EP2606997A1 - Method for manufacturing a component by metal powder injection moulding - Google Patents
Method for manufacturing a component by metal powder injection moulding Download PDFInfo
- Publication number
- EP2606997A1 EP2606997A1 EP12198188.0A EP12198188A EP2606997A1 EP 2606997 A1 EP2606997 A1 EP 2606997A1 EP 12198188 A EP12198188 A EP 12198188A EP 2606997 A1 EP2606997 A1 EP 2606997A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- bräunlingsteilstück
- sintering process
- sintered
- bräunlingsteilstücke
- brown body
- 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.)
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Links
- 238000000034 method Methods 0.000 title claims abstract description 102
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 41
- 239000002184 metal Substances 0.000 title claims abstract description 41
- 239000000843 powder Substances 0.000 title claims abstract description 36
- 238000001746 injection moulding Methods 0.000 title claims abstract description 22
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 8
- 238000005245 sintering Methods 0.000 claims abstract description 95
- 239000011230 binding agent Substances 0.000 claims abstract description 18
- 239000000463 material Substances 0.000 claims description 15
- 239000002131 composite material Substances 0.000 claims description 7
- 239000002245 particle Substances 0.000 claims description 6
- 238000005304 joining Methods 0.000 claims description 4
- 230000000295 complement effect Effects 0.000 claims description 2
- 230000013011 mating Effects 0.000 claims 1
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 229920001169 thermoplastic Polymers 0.000 description 3
- 239000004416 thermosoftening plastic Substances 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 230000009969 flowable effect Effects 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- -1 stainless steels Chemical class 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000005496 tempering Methods 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
Images
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
- 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
- B22F7/02—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 layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
- B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
-
- 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
- B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
-
- 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
-
- 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
- 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
- B22F2005/005—Article surface comprising protrusions
Definitions
- the invention relates to a method for producing a component by metal powder injection molding of metal powder mixed with a binder, in which individual components of the component are produced as separately shaped green compact and then unbonded brown compact sections which are assembled into a two- or multi-part brown compact and sintered in an assembled state become.
- the method is suitable, for example, for producing thermally stressed engine components with a geometrically complex structure.
- metal injection molding It is known to produce components of high geometric complexity from different metals such as stainless steels, case hardening and tempering steels, intermetallic phases, titanium based light metals and the like by metal injection molding (MIM) with full material utilization and no or only with little rework.
- MIM metal injection molding
- a metal powder is first mixed with a binder of thermoplastics and waxes to form a flowable material that can be processed in an injection molding process (feedstock). From the molded part produced during injection molding, the green compact, the binder is then dissolved out or thermally expelled, so that a porous - called B Hurnling - molding is available, which has the same dimensions as the green body.
- the browning is sintered slightly below the melting temperature of the respective metal in a sintering furnace, usually in a protective gas atmosphere or sometimes in a vacuum. After sintering, in which the browning shrinks to the desired finished dimensions, the final molded part is present. A rework is generally not required.
- the US 2007/0202000 A1 describes a method for joining two components produced by metal powder injection molding, in which the two components to be joined have a different shrinkage during sintering.
- the two components have form-fitting interlocking projections or recesses. During sintering, that component which encloses the projections of the other component exerts a pressure on these projections. The subsequent connection of the two components is primarily ensured by the projections.
- the invention has for its object to provide further methods for metal powder injection molding of geometrically complex shaped, composed of separately prefabricated B Hurnlingen components in which an intimate, firm connection is achieved during the sintering process between the joined B Hurnlingen.
- the invention provides that at least one of the B syndromenlingsteil sese to be joined undergoes a pre-sintering process in which it undergoes a first shrinkage.
- this first shrinkage is less than the maximum shrinkage that the Bhoffnlingsteil FIFA can experience by sintering.
- the at least one presintered and thus preshrunk Bhoffnlingsteil rave and at least one other Bhoffnlingsteil familia are then assembled into a two- or multi-part B Hurnling. Subsequently, the two- or multi-part Braunling undergoes a main sintering process.
- the at least one pre-sintered B syndromesteil undergoes less shrinkage than the at least one further Bhoffnlingsteil amino acid, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, amino acid sequence, and the at least one further B syndrome.
- the non-pre-sintered brown compact section shrinks more than the pre-sintered brown compact section, thereby providing pressure to the surfaces to be joined.
- the stronger shrinking B Hurnlingsteil Gi is automatically pressed to the less shrinking B Hurnlingsteil Gi so that always a Nullspaltrise and an intimate connection between the Bhoffnlingsteil familiaen is guaranteed.
- complex components can be provided in high quality.
- the method is suitable, for example, for producing thermally stressed engine components with a geometrically complex structure.
- a presintered B syndromenlingsteil and another B syndromenlingsteil
- form-fitting interlocking fasteners are interconnected before the main sintering process.
- the Bakinlingteil vorzufinternde before passing through the pre-sintering process has dimensions such that it is not connectable to the other Bhoffnlingsteil familia, and shrinks in the pre-sintering process such that the two Bhoffnlingsteil devise can now be connected via the interlocking fasteners.
- the B syndromenlingsteil vorzufinternde is thus provided with a connecting element such that a fit with the other B syndromenlingsteil Partners is guaranteed only after pre-sintering.
- the two components are then finished sintered, wherein the non-presintered component shrinks more than the pre-sintered component.
- connection elements of the B syndromenlingsteil sese is according to an embodiment of the invention to form-fitting interlocking projections and Recesses. It is provided that the projections taper towards the main body of the Bhoffnlingsteil familias and this example, dovetail-shaped or club-shaped. The recesses of the other Bhoffnlingsteil familias have a matching complementary shape.
- the projections are formed on that B Hurnlingsteil published which is pre-sintered, and the recesses are formed on the further B Hurnlingsteil consultancy. That is, in the main sintering process, the brown compact section having the recesses and enclosing the protrusions of the other brown compact section exerts pressure on these protrusions.
- the resulting connection of the two components is primarily ensured by the projections and is essentially limited to the region of the projections and recesses.
- the recesses are formed on that B Hurnlingsteil published which is pre-sintered, and the projections are formed on the further Bhoffnlingsteil.
- This embodiment causes, on sintering the composite tanning bristle, the tanning portion having recesses to the tanning portion having projections is attracted by its more shrinking projections, whereby the respective contact surfaces between the Bhoffnlingsteil Anlagenen pressed together.
- the surfaces on which the Bhoffnlingsteil developede are drawn together during sintering of the composite B Hurnlings, be arranged substantially parallel to each other, which includes a common curvature.
- the projections are convexly curved and the recesses concavely curved, for example in the form of spherical or lobe-shaped projections and recesses.
- a further embodiment of the invention provides that at least three B syndromenlingsteil developede are assembled and sintered together in the main sintering process.
- one of the B syndromenlingsteil developede represents a connecting part, which is composable before the main sintering process with two more of the Bhoffnlingsteil developede.
- the connecting part has for this purpose two connecting elements, for example in the form of projections or recesses. It is now either pre-sintered as part of the Bhoffnlingsteil familia or the two further Bhoffnlingsteilges are pre-sintered.
- the two further Braunling sections are connected to each other by means of the Bhoffnlingsteil Federations formed as a connecting part for the main sintering process.
