EP1604760A1 - A method of manufacturing a component with a cellular structure by consolidating a coated metal powder - Google Patents
A method of manufacturing a component with a cellular structure by consolidating a coated metal powder Download PDFInfo
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- EP1604760A1 EP1604760A1 EP05252858A EP05252858A EP1604760A1 EP 1604760 A1 EP1604760 A1 EP 1604760A1 EP 05252858 A EP05252858 A EP 05252858A EP 05252858 A EP05252858 A EP 05252858A EP 1604760 A1 EP1604760 A1 EP 1604760A1
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- Prior art keywords
- metal particles
- metal
- particles
- component
- coating
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Classifications
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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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/14—Treatment of metallic powder
- B22F1/145—Chemical treatment, e.g. passivation or decarburisation
-
- 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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/17—Metallic particles coated with metal
Definitions
- the present invention relates to a method of manufacturing a component by consolidating a metal powder.
- Near net shape components are manufactured by consolidating metal powder, for example by hot isostatic pressing.
- a vacuum purge system is used so as to maintain the composition of the metal powder constant throughout the consolidation process.
- the resulting component thus has a homogeneous composition.
- the present invention seeks to provide a novel method of manufacturing a component by consolidating a metal powder in which the microstructure of the metal of the component is modified and the component has improved physical and mechanical properties.
- the present invention provides a method of manufacturing a component by consolidating a metal powder comprising the steps of:-
- step (b) comprises oxidising the surfaces of the metal particles.
- step (b) comprises nitriding the surfaces of the metal particles.
- step (b) comprises vapour depositing a solid solution strengthening element on the surfaces of the metal particles.
- step (b) comprises coating the surfaces of the metal particles with a second metal having lower melting point than the metal particles.
- step (b) comprises coating the surfaces of the metal particles with particles of a second metal powder having a lower yield strength than the metal particles.
- the metal particles have an average size of 100 micrometers.
- the metal particles have a maximum size of 250 micrometers.
- the size of the metal particles may be varied to vary the properties of the component.
- the metal particles may be alloy particles.
- the second metal may be an alloy.
- the second metal particles may be alloy particles.
- the metal particles are titanium alloy particles. More preferably the titanium alloy particles comprise 6wt% aluminium, 4wt% vanadium and the balance titanium, minor additions and incidental impurities.
- step a) comprises supplying the titanium alloy particles into a container
- step b) comprises oxidising the titanium alloy particles
- step c) comprises sealing the container and applying heat and pressure.
- step b) comprises heating to a temperature of 450°C and maintaining at 450°C for 8 hours under a partial pressure of 10 -1 torr to oxidise the titanium alloy particles and step c) comprises hot isostatic pressing the container at a temperature of 925°C for 2 hours at a pressure of 150MPa.
- the container is removed by machining or dissolving in a suitable acid.
- the container comprises mild steel.
- the present invention also provides a component comprising consolidated metal powder, the metal powder comprising metal particles diffusion bonded together, the surfaces of the metal particles having a coating having at least one element which has partially diffused into the metal particles to form a cellular structure, the cellular structure comprising a framework of more highly alloyed material located at the boundaries of the diffusion bonded metal particles and the centres of the consolidated metal particles retain their original composition.
- the coating comprising an oxide or a nitride and the at least one element is oxygen or nitrogen respectively.
- the coating comprises a solid solution strengthening element on the surfaces of the metal particles.
- the coating comprises a second metal having lower melting point than the metal particles.
- the coating comprises a second metal powder having a lower yield strength than the metal particles.
- the metal particles are titanium alloy particles. More preferably the titanium alloy particles comprise 6wt% aluminium, 4wt% vanadium and the balance titanium, minor additions and incidental impurities.
- the component is a gas turbine engine component.
- the component is a fan blade, a part of a fan blade, a compressor blade or a casing.
- the present invention uses a metal powder consolidation process to produce a cellular structure into a component 10 or 20 in which the normal alloy composition is held within a framework of interstitial alloy or solid solution strengthened alloy.
