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EP0090118B1 - Moule céramique et procédé pour la production de celui-ci - Google Patents

Moule céramique et procédé pour la production de celui-ci Download PDF

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Publication number
EP0090118B1
EP0090118B1 EP82306346A EP82306346A EP0090118B1 EP 0090118 B1 EP0090118 B1 EP 0090118B1 EP 82306346 A EP82306346 A EP 82306346A EP 82306346 A EP82306346 A EP 82306346A EP 0090118 B1 EP0090118 B1 EP 0090118B1
Authority
EP
European Patent Office
Prior art keywords
mould
ceramic
article
mould cavity
cavity
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.)
Expired
Application number
EP82306346A
Other languages
German (de)
English (en)
Other versions
EP0090118A1 (fr
Inventor
Vijay Kumar Chandhok
Karl Simms Brosius
William Lee Mccollough
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.)
Crucible Materials Corp
Original Assignee
Crucible Materials Corp
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 Crucible Materials Corp filed Critical Crucible Materials Corp
Priority to AT82306346T priority Critical patent/ATE18364T1/de
Publication of EP0090118A1 publication Critical patent/EP0090118A1/fr
Application granted granted Critical
Publication of EP0090118B1 publication Critical patent/EP0090118B1/fr
Expired 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
    • 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
    • B22F3/1208—Containers or coating used therefor
    • B22F3/1258—Container manufacturing
    • B22F3/1275—Container manufacturing by coating a model and eliminating the model before consolidation
    • 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
    • B22F3/1208—Containers or coating used therefor
    • B22F3/1216—Container composition
    • B22F3/1241—Container composition layered
    • 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
    • B22F3/1208—Containers or coating used therefor
    • B22F3/1258—Container manufacturing
    • B22F3/1283—Container formed as an undeformable model eliminated after consolidation