- both brown compact sections are intimately connected to the brown compact section serving as a connecting part, so that they are intimately connected to one another via the connecting part.
- the connecting part can be designed, for example, as an insert part (so-called "insert") which essentially has the shape of two recesses which are formed in the brown compact sections to be connected. It can be provided that the connecting part in the main sintering process pulls the other two B Hurnlingsteilges each other and thereby a large area a Nullspaltrich between contact surfaces of the adjacent Bhoffnlingsteil unitede is achieved.
- insert part so-called "insert”
- the inventive method can also be used with rotationally symmetrical components.
- the composite brown compact comprises an inner brown compact section and an outer brown compact section surrounding this with or without connecting elements.
- the outer B Hurnlingsteil GmbH is not pre-sintered B Hurnlingsteil Gi.
- the outer brown compact section is pressed against the inner brown compact section.
- the at least one presintered B syndromenlingsteil Partners pre-sintering a volume shrinkage of at least 2% experiences. This ensures the creation of a sufficient pressure between the surfaces to be joined in the main sintering process.
- An advantage of the method according to the invention is that due to the inventive concept of pre-sintering at least one of the Bhoffnlingsteil developede a different shrinkage of Bhoffnlingsteil ravee is achieved during the main sintering process, even if the Bhoffnlingsteilgnae to be joined consist of the same material and have substantially identical shrinkage properties. Accordingly, according to one embodiment, the invention is realized with sections which consist of the same material, have the same binder shares and thus have substantially identical shrinkage properties. The use of different materials, which is associated with an additional cost along the process chain and thus increased component costs, is avoided.
- the invention can in principle also be realized with brown compact sections which have different shrinkage properties even without presintering of one of the brown compact sections in the sintering process.
- one or more of the Braunling sections including the Bhoffnlingsteilzusszuszusternden, consist of different metal powders in the sense that the metal powder used on the nature and / or size of the metal powder particles, in the metal powder material and / or in terms of the binder used differ. Different metal powders in this sense are present in particular if the metal powder particles are of different types and / or sizes, but also if only the binder used is different or added to varying degrees to the metal powder particles used.
- a method for producing components by metal powder injection molding in which at least three brown compact sections are assembled and then sintered together in a sintering process.
- One of these B Hurnlingsteil adoptede is a connecting part, which is assembled before the sintering process with at least two further Braunlingsteil raveen. This formed as a connecting part B Hurnlingsteil who undergoes during the sintering process in comparison to the other Bhoffnlingsteil raveen higher or lower shrinkage, whereby the at least two further Bhoffnlingsteil developede are firmly connected to each other via the connecting part.
- the connecting part and the other B syndromenlingsteil Federatione consist of the same material and have substantially identical shrinkage properties.
- either the connecting part or the further Braunling sections undergo a pre-sintering process before the sintering process, by a pre-shrinkage takes place.
- the method of the second aspect of the invention is also applicable using a connecting part, which has other shrinkage properties due to its material composition than the Bhoffnlingsteiluitee to be joined together. For example, it differs in type and / or size of the metal powder particles and / or in the metal powder material and / or in the binder used by the other Braunling sections.
- the connecting part is designed, for example, as an insert part, which has two projections which are arranged essentially completely in two corresponding recesses of the brown body sections to be connected to one another. If the insert has a greater shrinkage than the B Hurnlingsteil GmbHe to be joined together, it draws during sintering the latter together, which experience a large area a pressure along their contiguous contact surfaces. If the insert has a lower shrinkage than the B Hurnlingsteil developede to be joined together, these Bhoffnlingsteil developede exert pressure on the projections of the insert during sintering, the subsequent connection of the two components is primarily ensured by the projections.
- FIG. 1 schematically shows two B syndromenlingsteil developede 5, 6.
- the two B syndromenlingsteil developede are made of identical materials, so have the same shrinkage properties in a sintering process.
- To produce the Braunling sections 5, 6, separate green compacts are produced by metal powder injection molding of a metal powder mixed with a thermoplastic binder ("feedstock"). By melting out of the binder in an oven, the green bodies are then debinded, so that now existing from a porous material Bhoffnlingsteil developede 5, 6 are available.
- the one Braunling section 6 has on its outer surface a projection 7.
- the projection 7 is formed in the illustrated embodiment, but not necessarily dovetailed. Its side surfaces 75 taper in the direction of the main body of the Bhoffnlingsteil Switzerlands 6.
- the other B syndromenlingsteil Federation 5 has a recess 8, the shape of which corresponds to the shape of the projection 7 and, accordingly, also dovetail-shaped.
- the projection 7 and the recess 8 are form-fitting interlocking connecting elements of the two Bhoffnlingsteilges 5, 6 represents.
- the form-fitting interlocking connecting elements can be provided in other ways, for example by concave and convex shapes.
- the one Braunling section 6 before a positive connection with the B syndromenlingsteil Salt 5 passes through a pre-sintering process in which its volume from a first, larger volume 61 to a second, smaller volume 62 shrinks. Accordingly, the outer dimensions of the projection 7 shrink from a larger outer dimension 71 to a smaller outer dimension 72.
- the shrinkage process is schematically represented by arrows.
- the size of the projection 7 and the recess 8 are adapted to each other so that only after passing through the pre-sintering process, the projection 7 can be introduced into the recess 8, while this was not possible before passing through the pre-sintering process.
- the B Hurnlingsteil 5, 6 are shifted longitudinally to each other, wherein the projection 7 in positive engagement with the recess 8 device.
- FIG. 2 shows an alternative embodiment, which differs from the embodiment of FIG. 1 differs in that the B syndromenlingsteil Suite 5 having the recess 8, passes through a pre-sintering process and thereby shrinks from a larger volume 51 to a smaller volume 52. Accordingly, the surface within the recess also changes from a surface 81 to a surface 82.
- presintering the brown compact section 5 the two brown compact sections 5, 6 are connected to one another in a form-fitting manner via their connecting elements 7, 8. This is followed by a main sintering process in which the two browning sections 5, 6 are sintered simultaneously.
- FIG. 3 shows a possible embodiment of the in the Figures 1 and 2 illustrated technical teaching. It is shown a non-rotationally symmetrical engine component in the form of a turbine blade 1.
- the turbine blade 1 is composed of three separately produced by metal powder injection molding and then sintered in a sintering process and interconnected Bhoffnlingsteil GmbH. The three sintered Bhoffnlingsteil developede form an airfoil 2, an outer shroud 3 and an inner shroud 4 of the turbine blade. 1
- FIG. 4 shows the state after one of the two B syndromenlingsteil developede was pre-sintered and connected to the other Bhoffnlingsteil familia.
- the Bhoffnlingsteil In the considered embodiment, the Bhoffnlingsteil laminate 6, which has the recesses 8, pre-sintered. This means that in the subsequent common sintering of the Bhoffnlingteil developede 5, 6 positively connected by means of the recesses 8 and projections 7, the Bhoffnlingsteil familia 5 shrinks more.
- the contact surfaces 10, 11, which are formed adjacent to the projections or recesses 7, 8, are formed in a configuration substantially parallel, which includes that they form curved surfaces in the same way. As a result, a large-scale intensive pressing process is ensured during sintering.