- the method of manufacturing a component 10, or 20, by consolidating a metal powder comprises preparing a metal powder, the metal powder comprising metal particles 30.
- the metal particles ideally should have a narrow particle size, diameter, range, although this is not essential.
- the metal particles 30 have an average size of 100 micrometers and the metal particles 30 have a maximum size of 250 micrometers.
- a coating 32 containing at least one element is deposited on the surfaces 34 of the metal particles 30 of the metal powder. Heat and pressure is then applied to consolidate the metal particles 30 such that the at least one element of the coating 32 on the surfaces 34 of the metal particles 30 partially diffuses into the metal particles 30 and the coated metal particles 30 are diffusion bonded together to form a cellular structure 36.
- the roughly spherical metal particles 30 are deformed to a polyhedral shape. This results in a framework of more highly alloyed material 38 located at the boundaries of the diffusion bonded metal particles 30, or adjacent the original surfaces 34 of the metal particles 30. Because there is only limited diffusion of the at least one element from the coating 32 into the metal particles 30, the centres 40 of the consolidated metal particles 30 retain their original composition and thus a cellular structure 36 is created.
- the properties of the cellular structure 36 are dependent on the size, diameter, of the metal particles 30 of the metal powder, e.g. the dimensions of the resulting centres 40, and the at least one element in the coating 32.
- the size, diameter, of the metal particles 30 may be varied to vary the properties of the cellular structure 36 and hence the physical and mechanical properties of the component 10 or 20.
- the coating 32 for the metal particles 30 may be varied to vary the properties of the cellular structure 36 and hence the physical and mechanical properties of the component 10 or 20.
- the coating 32 may comprise an oxide, which is produced by oxidising the surfaces 34 the metal particles 30 in oxygen or air.
- the coating 32 may comprise a nitride, which is produced by nitriding the surfaces 34 of the metal particles 30.
- the coating 32 may comprise a solid solution strengthening element, which is produced by vapour depositing on the surfaces 34 of the metal particles 30.
- the coating 32 may comprise a second metal, having lower melting point than the metal particles 30.
- the coating 32 comprises a second metal powder having a lower yield strength than the metal particles 30.
- the metal particles 30 may be alloy particles.
- the second metal may be an alloy.
- the second metal particles may be alloy particles.
- the metal particles may be titanium alloy particles. More preferably the titanium alloy particles comprise 6wt% aluminium, 4wt% vanadium and the balance titanium, minor additions and incidental impurities.
- the present invention permits modification of the material structure to enhance physical and mechanical properties according to the laws of cellular structures.
- the present invention produces a cellular structure within a solid metallic component, the cellular structure improves the impact absorption properties, the ductility and the strength of a conventional alloy. In addition physical properties such as the elastic modulus, Poisson's Ratio, friction and damping characteristics are improved.
- Titanium alloy particles comprising 6wt% aluminium, 4wt% vanadium and the balance titanium, minor additions and incidental impurities were prepared.
- the titanium alloy particles were then filtered to the required titanium alloy particle size, 100 micrometers average size and 250 micrometers maximum size.
- the titanium alloy particles were poured through an inlet tube into and filled a mild steel container, which defines the shape of the component being produced.
- the container was heated to a temperature of 450°C and maintained at 450°C for 8 hours under a partial air pressure of 10 -1 torr to oxidise the titanium alloy particles.
- the container was then sealed by welding shut an inlet tube.
- the container was placed in a HIP vessel and hot isostatically pressed at a temperature of 925°C for 2 hours at a pressure of 150MPa. Then the container was removed from the consolidated metal powder component by machining or dissolving in a suitable acid.
- a second metal, or second alloy which has a lower melting point the metal particles will result in melting or evaporation of the second metal to produce a coating on the metal particles.
- the use of a second metal powder having a lower yield strength than the metal particles will result in the second metal powder deforming around the metal particles during consolidation to produce the cellular structure.