Definitions

  • This invention relates to ceramic moulds and to a method of producing same.
  • the ceramic mould has an interior which conforms to the desired configuration of the article to be produced.
  • the cavity is filled with powdered metal, the mould is sealed, heated and then subjected to force sufficient to compact the powdered metal therein to form a dense article.
  • the preferred compacting method is to place the powder filled mould at elevated temperature in an autoclave for hot isostatic pressing by the use of a gas, such as helium.
  • One practice for producing moulds of this type involves making a wax pattern of the configuration of the article to be produced and then casting the ceramic around the pattern so that the interior of the ceramic conforms to the surface configuration of the pattern and thus the article to be produced. An opening is provided in the ceramic through which upon heating the wax may be melted to expose the cavity. Thereafter the cavity is filled with powdered metal and the powder is compacted in the conventional manner as by hot isostatic compacting.
  • a ceramic mould body having a mould cavity therein with the surface of the mould cavity conforming substantially to the configuration of the article to be produced.
  • the mould cavity is generally somewhat "oversize" with respect to the final article to allow for shrinkage during compacting.
  • An opening is provided for filling the cavity with powdered metal and thereafter sealing it prior to compacting.
  • the mould cavity has a continuous metal coating covering its surface. This prevents contact between the metal powder and the ceramic material of the mould and thus acts as a barrier to prevent contamination by impurities such as oxides from entering the powder during the heating and compacting cycle.
  • a preferred material for this coating is nickel or nickel-base alloys as they remain continuous during the high temperatures incident to hot compacting operations such as hot isostatic pressing.
  • the alloy powders are generally superalloys, such as nickel, iron or cobalt-base alloys, and titanium- base alloys for use in high temperature applications, such as jet engine components and the like.
  • the mould of the invention is also suitable for use with high speed steels and tool steels.
  • the mould is segmented into at least two selectively separated parts. When separated the interior can be coated with the metal and then the parts can be joined to form the integral mould.
  • a preferred method for applying the coating so that it is thin and continuous involves vapour deposition.
  • Figure 1 shows two identical mould segments in cross-section identified as 10 having a ceramic body portion 12 with a mould cavity 14 conforming to the configuration of the article to be produced, which in this case is a gearwheel.
  • the gear teeth 16 are defined in the interior surface of the body 12. This may be achieved by dipping a wax pattern conforming substantially to the shape of the gear wheel in a refractory slurry and then melting away the wax after drying the refractory material. Although this method is preferred, any other method may be used for producing the mould.
  • the interior surfaces of the mould cavity are coated with a metal 18, as shown in Figure 2, and the segments are joined and filled with powdered metal 20. The mould is then sealed and compacted such as by hot isostatic compacting.
  • a ceramic shell was internally coated with nickel using the chemical vapour deposition (CVD) process. This involved injecting nickel carbonyl gas into the heated shell, whereupon the nickel metal was deposited by thermal decomposition of the gas onto the surface of the shell cavity. A coating was produced with certain areas left bare. The coating thickness was of the order of 0.0254 to 0.254 mm (1 to 10 mils).
  • the shell was then processed in a normal manner to produce a powder metallurgy part, using a conventional nickel-base superalloy powder (Rene 95). The resulting compact was normal with an unusually bright surface appearance.
  • Metallographic examination revealed a nickel surface coating, a boundary layer of interdiffusion products, and the Rene 95 base metal (see Figure 4).
  • the Rene 95 powder particles are outlined by a contamination layer, a normal phenomenon with the conventional ceramic mould process (see Figure 5).
  • the nickel coating is thus seen to provide protection for contamination for the Rene 95 base metal from which the final compacted superalloy is to be made.
  • a ceramic shell was split and the interior of the shell conforming to the powder metallurgy article to be produced was coated with nickel by the ion deposition process wherein metal atoms are directly deposited on the target surface in a vacuum chamber.
  • the coating thickness was of the order of 0.00254 mm (.1 mils).
  • the shell was then processed in a normal manner to produce a powder metallurgy part, using titanium alloy powder. This included filling the shell with titanium alloy powder, evacuating, heating and hot-isostatic pressing to compact the powder to full density. The resulting compact had an unusually smooth surface appearance.
  • Metallographic examination revealed a surface diffusion-products layer of the order of 0.00254 mm (.1 mil) thick (see Figure 6).
  • a metal coating may be produced on the interior surfaces of a ceramic shell such as by electroplating the metal coating, which may be nickel, on a wax pattern shape and then providing a ceramic shell around this metal-coated wax pattern, as by dipping the assembly in a refractory slurry.
  • the metal coating which may be nickel
  • a wax pattern may be coated with nickel by first spraying the surface of the pattern with graphite to provide an electrically conductive base and then electroplating onto this conductive base a metal such as nickel.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Moulds, Cores, Or Mandrels (AREA)

Claims (10)