- FIG. 5 shows an embodiment in which three Braunling sections 5a, 5b and 12 are joined together in a sintering process.
- the Bhoffnlingsteil Division 12 is formed in the form of an insert having two circular or lobe-shaped projections 12a, 12b, which are arranged in corresponding recesses 8a, 8b of the Bhoffnlingsteil proposede 5a, 5b.
- the insert 12 serves as a connecting part for connecting the two B Hurnlingsteil 5a, 5b in a sintering process. It is provided that the insert 12 in comparison to the Bhoffnlingsvons 5a, 5b in the sintering process a experiences higher or lower shrinkage. This can be achieved, on the one hand, by virtue of the insert part 12 having different shrinkage properties due to a different choice of material. For example, the type and / or size of the metal powder particles are different and / or a different binder or amount of binder is used. Because of these inherent different material properties, the brown compact section 12 serving as the insert undergoes a different shrinkage in the sintering process.
- a different shrinkage of the insert part 12 may according to the embodiment of Figures 1 and 2 but also be achieved in that either the insert part 12 or the B Hurnlingsmaschines 5a, 5b experience a pre-sintering, which also leads to the fact that the insert 12 and the B Hurnlingsteil 5a, 5b undergo shrinkage in the main sintering process in different ways.
- the insert part 12 provision is made for the insert part 12 to experience greater shrinkage in the sintering process than the brown body sections 5a, 5b.
- the two B Hurnlingsers 5a, 5b are not only firmly connected to each other via the insert 12, but while the insert 12 pulls the B Hurnlingsers 5a, 5b together, so that they are pressed together along their contact surfaces 10, 11.
- the insert 12 experiences a shrinkage in the sintering process, which is less than the shrinkage experienced by the Bönlingsteil 5 a, 5 b.
- a connection between the respective Braunling sections 5a, 5b and the insert 12 substantially in the region of the projections 12a, 12b.
- the invention is not limited in its embodiment to the above-described embodiments, which are only to be understood as examples.
- the shapes and dimensions of the recesses and recesses of the individual Bhoffnlingsteil developede are merely exemplary understood. It can also be provided that Bhoffnlingsteil grise to be joined together have a plurality of corresponding projections and recesses.
- FIG. 3 described embodiment of an engine component is to be understood as exemplary only.
- the invention can be realized in any components, in particular engine components, which consist of different, resulting from metal powder injection molding components, engine components can be made with geometrically complex structure.
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Abstract
Description
Die Erfindung betrifft ein Verfahren zur Herstellung eines Bauteils durch Metallpulverspritzgießen von mit einem Binder vermischtem Metallpulver, bei dem einzelne Komponenten des Bauteils als separat geformte Grünlings- und anschließend entbinderte Bräunlingsteilstücke gefertigt werden, die zu einem zwei- oder mehrteiligen Bräunling zusammengesetzt und in zusammengesetztem Zustand gesintert werden. Das Verfahren eignet sich beispielsweise zur Herstellung von thermisch beanspruchten Triebwerksbauteilen mit geometrisch komplexer Struktur.The invention relates to a method for producing a component by metal powder injection molding of metal powder mixed with a binder, in which individual components of the component are produced as separately shaped green compact and then unbonded brown compact sections which are assembled into a two- or multi-part brown compact and sintered in an assembled state become. The method is suitable, for example, for producing thermally stressed engine components with a geometrically complex structure.
Es ist bekannt, Bauteile mit hoher geometrischer Komplexität aus unterschiedlichen Metallen wie beispielsweise Edelstählen, Einsatz- und Vergütungsstählen, intermetallischen Phasen, Leichtmetallen auf Titanbasis und dgl. durch Metallpulverspritzgießen (Metal Injection Moulding - MIM) herzustellen, und zwar bei vollständiger Materialausnutzung und ohne oder nur mit geringer Nacharbeit. Beim Metallpulverspritzgießen wird zunächst ein Metallpulver mit einem Binder aus thermoplastischen Kunststoffen und Wachsen zu einem fließfähigen und in einem Spritzgießprozess verarbeitbaren Werkstoff (Feedstock) vermischt. Aus dem beim Spritzgießen erzeugten Formteil, dem Grünling, wird anschließend der Binder herausgelöst oder thermisch ausgetrieben, so dass ein poröses - als Bräunling bezeichnetes - Formteil zur Verfügung steht, das die gleichen Abmessungen wie der Grünling hat. In einem darauffolgenden Wärmeprozess wird der Bräunling geringfügig unterhalb der Schmelztemperatur des jeweiligen Metalls in einem Sinterofen, und zwar meist in einer Schutzgasatmosphäre oder manchmal auch im Vakuum, gesintert. Nach dem Sintern, bei dem der Bräunling auf die gewünschten Fertigabmessungen schwindet, liegt das endgültige Formteil vor. Eine Nacharbeit ist im allgemeinen nicht erforderlich.It is known to produce components of high geometric complexity from different metals such as stainless steels, case hardening and tempering steels, intermetallic phases, titanium based light metals and the like by metal injection molding (MIM) with full material utilization and no or only with little rework. In metal powder injection molding, a metal powder is first mixed with a binder of thermoplastics and waxes to form a flowable material that can be processed in an injection molding process (feedstock). From the molded part produced during injection molding, the green compact, the binder is then dissolved out or thermally expelled, so that a porous - called Bräunling - molding is available, which has the same dimensions as the green body. In a subsequent heat process, the browning is sintered slightly below the melting temperature of the respective metal in a sintering furnace, usually in a protective gas atmosphere or sometimes in a vacuum. After sintering, in which the browning shrinks to the desired finished dimensions, the final molded part is present. A rework is generally not required.
Aus der
Die
Der Erfindung liegt die Aufgabe zugrunde, weitere Verfahren zum Metallpulverspritzgießen von geometrisch komplex geformten, aus separat vorgefertigten Bräunlingen zusammengesetzten Bauteilen anzugeben, bei denen während des Sinterprozesses zwischen den aneinandergefügten Bräunlingen eine innige, feste Verbindung erzielt wird.The invention has for its object to provide further methods for metal powder injection molding of geometrically complex shaped, composed of separately prefabricated Bräunlingen components in which an intimate, firm connection is achieved during the sintering process between the joined Bräunlingen.