- the present invention may also be used to infill metal powder particles into an existing hollow metal structure, for example a hollow fan blade or hollow compressor blade, and then to produce the cellular structure within the existing hollow metal structure.
- an existing hollow metal structure for example a hollow fan blade or hollow compressor blade
- the present invention may also be used to produce a hollow fan blade of a hollow compressor blade.
- the mild steel container was provided with one or more removable cores in the mild steel container to define one or more chambers in the hollow fan blade, or hollow compressor blade.
- the titanium alloy particles were poured into the mild steel container to fill the space in the mild steel container around the one or more removable cores.
- the container was heated to 450°C and maintained at 450°C for 8 hours under a partial air pressure of 10 -1 torr to oxidise the titanium alloy particles.
- the container was then sealed by welding shut the inlet tube.
- the container was placed in a HIP vessel and hot isostatically pressed at a temperature of 925°C for 2 hours at a pressure of 150 MPa.
- the removable cores may comprise an inert metal, for example lead or other metal with large atoms which are too large to diffuse into the titanium particles, having a lower melting point than the titanium alloy particles such that the hollow fan blade, or hollow compressor blade, is heated to a temperature at which the inert metal melts and is run out of the hollow fan blade, or hollow compressor blade. Remnants of the metal, may be removed from the hollow fan blade or hollow compressor blade, using a suitable solvent or a suitable acid.
- the removable cores may comprise mild steel which may be removed with a suitable acid.
- the hollow fan blade, or hollow compressor blade may be produced by ensuring that the container defines one or more chambers in the hollow fan blade or hollow compressor blade.
- the chambers are arranged to be pressurised during the hot isostatic pressing.
- the present invention may also entail machining a consolidated metal powder solid fan blade or solid compressor blade to final shape.
- the present invention is also applicable to titanium alloy particles comprising 6wt% aluminium, 2wt% tin, 4wt% zirconium, 2wt% molybdenum and the balance titanium, minor additions or incidental impurities.
- the oxygen or nitrogen partially diffuses into the metal particles, or alloy particles, to form interstitials in the metal, or alloy and the normal, or original, alloy composition at the centres of the consolidated metal particles, or alloy particles, is arranged within a framework of more highly alloyed, interstitial alloy, material located at the boundaries of the diffusion bonded metal particles, or alloy particles.
- the present invention has been described with reference to titanium alloys, the invention is equally applicable to aluminium alloys, iron alloys, nickel alloys, cobalt alloys and to intermetallics, for example nickel aluminides, titanium aluminides.
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Powder Metallurgy (AREA)
Abstract
A method of manufacturing a component (10,20) by
consolidating a metal powder comprises preparing a metal
powder, the metal powder comprising metal particles (30).
Depositing a coating (32) containing at least one element
on the surfaces (34) of the metal particles (30) of the
metal powder. Applying heat and pressure to consolidate
the metal particles (30) such that the at least one element
of the coating (32) on the surfaces (34) of the metal
particles (30) partially diffuses into the metal particles
(30) and the coated metal particles (30) are diffusion
bonded together to form a cellular structure (36).
Description
The present invention relates to a method of
manufacturing a component by consolidating a metal powder.
Conventional alloys have their physical and mechanical
properties improved by modifying the microstructure of the
alloys by processing and heat treatment of the source ingot
material, which is normally cast, though powder billet may
be used.
Near net shape components are manufactured by
consolidating metal powder, for example by hot isostatic
pressing. In the hot isostatic pressing process a vacuum
purge system is used so as to maintain the composition of
the metal powder constant throughout the consolidation
process. The resulting component thus has a homogeneous
composition.
Accordingly the present invention seeks to provide a
novel method of manufacturing a component by consolidating
a metal powder in which the microstructure of the metal of
the component is modified and the component has improved
physical and mechanical properties.
Accordingly the present invention provides a method of
manufacturing a component by consolidating a metal powder
comprising the steps of:-
Preferably step (b) comprises oxidising the surfaces
of the metal particles.
