11-21 2004-11-22 Method for making inner channels of a component WO2005049251A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI20031698 2003-11-21
FI20031698A FI117085B (en) 2003-11-21 2003-11-21 Procedure for making internal channels in a component

Publications (1)

Publication Number Publication Date
WO2005049251A1 true WO2005049251A1 (en) 2005-06-02

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Family Applications (1)

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PCT/FI2004/050170 WO2005049251A1 (en) 2003-11-21 2004-11-22 Method for making inner channels of a component

Country Status (2)

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FI (1) FI117085B (en)
WO (1) WO2005049251A1 (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2123377A1 (en) * 2008-05-23 2009-11-25 Rovalma, S.A. Method for manufacturing a workpiece, in particular a forming tool or a forming tool component
EP2452766A1 (en) 2010-11-10 2012-05-16 Sandvik Intellectual Property AB Method for manufacturing a component with internal cavities
US8758676B2 (en) 2009-12-16 2014-06-24 Rolls-Royce Plc Method of manufacturing a component
US9714577B2 (en) 2013-10-24 2017-07-25 Honeywell International Inc. Gas turbine engine rotors including intra-hub stress relief features and methods for the manufacture thereof
US10040122B2 (en) 2014-09-22 2018-08-07 Honeywell International Inc. Methods for producing gas turbine engine rotors and other powdered metal articles having shaped internal cavities
GB2577788A (en) * 2018-08-07 2020-04-08 Bae Systems Plc Hot isostatic pressing consolidation of powder derived parts

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3726259C1 (en) * 1987-08-07 1988-12-08 Mtu Muenchen Gmbh Process for the production of components from metallic or non-metallic powder
WO1993017820A1 (en) * 1992-03-05 1993-09-16 Abb Cerama Ab Method of removing cores during injection moulding of objects starting from metallic and/or ceramic materials in powdered state

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3726259C1 (en) * 1987-08-07 1988-12-08 Mtu Muenchen Gmbh Process for the production of components from metallic or non-metallic powder
WO1993017820A1 (en) * 1992-03-05 1993-09-16 Abb Cerama Ab Method of removing cores during injection moulding of objects starting from metallic and/or ceramic materials in powdered state

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2123377A1 (en) * 2008-05-23 2009-11-25 Rovalma, S.A. Method for manufacturing a workpiece, in particular a forming tool or a forming tool component
WO2009141152A1 (en) * 2008-05-23 2009-11-26 Rovalma, S.A. Method and device for producing a workpiece, particularly a shaping tool or a part of a shaping tool
US8758676B2 (en) 2009-12-16 2014-06-24 Rolls-Royce Plc Method of manufacturing a component
EP2452766A1 (en) 2010-11-10 2012-05-16 Sandvik Intellectual Property AB Method for manufacturing a component with internal cavities
WO2012062786A1 (en) 2010-11-10 2012-05-18 Sandvik Intellectual Property Ab Method for manufacturing a component with internal cavities
US9714577B2 (en) 2013-10-24 2017-07-25 Honeywell International Inc. Gas turbine engine rotors including intra-hub stress relief features and methods for the manufacture thereof
US10040122B2 (en) 2014-09-22 2018-08-07 Honeywell International Inc. Methods for producing gas turbine engine rotors and other powdered metal articles having shaped internal cavities
US10807166B2 (en) 2014-09-22 2020-10-20 Honeywell International Inc. Methods for producing gas turbine engine rotors and other powdered metal articles having shaped internal cavities
US11305348B2 (en) 2014-09-22 2022-04-19 Honeywell International Inc. Methods for producing gas turbine engine rotors and other powdered metal articles having shaped internal cavities
GB2577788A (en) * 2018-08-07 2020-04-08 Bae Systems Plc Hot isostatic pressing consolidation of powder derived parts
GB2577788B (en) * 2018-08-07 2021-09-29 Bae Systems Plc Hot isostatic pressing consolidation of powder derived parts
US11638956B2 (en) 2018-08-07 2023-05-02 Bae Systems Plc Hot isostatic pressing consolidation of powder derived parts

Also Published As

Publication number Publication date
FI20031698A (en) 2005-05-22
FI117085B (en) 2006-06-15
FI20031698A0 (en) 2003-11-21

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