Erfindungsgemäß wird diese Aufgabe durch ein Verfahren mit den Merkmalen des Patentanspruchs 1 und ein Verfahren mit den Merkmalen des Patentanspruchs 14 gelöst. Ausgestaltungen der Erfindung sind in den Unteransprüchen angegeben.According to the invention, this object is achieved by a method having the features of
Danach ist erfindungsgemäß vorgesehen, dass mindestens eines der zu verbindenden Bräunlingsteilstücke einen Vorsinterprozess durchläuft, in dem es eine erste Schwindung erfährt. Diese erste Schwindung ist aber geringer als die maximale Schwindung, die das Bräunlingsteilstück durch Sintern erfahren kann. Das mindestens eine vorgesinterte und dadurch vorgeschrumpfte Bräunlingsteilstück und mindestens ein weiteres Bräunlingsteilstück werden anschließend zu einem zwei- oder mehrteiligen Bräunling zusammengesetzt. Anschließend durchläuft der zwei- oder mehrteilige Bräunling einen Hauptsinterprozess. Dabei erfährt das mindestens eine vorgesinterte Bräunlingsteilstück eine geringere Schwindung als das mindestens eine weitere Bräunlingsteilstück, wodurch das mindestens eine vorgesinterte Bräunlingsteilstück und das mindestens eine weitere Bräunlingsteilstück fest miteinander verbunden werden.Thereafter, the invention provides that at least one of the Bräunlingsteilstücke to be joined undergoes a pre-sintering process in which it undergoes a first shrinkage. However, this first shrinkage is less than the maximum shrinkage that the Bräunlingsteilstück can experience by sintering. The at least one presintered and thus preshrunk Bräunlingsteilstück and at least one other Bräunlingsteilstück are then assembled into a two- or multi-part Bräunling. Subsequently, the two- or multi-part Braunling undergoes a main sintering process. Here, the at least one pre-sintered Bräunlingsteilstück undergoes less shrinkage than the at least one further Bräunlingsteilstück, whereby the at least one pre-sintered Bräunlingsteil and the at least one further Bräunlingsteilstück are firmly connected.
So schrumpft das nicht-vorgesinterte Bräunlingsteilstück stärker als das vorgesinterte Bräunlingsteilstück, wodurch eine Pressung der zu fügenden Flächen bereitgestellt wird. Das stärker schwindende Bräunlingsteilstück wird selbsttätig an das weniger stark schrumpfende Bräunlingsteilstück gepresst, so dass stets eine Nullspaltmaß und eine innige Verbindung zwischen den Bräunlingsteilstücken gewährleistet wird. Dabei können im Metallspritzgießprozess auch komplex geformte Bauteile in hoher Qualität bereitgestellt werden. Das Verfahren eignet sich beispielsweise zur Herstellung von thermisch beanspruchten Triebwerksbauteilen mit geometrisch komplexer Struktur.Thus, the non-pre-sintered brown compact section shrinks more than the pre-sintered brown compact section, thereby providing pressure to the surfaces to be joined. The stronger shrinking Bräunlingsteilstück is automatically pressed to the less shrinking Bräunlingsteilstück so that always a Nullspaltmaß and an intimate connection between the Bräunlingsteilstücken is guaranteed. In the metal injection molding process, complex components can be provided in high quality. The method is suitable, for example, for producing thermally stressed engine components with a geometrically complex structure.
In einer Ausgestaltung der Erfindung ist vorgesehen, dass ein vorgesintertes Bräunlingsteilstück und ein weiteres Bräunlingsteilstück über an Fügeflächen der zu verbindenden Bräunlingsteilstücke ausgebildete, formschlüssig ineinandergreifende Verbindungselemente vor dem Hauptsinterprozess miteinander verbunden werden. Dabei kann vorgesehen sein, dass das vorzusinternde Bräunlingsteilstück vor Durchlaufen des Vorsinterprozesses Abmessungen derart aufweist, dass es nicht mit dem weiteren Bräunlingsteilstück verbindbar ist, und beim Vorsinterprozess derart schrumpft, dass die beiden Bräunlingsteilstücke nun über die ineinander greifenden Verbindungselemente verbunden werden können. Das vorzusinternde Bräunlingsteilstück wird somit derart mit einem Verbindungselement versehen, dass eine Passung mit dem weiteren Bräunlingsteilstück erst nach dem Vorsintern gewährleistet wird. Nach der Montage werden die beiden Bauteile dann fertig gesintert, wobei das nicht-vorgesinterte Bauteil stärker schrumpft als das vorgesinterte Bauteil.In one embodiment of the invention, it is provided that a presintered Bräunlingsteilstück and another Bräunlingsteilstück be formed on joining surfaces of the Bräunlingsteilstücke to be connected, form-fitting interlocking fasteners are interconnected before the main sintering process. It can be provided that the Bräunlingteil vorzufinternde before passing through the pre-sintering process has dimensions such that it is not connectable to the other Bräunlingsteilstück, and shrinks in the pre-sintering process such that the two Bräunlingsteilstücke can now be connected via the interlocking fasteners. The Bräunlingsteil vorzufinternde is thus provided with a connecting element such that a fit with the other Bräunlingsteilstück is guaranteed only after pre-sintering. After assembly, the two components are then finished sintered, wherein the non-presintered component shrinks more than the pre-sintered component.
Auf diese Weise können auch nicht rotationssymmetrisch geformte Bräunlingsteilstücke ohne störende Hilfsmittel im Sinterprozess fest miteinander verbunden und kompliziert geformte, nicht rotationssymmetrische Bauteile, wie beispielsweise mit Deckbändern ausgebildete Turbinenschaufeln, durch Metallpulverspritzgießen gefertigt werden.In this way, not rotationally symmetrically shaped Bräunlingsteilstücke without interfering tools in the sintering process firmly connected to each other and complicated shaped, non-rotationally symmetric components, such as formed with shrouds turbine blades, are manufactured by metal powder injection molding.
Bei den Verbindungselementen der Bräunlingsteilstücke handelt es sich gemäß einer Ausgestaltung der Erfindung um formschlüssig ineinandergreifende Vorsprünge und Ausnehmungen. Dabei ist vorgesehen, dass die Vorsprünge sich zum Hauptkörper des Bräunlingsteilstücks hin verjüngen und hierzu beispielsweise schwalbenschwanzförmig oder keulenförmig ausgebildet sind. Die Ausnehmungen des anderen Bräunlingsteilstücks weisen eine dazu passende komplementäre Form auf.In the connection elements of the Bräunlingsteilstücke is according to an embodiment of the invention to form-fitting interlocking projections and Recesses. It is provided that the projections taper towards the main body of the Bräunlingsteilstücks and this example, dovetail-shaped or club-shaped. The recesses of the other Bräunlingsteilstücks have a matching complementary shape.
Dabei sind zwei Ausführungsvarianten denkbar. Gemäß einer ersten Ausführungsvariante sind die Vorsprünge an demjenigen Bräunlingsteilstück ausgebildet, das vorgesintert ist, und sind die Ausnehmungen an dem weiteren Bräunlingsteilstück ausgebildet. Dies bedeutet, dass beim Hauptsinterprozess das Bräunlingsteilstück, das die Ausnehmungen aufweist und die Vorsprünge des anderen Bräunlingsteilstücks umschließt, auf diese Vorsprünge einen Druck ausübt. Die dabei entstehende Verbindung der beiden Komponenten wird primär über die Vorsprünge gewährleistet und ist im Wesentlichen auf den Bereich der Vorsprünge und Aussparungen begrenzt.Two variants are conceivable. According to a first embodiment, the projections are formed on that Bräunlingsteilstück which is pre-sintered, and the recesses are formed on the further Bräunlingsteilstück. That is, in the main sintering process, the brown compact section having the recesses and enclosing the protrusions of the other brown compact section exerts pressure on these protrusions. The resulting connection of the two components is primarily ensured by the projections and is essentially limited to the region of the projections and recesses.