Alternatively step (b) comprises nitriding the
surfaces of the metal particles.
Alternatively step (b) comprises vapour depositing a
solid solution strengthening element on the surfaces of the
metal particles.
Alternatively step (b) comprises coating the surfaces
of the metal particles with a second metal having lower
melting point than the metal particles.
Alternatively step (b) comprises coating the surfaces
of the metal particles with particles of a second metal
powder having a lower yield strength than the metal
particles.
Preferably the metal particles have an average size of
100 micrometers. Preferably the metal particles have a
maximum size of 250 micrometers.
Alternatively the size of the metal particles may be
varied to vary the properties of the component.
The metal particles may be alloy particles.
The second metal may be an alloy.
The second metal particles may be alloy particles.
Preferably the metal particles are titanium alloy
particles. More preferably the titanium alloy particles
comprise 6wt% aluminium, 4wt% vanadium and the balance
titanium, minor additions and incidental impurities.
Preferably the step a) comprises supplying the
titanium alloy particles into a container, step b)
comprises oxidising the titanium alloy particles, step c)
comprises sealing the container and applying heat and
pressure.
Preferably step b) comprises heating to a temperature
of 450°C and maintaining at 450°C for 8 hours under a
partial pressure of 10-1 torr to oxidise the titanium alloy
particles and step c) comprises hot isostatic pressing the
container at a temperature of 925°C for 2 hours at a
pressure of 150MPa.
Preferably the container is removed by machining or
dissolving in a suitable acid. Preferably the container
comprises mild steel.
The present invention also provides a component
comprising consolidated metal powder, the metal powder
comprising metal particles diffusion bonded together, the
surfaces of the metal particles having a coating having at
least one element which has partially diffused into the
metal particles to form a cellular structure, the cellular
structure comprising a framework of more highly alloyed
material located at the boundaries of the diffusion bonded
metal particles and the centres of the consolidated metal
particles retain their original composition.
Preferably the coating comprising an oxide or a
nitride and the at least one element is oxygen or nitrogen
respectively.
Alternatively the coating comprises a solid solution
strengthening element on the surfaces of the metal
particles.
Alternatively the coating comprises a second metal
having lower melting point than the metal particles.
Alternatively the coating comprises a second metal
powder having a lower yield strength than the metal
particles.
Preferably the metal particles are titanium alloy
particles. More preferably the titanium alloy particles
comprise 6wt% aluminium, 4wt% vanadium and the balance
titanium, minor additions and incidental impurities.
Preferably the component is a gas turbine engine
component.
Preferably the component is a fan blade, a part of a
fan blade, a compressor blade or a casing.
The present invention will be more fully described by
way of example with reference to the accompanying drawings
in which:-
A component 10, in this example a casing, is shown in
figure 1 and a further component 20, in this example a fan
blade, is shown in figure 2 are manufactured by
consolidating a metal powder according to the present
invention.
The present invention uses a metal powder
consolidation process to produce a cellular structure into
a component 10 or 20 in which the normal alloy composition
is held within a framework of interstitial alloy or solid
solution strengthened alloy.
The method of manufacturing a component 10, or 20, by
consolidating a metal powder comprises preparing a metal
powder, the metal powder comprising metal particles 30.
The metal particles ideally should have a narrow particle
size, diameter, range, although this is not essential. For
example the metal particles 30 have an average size of 100
micrometers and the metal particles 30 have a maximum size
of 250 micrometers. A coating 32 containing at least one
element is deposited on the surfaces 34 of the metal
particles 30 of the metal powder. Heat and pressure is
then applied to consolidate the metal particles 30 such
that the at least one element of the coating 32 on the
surfaces 34 of the metal particles 30 partially diffuses
into the metal particles 30 and the coated metal particles
30 are diffusion bonded together to form a cellular
structure 36. During the consolidation of the metal
particles 30, the roughly spherical metal particles 30 are
deformed to a polyhedral shape. This results in a
framework of more highly alloyed material 38 located at the
boundaries of the diffusion bonded metal particles 30, or
adjacent the original surfaces 34 of the metal particles
30. Because there is only limited diffusion of the at
least one element from the coating 32 into the metal
particles 30, the centres 40 of the consolidated metal
particles 30 retain their original composition and thus a
cellular structure 36 is created.