1. Moule (10) destiné à être utilisé pour produire par la métallurgie des poudres un objet (22), comprenant un corps de moule céramique (12), à l'intérieur duquel se trouve une cavité de moule (14) dont la surface se conforme pratiquement à la configuration de l'objet à produire et qui est adaptée pour être remplie par un métal en poudre (20) pour subir un compactage pour former cet objet, caractérisé en ce qu'un revêtement métallique continu (18) recouvre la surface de la cavité du moule (14).
2. Moule selon la revendication 1, caractérisé en ce que ce revêtement métallique (18) est du nickel.
3. Moule selon la revendication 1 ou la revendication 2, caractérisé en ce que le corps (12) du moule céramique est segmenté en au moins deux parties sélectivement séparables.
4. Moule selon l'une des revendications 1, 2 ou 3, caractérisé en ce que ce moule (10) a un noyau céramique à l'intérieur de la cavité de moule (14) et qu'un revêtement métallique continu est déposé sur ce noyau céramique.
5. Procédé pour produire une moule (10) destiné à être utilisé pour produire, par la métallurgie des poudres, un objet (22), ce procédé consistant à produire un corps de moule céramique (12) à l'intérieur duquel se trouve une cavité de moule (14) dont la surface se conforme pratiquement à la configuration de l'objet (22) et qui est adaptée pour être remplie d'un métal en poudre (20) pour subir en compactage pour former cet objet (22), caractérisé en ce que ce procédé consiste en outre à appliquer un revêtement métallique continu (18) sur cette surface.
6. Procédé selon la revendication 5, caractérisé en ce que ce corps de moule céramique (12) est produit en formant au moins deux segments séparables (10) et en raccordant ces segments pour obtenir la cavité de moule (14).
7. Procédé selon la revendication 6, caractérisé en ce que chacun de ces segments (10) a une portion de surface adaptée pour former la cavité de moule (14) lorsque ces segments (10) sont raccordés et en ce qu'un revêtement métallique continu (18) est appliqué sur cette portion de surface avant raccordement des segments (10) pour obtenir la cavité de moule (14).
8. Procédé selon l'une des revendications 5, 6 ou 7, caractérisé en ce que ce revêtement métallique (18) est du nickel.
9. Procédé selon l'une quelconque des revendications 5 à 8 précédentes, caractérisé en ce que ce revêtement (18) est appliqué par dépôt chimique en phase vapeur.
10. Procédé selon l'une quelconque des revendications 5 à 9 précédentes, caractérisé en ce qu'un noyau céramique, sur lequel est déposé un revêtement métallique continu, est prévu à l'intérieur de la cavité du moule.
EP82306346A 1982-03-26 1982-11-30 Moule céramique et procédé pour la production de celui-ci Expired EP0090118B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT82306346T ATE18364T1 (de) 1982-03-26 1982-11-30 Keramikform und verfahren zur herstellung derselben.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US36234182A 1982-03-26 1982-03-26
US362341 1994-12-22

Publications (2)

Publication Number Publication Date
EP0090118A1 EP0090118A1 (fr) 1983-10-05
EP0090118B1 true EP0090118B1 (fr) 1986-03-05

Family

ID=23425705

Family Applications (1)

Application Number Title Priority Date Filing Date
EP82306346A Expired EP0090118B1 (fr) 1982-03-26 1982-11-30 Moule céramique et procédé pour la production de celui-ci

Country Status (4)

Country Link
EP (1) EP0090118B1 (fr)
AT (1) ATE18364T1 (fr)
CA (1) CA1203659A (fr)
DE (1) DE3269719D1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10223371A1 (de) * 2002-05-25 2003-12-04 Peter Amborn Werkzeugform zur Herstellung von metallischen Formteilen durch Gieß-, Heiß-, Warm o. Kaltumformung sowie ein Verfahren zur Herstellung einer derartigen Werkzeugform

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4772450A (en) * 1984-07-25 1988-09-20 Trw Inc. Methods of forming powdered metal articles
US5985207A (en) * 1995-11-16 1999-11-16 Vawter; Paul D. Method for manufacturing powder metallurgical tooling
US6939508B2 (en) * 2002-10-24 2005-09-06 The Boeing Company Method of manufacturing net-shaped bimetallic parts
GB0623048D0 (en) * 2006-11-18 2006-12-27 Bentley Motors Ltd Improvements in or relating to ceramic tooling
EP3391982B1 (fr) * 2017-04-21 2023-08-16 Raytheon Technologies Corporation Systèmes, dispositifs et procédés de frittage par plasma à étincelles

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL277617A (fr) * 1961-05-01
FR2002321A1 (fr) * 1968-02-21 1969-10-17 Inst Odlewnictwa

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10223371A1 (de) * 2002-05-25 2003-12-04 Peter Amborn Werkzeugform zur Herstellung von metallischen Formteilen durch Gieß-, Heiß-, Warm o. Kaltumformung sowie ein Verfahren zur Herstellung einer derartigen Werkzeugform

Also Published As

Publication number Publication date
DE3269719D1 (en) 1986-04-10
ATE18364T1 (de) 1986-03-15
EP0090118A1 (fr) 1983-10-05
CA1203659A (fr) 1986-04-29

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