Gemäß einer zweiten Ausführungsvariante sind die Ausnehmungen an demjenigen Bräunlingsteilstück ausgebildet, das vorgesintert ist, und sind die Vorsprünge an dem weiteren Bräunlingsteilstück ausgebildet. Diese Ausführungsvariante bewirkt, dass beim Sintern des zusammengesetzten Bräunlings das Bräunlingsteilstück, das Ausnehmungen aufweist, zum Bräunlingsteilstück, das Vorsprünge aufweist, durch dessen stärker schrumpfende Vorsprünge hingezogen wird, wodurch die jeweiligen Kontaktflächen zwischen den Bräunlingsteilstücken aneinander gepresst werden. Dabei können die Flächen, an denen die Bräunlingsteilstücke beim Sintern des zusammengesetzten Bräunlings aneinandergezogen werden, im Wesentlichen parallel zueinander angeordnet sein, was eine gemeinsame Krümmung einschließt.According to a second embodiment, the recesses are formed on that Bräunlingsteilstück which is pre-sintered, and the projections are formed on the further Bräunlingsteilstück. This embodiment causes, on sintering the composite tanning bristle, the tanning portion having recesses to the tanning portion having projections is attracted by its more shrinking projections, whereby the respective contact surfaces between the Bräunlingsteilstücken pressed together. In this case, the surfaces on which the Bräunlingsteilstücke are drawn together during sintering of the composite Bräunlings, be arranged substantially parallel to each other, which includes a common curvature.
Bei dieser Ausführungsvariante wird erreicht, dass ein hoher Druck und damit ein intensiver Oberflächenkontakt der beiden Bräunlingsteilstücke nicht lediglich im Bereich der Vorsprünge und Ausnehmungen erreicht wird, sondern vielmehr entlang der gesamten Kontaktflächen, entlang derer die beiden Bräunlingsteilstücke aneinander anliegen. Die Bräunlingsteilstücke werden bei dieser Erfindungsvariante beim Sintern des zusammengesetzten Bräunlings mit anderen Worten großflächig an Kontaktflächen aneinander gepresst, die benachbart der Vorsprünge und Ausnehmungen an den Bräunlingsteilstücken ausgebildet sind.In this embodiment, it is achieved that a high pressure and thus an intensive surface contact of the two Bräunlingsteilstücke is achieved not only in the region of the projections and recesses, but rather along the entire contact surfaces, along which the two Bräunlingsteilstücke abut each other. In this variant of the invention, during the sintering of the composite bronling, in other words, the brown compact sections are pressed together over a large area against contact surfaces which are formed adjacent to the projections and recesses on the brown compact sections.
Die Vorsprünge und Aussparungen der zu verbindenden Bräunlingsteilstücke werden vor dem Sintern beispielsweise durch Längsverschiebung oder Drehung der zu verbindenden Bräunlingsteilstücke in formschlüssigen Eingriff gebracht.The projections and recesses of the Bräunlingsteilstücke to be joined are brought into positive engagement, for example by longitudinal displacement or rotation of the Bräunlingsteilstücke to be joined before sintering.
In weiteren Ausführungsvarianten sind die Vorsprünge konvex gewölbt und die Ausnehmungen konkav gewölbt, beispielsweise in Form von kugelförmigen oder keulenförmigen Vorsprüngen und Ausnehmungen.In further embodiments, the projections are convexly curved and the recesses concavely curved, for example in the form of spherical or lobe-shaped projections and recesses.
Eine weitere Ausführungsvariante der Erfindung sieht vor, dass mindestens drei Bräunlingsteilstücke zusammengesetzt und in dem Hauptsinterprozess gemeinsam gesintert werden. Dabei stellt eines der Bräunlingsteilstücke ein Verbindungsteil dar, das vor dem Hauptsinterprozess mit zwei weiteren der Bräunlingsteilstücke zusammensetzbar ist. Das Verbindungsteil weist hierzu zwei Verbindungselemente, beispielsweise in Form von Vorsprüngen oder Aussparungen auf. Es wird nun entweder das als Verbindungsteil ausgebildete Bräunlingsteilstück vorgesintert oder es werden die zwei weiteren Bräunlingsteilstücke vorgesintert. Anschließend werden die zwei weiteren Bräunlingsteilstücke mittels des als Verbindungsteil ausgebildeten Bräunlingsteilstücks für den Hauptsinterprozess miteinander verbunden. Beim Hauptsinterprozess werden beide Bräunlingsteilstücke innig mit dem als Verbindungsteil dienenden Bräunlingsteilstück verbunden, so dass sie über das Verbindungsteil miteinander innig verbunden sind.A further embodiment of the invention provides that at least three Bräunlingsteilstücke are assembled and sintered together in the main sintering process. In this case, one of the Bräunlingsteilstücke represents a connecting part, which is composable before the main sintering process with two more of the Bräunlingsteilstücke. The connecting part has for this purpose two connecting elements, for example in the form of projections or recesses. It is now either pre-sintered as part of the Bräunlingsteilstück or the two further Bräunlingsteilges are pre-sintered. Subsequently, the two further Braunling sections are connected to each other by means of the Bräunlingsteilstücks formed as a connecting part for the main sintering process. In the main sintering process, both brown compact sections are intimately connected to the brown compact section serving as a connecting part, so that they are intimately connected to one another via the connecting part.
Das Verbindungsteil kann dabei beispielsweise als Einsetzteil (sogenanntes "Insert") ausgebildet sein, das im Wesentlichen die Form zweier Aussparungen besitzt, die in den zu verbindenden Bräunlingsteilstücken ausgebildet sind. Dabei kann vorgesehen sein, dass das Verbindungsteil beim Hauptsinterprozess die beiden anderen Bräunlingsteilstücke aneinander zieht und dabei großflächig ein Nullspaltmaß zwischen Kontaktflächen der aneinandergrenzenden Bräunlingsteilstücke erzielt wird.In this case, the connecting part can be designed, for example, as an insert part (so-called "insert") which essentially has the shape of two recesses which are formed in the brown compact sections to be connected. It can be provided that the connecting part in the main sintering process pulls the other two Bräunlingsteilges each other and thereby a large area a Nullspaltmaß between contact surfaces of the adjacent Bräunlingsteilstücke is achieved.
Das erfindungsgemäße Verfahren ist auch bei rotationssymmetrisch ausgebildeten Bauteilen einsetzbar. Hierbei ist in einer Ausführungsvariante vorgesehen, dass der zusammengesetzte Bräunling ein inneres Bräunlingsteilstück und ein dieses umschließendes äußeres Bräunlingsteilstück mit oder ohne Verbindungselemente umfasst. Dabei ist das äußere Bräunlingsteilstück das nicht vorgesinterte Bräunlingsteilstück. Beim Hauptsinterprozess wird das äußere Bräunlingsteilstück an das innere Bräunlingsteilstück gepresst.The inventive method can also be used with rotationally symmetrical components. In this case, it is provided in an embodiment variant that the composite brown compact comprises an inner brown compact section and an outer brown compact section surrounding this with or without connecting elements. Here, the outer Bräunlingsteilstück is not pre-sintered Bräunlingsteilstück. In the main sintering process, the outer brown compact section is pressed against the inner brown compact section.