The properties of the cellular structure 36 are
dependent on the size, diameter, of the metal particles 30
of the metal powder, e.g. the dimensions of the resulting
centres 40, and the at least one element in the coating 32.
Thus the size, diameter, of the metal particles 30 may be
varied to vary the properties of the cellular structure 36
and hence the physical and mechanical properties of the
component 10 or 20. The coating 32 for the metal particles
30 may be varied to vary the properties of the cellular
structure 36 and hence the physical and mechanical
properties of the component 10 or 20.
The coating 32 may comprise an oxide, which is
produced by oxidising the surfaces 34 the metal particles
30 in oxygen or air. Alternatively the coating 32 may
comprise a nitride, which is produced by nitriding the
surfaces 34 of the metal particles 30. Alternatively the
coating 32 may comprise a solid solution strengthening
element, which is produced by vapour depositing on the
surfaces 34 of the metal particles 30. Alternatively the
coating 32 may comprise a second metal, having lower
melting point than the metal particles 30. Alternatively
the coating 32 comprises a second metal powder having a
lower yield strength than the metal particles 30. The
metal particles 30 may be alloy particles. The second
metal may be an alloy. The second metal particles may be
alloy particles. The metal particles may be titanium alloy
particles. More preferably the titanium alloy particles
comprise 6wt% aluminium, 4wt% vanadium and the balance
titanium, minor additions and incidental impurities.
The present invention permits modification of the
material structure to enhance physical and mechanical
properties according to the laws of cellular structures.
The present invention produces a cellular structure within
a solid metallic component, the cellular structure improves
the impact absorption properties, the ductility and the
strength of a conventional alloy. In addition physical
properties such as the elastic modulus, Poisson's Ratio,
friction and damping characteristics are improved.
Titanium alloy particles comprising 6wt% aluminium,
4wt% vanadium and the balance titanium, minor additions and
incidental impurities were prepared. The titanium alloy
particles were then filtered to the required titanium alloy
particle size, 100 micrometers average size and 250
micrometers maximum size. The titanium alloy particles
were poured through an inlet tube into and filled a mild
steel container, which defines the shape of the component
being produced. The container was heated to a temperature
of 450°C and maintained at 450°C for 8 hours under a partial
air pressure of 10-1 torr to oxidise the titanium alloy
particles. The container was then sealed by welding shut
an inlet tube. The container was placed in a HIP vessel
and hot isostatically pressed at a temperature of 925°C for
2 hours at a pressure of 150MPa. Then the container was
removed from the consolidated metal powder component by
machining or dissolving in a suitable acid.
The use of a second metal, or second alloy, which has
a lower melting point the metal particles will result in
melting or evaporation of the second metal to produce a
coating on the metal particles. The use of a second metal
powder having a lower yield strength than the metal
particles will result in the second metal powder deforming
around the metal particles during consolidation to produce
the cellular structure.
The present invention may also be used to infill metal
powder particles into an existing hollow metal structure,
for example a hollow fan blade or hollow compressor blade,
and then to produce the cellular structure within the
existing hollow metal structure. Alternatively, it may be
possible to infill metal powder between at least two metal
workpieces, then to produce the cellular structure between
the at least two metal workpieces and to diffusion bond the
cellular structure to the at least two workpieces and to
diffusion bond the at least two workpieces together, for
example a fan blade.