Es ist in einer Ausführungsvariante vorgesehen, dass das mindestens eine vorgesinterte Bräunlingsteilstück beim Vorsintern eine Volumenschrumpfung von mindestens 2% erfährt. Hierdurch wird das Entstehen einer ausreichenden Pressung zwischen den zu fügenden Flächen im Hauptsinterprozess sichergestellt.It is provided in one embodiment that the at least one presintered Bräunlingsteilstück pre-sintering a volume shrinkage of at least 2% experiences. This ensures the creation of a sufficient pressure between the surfaces to be joined in the main sintering process.
Ein Vorteil des erfindungsgemäßen Verfahrens besteht darin, dass aufgrund des erfindungsgemäßen Gedankens der Vorsinterung mindestens einer der Bräunlingsteilstücke eine unterschiedliche Schwindung der Bräunlingsteilstücke während des Hauptsinterprozesses erreicht wird, auch wenn die zu verbindenden Bräunlingsteilstücke aus dem gleichen Material bestehen und im Wesentlichen identische Schwindungseigenschaften besitzen. Dementsprechend wird die Erfindung gemäß einer Ausgestaltung mit Teilstücken realisiert, die aus dem gleichen Material bestehen, gleiche Binderanteile besitzen und somit im Wesentlichen identische Schwindungseigenschaften besitzen. Die Verwendung unterschiedlicher Materialien, die mit einem Mehraufwand entlang der Prozesskette und dadurch erhöhten Bauteilkosten verbunden ist, wird vermieden.An advantage of the method according to the invention is that due to the inventive concept of pre-sintering at least one of the Bräunlingsteilstücke a different shrinkage of Bräunlingsteilstücke is achieved during the main sintering process, even if the Bräunlingsteilstücke to be joined consist of the same material and have substantially identical shrinkage properties. Accordingly, according to one embodiment, the invention is realized with sections which consist of the same material, have the same binder shares and thus have substantially identical shrinkage properties. The use of different materials, which is associated with an additional cost along the process chain and thus increased component costs, is avoided.
Gleichwohl kann die Erfindung grundsätzlich auch mit Bräunlingsteilstücken realisiert werden, die auch ohne Vorsinterung eines der Bräunlingsteilstücke im Sinterprozess unterschiedliche Schwindungseigenschaften besitzen. So kann alternativ vorgesehen sein, dass ein oder mehrere der Bräunlingsteilstücke, einschließlich des vorzusinternden Bräunlingsteilstücks, aus unterschiedlichen Metallpulvern in dem Sinne bestehen, dass die eingesetzten Metallpulver sich von der Art und/oder Größe der Metallpulverpartikel, im Metallpulverwerkstoff und/oder hinsichtlich des verwendeten Binders unterscheiden. Unterschiedliche Metallpulver in diesem Sinne liegen insbesondere dann vor, wenn die Metallpulverpartikel unterschiedlicher Art und/oder Größe sind, aber auch, wenn lediglich der verwendete Binder unterschiedlich ist oder in unterschiedlichem Maße den verwendeten Metallpulverpartikeln hinzugefügt ist.Nevertheless, the invention can in principle also be realized with brown compact sections which have different shrinkage properties even without presintering of one of the brown compact sections in the sintering process. Thus, it may alternatively be provided that one or more of the Braunling sections, including the Bräunlingsteilzusszuszusternden, consist of different metal powders in the sense that the metal powder used on the nature and / or size of the metal powder particles, in the metal powder material and / or in terms of the binder used differ. Different metal powders in this sense are present in particular if the metal powder particles are of different types and / or sizes, but also if only the binder used is different or added to varying degrees to the metal powder particles used.
Gemäß einem zweiten Erfindungsaspekt wird ein Verfahren zur Herstellung von Bauteilen durch Metallpulverspritzgießen bereitgestellt, bei dem mindestens drei Bräunlingsteilstücke zusammengesetzt und anschließend in einem Sinterprozess gemeinsam gesintert werden. Eines dieser Bräunlingsteilstücke ist ein Verbindungsteil, das vor dem Sinterprozess mit mindestens zwei weiteren Bräunlingsteilstücken zusammengesetzt wird. Dieses als Verbindungsteil ausgebildete Bräunlingsteilstück erfährt während des Sinterprozesses eine im Vergleich zu den weiteren Bräunlingsteilstücken höhere oder niedrigere Schrumpfung, wodurch die mindestens zwei weiteren Bräunlingsteilstücke über das Verbindungsteil fest miteinander verbunden werden.According to a second aspect of the invention, there is provided a method for producing components by metal powder injection molding, in which at least three brown compact sections are assembled and then sintered together in a sintering process. One of these Bräunlingsteilstücke is a connecting part, which is assembled before the sintering process with at least two further Braunlingsteilstücken. This formed as a connecting part Bräunlingsteilstück undergoes during the sintering process in comparison to the other Bräunlingsteilstücken higher or lower shrinkage, whereby the at least two further Bräunlingsteilstücke are firmly connected to each other via the connecting part.
Dabei kann vorgesehen werden, dass das Verbindungsteil und die weiteren Bräunlingsteilstücke aus dem gleichen Material bestehen und im Wesentlichen identische Schwindungseigenschaften besitzen. Für diesen Fall durchlaufen entweder das Verbindungsteil oder die weiteren Bräunlingsteilstücke vor dem Sinterprozess einen Vorsinterprozess, indem eine Vorschwindung erfolgt. Das Verfahren des zweiten Erfindungsaspektes ist jedoch ebenfalls einsetzbar unter Verwendung eines Verbindungsteils, das aufgrund seiner materiellen Zusammensetzung andere Schwindungseigenschaften aufweist als die miteinander zu verbindenden Bräunlingsteilstücke. Beispielsweise unterscheidet es sich in Art und/oder Größe der Metallpulverpartikel und/oder im Metallpulverwerkstoff und/oder im verwendeten Binder von den weiteren Bräunlingsteilstücken.It can be provided that the connecting part and the other Bräunlingsteilstücke consist of the same material and have substantially identical shrinkage properties. For this case, either the connecting part or the further Braunling sections undergo a pre-sintering process before the sintering process, by a pre-shrinkage takes place. However, the method of the second aspect of the invention is also applicable using a connecting part, which has other shrinkage properties due to its material composition than the Bräunlingsteilstücke to be joined together. For example, it differs in type and / or size of the metal powder particles and / or in the metal powder material and / or in the binder used by the other Braunling sections.
Das Verbindungsteil ist beispielsweise als Einsatzteil ausgebildet, das zwei Vorsprünge aufweist, die im wesentlichen vollständig in zwei entsprechenden Aussparungen der miteinander zu verbindenden Bräunlingsteilstücke angeordnet sind. Sofern das Einsatzstück eine größere Schwindung aufweist als die miteinander zu verbindenden Bräunlingsteilstücke, zieht es während des Sinterns letztere aneinander, wobei diese großflächig eine Pressung entlang ihrer aneinandergrenzenden Kontaktflächen erfahren. Sofern das Einsatzteil eine geringere Schwindung aufweist als die miteinander zu verbindenden Bräunlingsteilstücke, üben diese Bräunlingsteilstücke auf die Vorsprünge des Einsatzteils beim Sintern einen Druck aus, wobei die anschließende Verbindung der beiden Komponenten primär über die Vorsprünge gewährleistet ist.The connecting part is designed, for example, as an insert part, which has two projections which are arranged essentially completely in two corresponding recesses of the brown body sections to be connected to one another. If the insert has a greater shrinkage than the Bräunlingsteilstücke to be joined together, it draws during sintering the latter together, which experience a large area a pressure along their contiguous contact surfaces. If the insert has a lower shrinkage than the Bräunlingsteilstücke to be joined together, these Bräunlingsteilstücke exert pressure on the projections of the insert during sintering, the subsequent connection of the two components is primarily ensured by the projections.
Die Erfindung wird nachfolgend unter Bezugnahme auf die Figuren der Zeichnung anhand mehrerer Ausführungsbeispiele näher erläutert. Es zeigen:
- Fig. 1
- schematisch ein erstes Bräunlingsteilstück mit einem Vorsprung und ein zweites Bräunlingsteilstück mit einer Ausnehmung, wobei das mit einem Vorsprung versehene Bräunlingsteilstück in einem Vorsinterprozess eine erste Schwindung erfahren hat;
- Fig. 2
- schematisch ein erstes Bräunlingsteilstück mit einem Vorsprung und ein zweites Bräunlingsteilstück mit einer Ausnehmung, wobei das mit einer Aussparung versehene Bräunlingsteilstück bei einem Vorsinterprozess eine erste Schwindung erfahren hat;
- Fig. 3
- ein Ausführungsbeispiel eines erfindungsgemäß hergestellten Bauteils in Form einer mit einem Innen- und einem Außenband ausgebildeten Turbinenschaufel, die aus drei separat gefertigten Bräunlingsteilstücken zusammengesetzt ist;
- Fig. 4
- eine schematische Darstellung des Fügebereichs eines aus zwei Bräunlingsteilstücken zusammengesetzten Bräunlings, wobei der Zustand beim Hauptsinterprozess dargestellt ist; und
- Fig. 5
- schematisch ein Ausführungsbeispiel, bei dem ein erstes und ein zweites Bräunlingsteilstück durch ein drittes Bräunlingsteilstück, das als Einsatzteil ausgebildet ist und eine unterschiedliche Schwindung besitzt, miteinander verbunden werden.
- Fig. 1
- schematically a first Braunling section with a projection and a second Braunling section with a recess, wherein the provided with a projection Bräunlingsteilstück has undergone a first shrinkage in a pre-sintering process;
- Fig. 2
- schematically a first Braunling section with a projection and a second Bräunlingsteilstück with a recess, said provided with a recess Bräunlingsteilstück has undergone a first shrinkage in a pre-sintering process;
- Fig. 3
- an embodiment of a component according to the invention in the form of a formed with an inner and an outer belt turbine blade, which is composed of three separately manufactured Bräunlingsteilstücken;
- Fig. 4
- a schematic representation of the joining region of a Bräunlings composed of two Bräunlingsteilstücken, the state is shown in the main sintering process; and
- Fig. 5
- schematically an embodiment in which a first and a second Bräunlingsteilstück by a third Bräunlingsteilstück, which is designed as an insert part and has a different shrinkage, are interconnected.
Die
Das eine Bräunlingsteilstück 6 weist an seiner Außenfläche einen Vorsprung 7 auf. Der Vorsprung 7 ist im dargestellten Ausführungsbeispiel, jedoch nicht notwendigerweise schwalbenschwanzförmig ausgebildet. Seine Seitenflächen 75 verjüngen sich in Richtung des Hauptkörpers des Bräunlingsteilstücks 6.The one
Das andere Bräunlingsteilstück 5 weist eine Aussparung 8 auf, deren Form mit der Form des Vorsprungs 7 korrespondiert und dementsprechend ebenfalls schwalbenschwanzförmig ausgebildet ist. Der Vorsprung 7 und die Aussparung 8 stellen formschlüssig ineinandergreifende Verbindungselemente der beiden Bräunlingsteilstücke 5, 6 dar. In anderen Ausführungsbeispielen können die formschlüssig ineinandergreifenden Verbindungselemente auch in anderer Weise bereitgestellt werden, beispielsweise durch konkave und konvexe Formen.The
Die über die ineinandergreifenden Verbindungselementen 7, 8 miteinander verbundenen Bräunlingsteilstücke 5, 6 bilden einen zweiteiligen Bräunling 9.The
Es ist nun vorgesehen, dass das eine Bräunlingsteilstück 6 vor einer formschlüssigen Verbindung mit dem Bräunlingsteilstück 5 einen Vorsinterprozess durchläuft, in dem sein Volumen von einem ersten, größeren Volumen 61 auf ein zweites, kleineres Volumen 62 schrumpft. Dementsprechend schrumpfen auch die Außenabmessungen des Vorsprungs 7 von einer größeren Außenabmessung 71 auf eine kleinere Außenabmessung 72. Der Schrumpfungsprozess ist schematisch durch Pfeile dargestellt. Die Größe des Vorsprungs 7 und der Aussparung 8 sind dabei derart aneinander angepasst, dass erst nach Durchlaufen des Vorsinterprozesses der Vorsprung 7 in die Aussparung 8 eingebracht werden kann, während dies vor Durchlaufen des Vorsinterprozesses nicht möglich war. Zur formschlüssigen Verbindung werden die Bräunlingsteilstücke 5, 6 zueinander längs verschoben, wobei der Vorsprung 7 in formschlüssigem Eingriff mit der Aussparung 8 gerät.It is now envisaged that the one
Nach dem Vorsintern des Bräunlingsteilstücks 6 und dessen Verbindung mit dem nicht vorgesinterten Bräunlingsteilstück 5 durchlaufen die beiden Bräunlingsteilstücke 5, 6 einen Hauptsinterprozess. Da das Bräunlingsteilstück 6 bereits in dem Vorsinterprozess eine erste Schwindung erfahren hat, erfährt es während des Hauptsinterprozesses eine geringere Schwindung als das andere Bräunlingsteilstück 5. Hierdurch werden das Bräunlingsteilstück 5 und das Bräunlingsteilstück 6 fest miteinander verbunden. Diese Verbindung erfolgt derart, dass das Bräunlingsteilstück 5, das beim Hauptsinterprozess stärker schrumpft, auf den Vorsprung 7 einen Druck ausübt. Die dabei entstehende Verbindung der beiden Komponenten 5, 6 wird primär über die Vorsprünge 7 gewährleistet und ist durch die Querschnittsfläche (d. h. die Basisfläche der Vorsprünge) begrenzt.After presintering of the brown
Die
Im Ausführungsbeispiel der
Die
Zur Herstellung des nicht rotationssymmetrischen Triebwerksbauteils 1 werden durch Metallpulverspritzgießen eines mit einem thermoplastischen Binder vermischten Metallpulvers (Feedstock) separate Grünlinge der Außen- und Innendeckbänder und der Schaufelblätter erzeugt. Durch Herausschmelzen des Binders in einem Ofen werden die Grünlinge anschließend entbindert, so dass nunmehr aus einem porösen Material bestehende Bräunlingsteilstücke für das Schaufelblatt sowie die Innen- und Außendeckbänder zur Verfügung stehen.To produce the non-rotationally
Wie die in
Die beim Metallpulverspritzgießprozess erzeugten Verbindungselemente in Form von Vorsprüngen 7 und Ausnehmungen 8 greifen bei dem zusammengesetzten Bräunling 9 formschlüssig ineinander. Die
Im Ergebnis des Sinterprozesses wird ein durch Metallpulverspritzgießen gefertigtes Triebwerkbauteil von geometrisch komplizierter Struktur bereitgestellt.As a result of the sintering process, an engine component made of metal powder injection molding of geometrically complicated structure is provided.