The present invention may also be used to produce a
hollow fan blade of a hollow compressor blade. The mild
steel container was provided with one or more removable
cores in the mild steel container to define one or more
chambers in the hollow fan blade, or hollow compressor
blade. The titanium alloy particles were poured into the
mild steel container to fill the space in the mild steel
container around the one or more removable cores. The
container was heated to 450°C and maintained at 450°C for 8
hours under a partial air pressure of 10-1 torr to oxidise
the titanium alloy particles. The container was then
sealed by welding shut the inlet tube. The container was
placed in a HIP vessel and hot isostatically pressed at a
temperature of 925°C for 2 hours at a pressure of 150 MPa.
Then the container was removed from the consolidated metal
powder hollow fan blade, or hollow compressor blade, by
machining or dissolving in a suitable acid. Then the
removable cores were removed. The removable cores may
comprise an inert metal, for example lead or other metal
with large atoms which are too large to diffuse into the
titanium particles, having a lower melting point than the
titanium alloy particles such that the hollow fan blade, or
hollow compressor blade, is heated to a temperature at
which the inert metal melts and is run out of the hollow
fan blade, or hollow compressor blade. Remnants of the
metal, may be removed from the hollow fan blade or hollow
compressor blade, using a suitable solvent or a suitable
acid. The removable cores may comprise mild steel which
may be removed with a suitable acid.
Alternatively, the hollow fan blade, or hollow
compressor blade may be produced by ensuring that the
container defines one or more chambers in the hollow fan
blade or hollow compressor blade. The chambers are
arranged to be pressurised during the hot isostatic
pressing.
The present invention may also entail machining a
consolidated metal powder solid fan blade or solid
compressor blade to final shape.
The present invention is also applicable to titanium
alloy particles comprising 6wt% aluminium, 2wt% tin, 4wt%
zirconium, 2wt% molybdenum and the balance titanium, minor
additions or incidental impurities.
In the case of oxidising and nitriding the metal
particles, or alloy particles, the oxygen or nitrogen
partially diffuses into the metal particles, or alloy
particles, to form interstitials in the metal, or alloy and
the normal, or original, alloy composition at the centres
of the consolidated metal particles, or alloy particles, is
arranged within a framework of more highly alloyed,
interstitial alloy, material located at the boundaries of
the diffusion bonded metal particles, or alloy particles.
Although the present invention has been described with
reference to titanium alloys, the invention is equally
applicable to aluminium alloys, iron alloys, nickel alloys,
cobalt alloys and to intermetallics, for example nickel
aluminides, titanium aluminides.
Claims (27)
- A method of manufacturing a component (10,20) by consolidating a metal powder comprising the steps of:-(d) preparing a metal powder, the metal powder comprising metal particles (30),(e) depositing a coating (32) containing at least one element on the surfaces (34) of the metal particles (30) of the metal powder,(f) applying heat and pressure to consolidate the metal particles (30) such that the at least one element of the coating (32) on the surfaces (34) of the metal particles (30) partially diffuses into the metal particles (30) and the coated metal particles (30) are diffusion bonded together to form a cellular structure (36), the cellular structure (36) comprising a framework of more highly alloyed material (38) located at the boundaries of the diffusion bonded metal particles (30) and the centres (40) of the consolidated metal particles (30) retain their original composition.
- A method as claimed in claim 1 wherein step (b) comprises oxidising the surfaces (34) of the metal particles (30).
- A method as claimed in claim 1 wherein step (b) comprises nitriding the surfaces (34) of the metal particles (30).
- A method as claimed in claim 1 wherein step (b) comprises vapour depositing a solid solution strengthening element on the surfaces (34) of the metal particles (30).
- A method as claimed in claim 1 wherein step (b) comprises coating the surfaces (34) of the metal particles (30) with a second metal having lower melting point than the metal particles (30).
- A method as claimed in claim 1 wherein step (b) comprises coating the surfaces (34) of the metal particles (30) with particles of a second metal powder having a lower yield strength than the metal particles (30).
- A method as claimed in any of claims 1 to 6 wherein the metal particles (30) are alloy particles.
- A method as claimed in claim 5 wherein the second metal is an alloy.
- A method as claimed in claim 6 wherein the second metal particles are alloy particles.
- A method as claimed in claim 7 wherein the metal particles (30) are titanium alloy particles.
- A method as claimed in claim 10 wherein the titanium alloy particles (30) comprise 6wt% aluminium, 4wt% vanadium and the balance titanium, minor additions and incidental impurities.
- A method as claimed in claim 11 wherein step a) comprises supplying the titanium alloy particles (30) into a container, step b) comprises oxidising the titanium alloy particles (30), step c) comprises sealing the container and applying heat and pressure.
- A method as claimed in claim 12 wherein step b) comprises heating to a temperature of 450°C and maintaining at 450°C for 8 hours under a partial pressure of 10-1 torr to oxidise the titanium alloy particles (30) and step c) comprises hot isostatic pressing the container at a temperature of 925°C for 2 hours at a pressure of 150MPa.
- A method as claimed in claim 12 or claim 13 wherein the container is removed by machining or dissolving in a suitable acid.
- A method as claimed in claim 12, claim 13 or claim 14 wherein the container comprises mild steel.
- A method as claimed in any of claims 1 to 15 wherein the metal particles (30) have an average size of 100 micrometers.
- A method as claimed in any of claims 1 to 16 wherein the metal particles (30) have a maximum size of 250 micrometers.
- A method as claimed in any of claims 1 to 15 wherein the size of the metal particles (30) is varied to vary the properties of the component (10,20).
- A component (10,20) comprising consolidated metal powder, the metal powder comprising metal particles (30) diffusion bonded together, the surfaces (34) of the metal particles (30) having a coating having at least one element, which has partially diffused into the metal particles (30) to form a cellular structure (36), the cellular structure (36) comprising a framework of more highly alloyed material (38) located at the boundaries of the diffusion bonded metal particles (30) and the centres (40) of the consolidated metal particles (30) retain their original composition.
- A component as claimed in claim 19 wherein the coating (34) comprising an oxide or a nitride and the at least one element is oxygen or nitrogen respectively.
- A component as claimed in claim 19 wherein the coating comprises a solid solution strengthening element on the surfaces of the metal particles (30).
- A component as claimed in claim 19 wherein the coating (34) comprises a second metal having lower melting point than the metal particles (30).
- A component as claimed in claim 19 wherein the coating (34) comprises a second metal powder having a lower yield strength than the metal particles (30).
- A component as claimed in any of claims 19 to 23 wherein the metal particles (30) are titanium alloy particles.
- A component as claimed in claim 24 wherein the titanium alloy particles (30) comprise 6wt% aluminium, 4wt% vanadium and the balance titanium, minor additions and incidental impurities.
- A component as claimed in any of claims 19 to 25 wherein the component (10,20) is a gas turbine engine component.
- A component as claimed in claim 26 wherein the component is a fan blade (20), a part of a fan blade, a compressor blade or a casing (10).