Die Kontaktflächen 10, 11, die benachbart der Vorsprünge bzw. Aussparungen 7, 8 ausgebildet sind, sind dabei in einer Ausgestaltung im wesentlichen parallel ausgebildet, was mit einschließt, dass sie in gleicher Weise gekrümmte Flächen ausbilden. Hierdurch wird ein großflächiger intensiver Anpressvorgang beim Sintern sichergestellt.The contact surfaces 10, 11, which are formed adjacent to the projections or recesses 7, 8, are formed in a configuration substantially parallel, which includes that they form curved surfaces in the same way. As a result, a large-scale intensive pressing process is ensured during sintering.
Die
Das Einsatzteil 12 dient als Verbindungsteil zur Verbindung der beiden Bräunlingsteilstücke 5a, 5b in einem Sinterprozess. Dabei ist vorgesehen, dass das Einsatzteil 12 im Vergleich zu den Bräunlingsteilstücken 5a, 5b im Sinterprozess eine höhere oder eine niedrigere Schrumpfung erfährt. Dies kann zum einen dadurch erreicht werden, dass das Einsatzteil 12 aufgrund einer anderen Materialwahl unterschiedliche Schwindungseigenschaften befindet. Beispielsweise sind Art und/oder Größe der Metallpulverpartikel unterschiedlich und/oder es wird ein anderer Binder oder eine andere Menge von Binder verwendet. Aufgrund dieser inhärenten unterschiedlichen Materialeigenschaften erfährt das als Einsatzteil dienende Bräunlingsteilstück 12 im Sinterprozess eine unterschiedliche Schwindung.The
Eine unterschiedliche Schrumpfung des Einsatzteils 12 kann entsprechend dem Ausführungsbeispiel der
In einem Ausführungsbeispiel ist vorgesehen, dass das Einsatzteil 12 eine stärkere Schwindung im Sinterprozess erfährt als die Bräunlingsteilstücke 5a, 5b. Dies führt - entsprechend der Erläuterung der
Es ist jedoch ebenfalls möglich, dass das Einsatzteil 12 eine Schwindung im Sinterprozess erfährt, die geringer ist als die Schwindung, die die Bräunlingsteilstücke 5a, 5b erfahren. In diesem Fall erfolgt eine Verbindung zwischen den jeweiligen Bräunlingsteilstücken 5a, 5b und dem Einsatzstück 12 im Wesentlichen im Bereich der Vorsprünge 12a, 12b.However, it is also possible that the
Die zuvor geschilderten Ausführungsbeispiele waren auf die Herstellung von nicht rotationssymmetrischen Bauteilen aus zwei oder mehreren mit Verbindungselementen ausgebildeten Bräunlingen gerichtet. Die Erfindung ist jedoch nicht auf derartige Ausführungsbeispiele beschränkt. Ausgehend von dem Gedanken, die aneinanderzufügenden Bräunlingsteilstücke durch eine Vorschwindung eines Teilstücks in einem Vorsinterprozess und durch eine unterschiedliche Schwindung in einem Hauptsinterprozess einer Pressung auszusetzen, reicht es bei rotationssymmetrischen Bauteilen auch ohne die erwähnten Verbindungselemente 7, 8 aus, wenn ein das innere Bräunlingsteilstück umfassendes äußeres Bräunlingsteilstück eine stärkere Schwindung bzw. Schrumpfung im Hauptsinterprozess aufweist, so dass die separat gefertigten, rotationssymmetrischen Bräunlingsteilstücke beim Sintern fest aneinander gepresst werden.The exemplary embodiments described above were directed to the production of non-rotationally symmetrical components made of two or more tufts formed with connecting elements. However, the invention is not limited to such embodiments. Starting from the idea of suspending the Bräunlingsteilstücke to be joined by a pre-shrinkage of a section in a Vorsinterprozess and a different shrinkage in a main sintering process of a press, it is sufficient for rotationally symmetrical components without the mentioned connecting
Schließlich ist es auch denkbar, einen zusätzlichen, stärker schrumpfenden Bräunling als Werkzeug zu benutzen, der die zu verbindenden Bräunlingsteilstücke umfasst und beim gemeinsamen Sintern fest aneinander drückt.Finally, it is also conceivable to use an additional, more shrinking Bräunling as a tool that comprises the Bräunlingsteilstücke to be connected and presses together during common sintering together.
Die Erfindung beschränkt sich in ihrer Ausgestaltung nicht auf die vorstehend erläuterten Ausführungsbeispiele, die lediglich beispielhaft zu verstehen sind. Beispielsweise sind die Formen und Abmessungen der Aussparungen und Ausnehmungen der einzelnen Bräunlingsteilstücke lediglich beispielhaft zu verstehen. Auch kann vorgesehen sein, dass miteinander zu verbindende Bräunlingsteilstücke eine Vielzahl entsprechender Vorsprünge und Ausnehmungen aufweisen. Auch das in der
Claims (15)
dadurch gekennzeichnet,
characterized,
dadurch gekennzeichet,
dass mindestens drei Bräunlingsteilstücke (5a, 5b, 12) zusammengesetzt und anschließend in einem Sinterprozess gemeinsam gesintert werden, wobei eines der Bräunlingsteilstücke ein Verbindungsteil (12) ist, das vor dem Sinterprozess mit mindestens zwei weiteren Bräunlingsteilstücken (5a, 5b) zusammengesetzt wird, und das im Vergleich zu den mindestens zwei weiteren Bräunlingsteilstücken (5a, 5b) während des Sinterprozesses eine höhere oder niedrigere Schrumpfung erfährt, wodurch die mindestens zwei weiteren Bräunlingsteilstücke (5a, 5b) über das Verbindungsteil (12) fest miteinander verbunden werden.Method of manufacturing a component (1) by metal powder injection molding of metal powder mixed with a binder, in which individual components of the component are produced as separately shaped green compact and then unbonded brown compact sections (5a, 5b, 12) which are assembled into a multi-part brown compact and integrated in sintered composite state, wherein the Bräunlingsteilstücke (5a, 5b, 12) experience a shrinkage in the sintering process,
characterized
that at least three Bräunlingsteilstücke (5a, 5b, 12) are assembled and then sintered together in a sintering process, wherein one of the Bräunlingsteilstücke is a connecting part (12), which is assembled before the sintering process with at least two further Bräunlingsteilstücken (5a, 5b), and that undergoes a higher or lower shrinkage compared to the at least two further Braunling sections (5a, 5b) during the sintering process, whereby the at least two further Bräunlingsteilstücke (5a, 5b) are firmly connected to each other via the connecting part (12).
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DE102011089260A DE102011089260A1 (en) | 2011-12-20 | 2011-12-20 | Method for producing a component by metal powder injection molding |
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US (1) | US9950370B2 (en) |
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US9950370B2 (en) | 2018-04-24 |
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EP2606997B1 (en) | 2019-12-18 |
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