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GBGB0413135.5A GB0413135D0 (en) | 2004-06-12 | 2004-06-12 | A method of manufacturing a component by consolidating a metal powder |
| GB0413135 | 2004-06-12 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| EP1604760A1 true EP1604760A1 (en) | 2005-12-14 |
| EP1604760B1 EP1604760B1 (en) | 2007-02-21 |
Family
ID=32732386
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP05252858A Not-in-force EP1604760B1 (en) | 2004-06-12 | 2005-05-10 | A method of manufacturing a component with a cellular structure by consolidating a coated metal powder |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US20050276715A1 (en) |
| EP (1) | EP1604760B1 (en) |
| DE (1) | DE602005000580T2 (en) |
| GB (1) | GB0413135D0 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109759594A (en) * | 2019-01-08 | 2019-05-17 | 钢铁研究总院 | A kind of combined material hot isostatic pressing high throughput micro manufacturing method and its thin wall wrap model |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10343217B2 (en) | 2014-01-24 | 2019-07-09 | United Technologies Corporation | Nanoparticle enhancement for additive manufacturing |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0024984A1 (en) * | 1979-08-27 | 1981-03-11 | COMMISSARIAT A L'ENERGIE ATOMIQUE Etablissement de Caractère Scientifique Technique et Industriel | Process of making titanium alloy articles by powder metallurgy |
| GB2157711A (en) * | 1984-04-04 | 1985-10-30 | Krebsoege Gmbh Sintermetall | Improvements relating to tough material for tools and/or wearing parts |
| JPH04187704A (en) * | 1990-11-20 | 1992-07-06 | Daido Sanso Kk | Manufacture of aluminum powder compression compact |
| US6024915A (en) * | 1993-08-12 | 2000-02-15 | Agency Of Industrial Science & Technology | Coated metal particles, a metal-base sinter and a process for producing same |
| US6162497A (en) * | 1991-07-17 | 2000-12-19 | Materials Innovation, Inc. | Manufacturing particles and articles having engineered properties |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2273589A (en) * | 1940-03-07 | 1942-02-17 | Gen Motors Corp | Method of making porous metal bodies |
| US3963485A (en) * | 1972-05-01 | 1976-06-15 | Gould Inc. | Method of producing sintered titanium base articles |
| US4880460A (en) * | 1986-02-25 | 1989-11-14 | Crucible Materials Corporation | Powder metallurgy high speed tool steel article and method of manufacture |
| US4981512A (en) * | 1990-07-27 | 1991-01-01 | The United States Of America As Represented By The Secretary Of The Army | Methods are producing composite materials of metal matrix containing tungsten grain |
| US6017488A (en) * | 1998-05-11 | 2000-01-25 | Sandvik Ab | Method for nitriding a titanium-based carbonitride alloy |
-
2004
- 2004-06-12 GB GBGB0413135.5A patent/GB0413135D0/en not_active Ceased
-
2005
- 2005-05-10 EP EP05252858A patent/EP1604760B1/en not_active Not-in-force
- 2005-05-10 DE DE602005000580T patent/DE602005000580T2/en active Active
- 2005-05-11 US US11/126,230 patent/US20050276715A1/en not_active Abandoned
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0024984A1 (en) * | 1979-08-27 | 1981-03-11 | COMMISSARIAT A L'ENERGIE ATOMIQUE Etablissement de Caractère Scientifique Technique et Industriel | Process of making titanium alloy articles by powder metallurgy |
| GB2157711A (en) * | 1984-04-04 | 1985-10-30 | Krebsoege Gmbh Sintermetall | Improvements relating to tough material for tools and/or wearing parts |
| JPH04187704A (en) * | 1990-11-20 | 1992-07-06 | Daido Sanso Kk | Manufacture of aluminum powder compression compact |
| US6162497A (en) * | 1991-07-17 | 2000-12-19 | Materials Innovation, Inc. | Manufacturing particles and articles having engineered properties |
| US6024915A (en) * | 1993-08-12 | 2000-02-15 | Agency Of Industrial Science & Technology | Coated metal particles, a metal-base sinter and a process for producing same |
Non-Patent Citations (1)
| Title |
|---|
| PATENT ABSTRACTS OF JAPAN vol. 016, no. 507 (M - 1327) 20 October 1992 (1992-10-20) * |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109759594A (en) * | 2019-01-08 | 2019-05-17 | 钢铁研究总院 | A kind of combined material hot isostatic pressing high throughput micro manufacturing method and its thin wall wrap model |
| US11040397B2 (en) | 2019-01-08 | 2021-06-22 | Central Iron And Steel Research Institute | Method of high-throughput hot isostatic pressing micro-synthesis for the combinatorial materials and sleeve mould thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| DE602005000580D1 (en) | 2007-04-05 |
| US20050276715A1 (en) | 2005-12-15 |
| DE602005000580T2 (en) | 2007-06-21 |
| GB0413135D0 (en) | 2004-07-14 |
| EP1604760B1 (en) | 2007-02-21 |
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