US3844778A - Method for producing grooved alloy structures - Google Patents
Method for producing grooved alloy structures Download PDFInfo
- Publication number
- US3844778A US3844778A US00350423A US35042373A US3844778A US 3844778 A US3844778 A US 3844778A US 00350423 A US00350423 A US 00350423A US 35042373 A US35042373 A US 35042373A US 3844778 A US3844778 A US 3844778A
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- US
- United States
- Prior art keywords
- alloy
- mandrel
- assembly
- plate
- fully dense
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- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
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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
- B22F7/06—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
- B22F7/08—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 with one or more parts not made from powder
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12014—All metal or with adjacent metals having metal particles
- Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
- Y10T428/12063—Nonparticulate metal component
Definitions
- ABSTRACT A method for producing an alloy structure having deep surface grooves therein by bonding of alloy powder to a fully dense member, such as a plate having on surfaces thereof nondeformable ceramic mandrels defining the grooves desired. After compacting to fully densify the alloy powder and bond it to the fully dense alloy plate member the ceramic mandrels are removed to expose the grooves. An air-tight, evacuated assembly constituting the powder, plate and nondeformable ceramic mandrels is provided for unitary hot isostatic compacting.
- FIG. 1 is a perspective view of an assembly suitable for compacting to form deep-pocketed structural members in accordance with the method of the invention
- FIG. 2 is a transverse section of the assembly of FIG. 1;
- FIG. 3 is a perspective view of the deep-pocketed alloy structure resulting from the use of the method of the invention with the assembly of FIGS. 1 and 2.
- alloy structures particularly of titanium-base alloys, having deepsurface grooves are produced by bonding alloy powder to a fully dense alloy member, such as a plate, with the alloy powder constituting the ribs or other projections defining the deep-surface grooves.
- a fully dense alloy member such as a plate
- the alloy powder constituting the ribs or other projections defining the deep-surface grooves.
- nondeformable mandrels preferably of a ceramic material, are placed on the fully dense alloy member, which may be a plate, with the mandrels having a configuration and orientation with respect to the plate conforming to the desired configuration and orientation of the deep-surface grooves desired on the final structure.
- the plate with the associated mandrels is placed in an envelope that may be sealed against the atmosphere and the interior of the same is filled with alloy powder generally of the same composition as the alloy of the fully dense plate member.
- the envelope should be of a deformable material such as mild steel.
- the envelope is evacuated for removal of impurities, particularly oxygen, and heated to an elevated temperature suitable for compacting, which may be within the range of l,500 to l,950 F with a preferred range of l,650 to 1,850" F for titanium-base alloys for which the method of the invention is particularly adapted.
- an elevated temperature suitable for compacting, which may be within the range of l,500 to l,950 F with a preferred range of l,650 to 1,850" F for titanium-base alloys for which the method of the invention is particularly adapted.
- the assembly which is sealed against the atmosphere, is transferred to a pressure vessel for hot isostatic compacting to final density.
- Generally for this purpose when using autoclaves with gas as the pressure medium pressures on the order of 12,000 to 20,000 p.s.i. are sufficient.
- the assembly After compacting during which the alloy powder is compacted to substantially full density and metallurgically bonded to the fully dense member the assembly is cooled and the ceramic mandrels are removed to expose the desired grooves or pockets in the final structure.
- the envelope providing the gas-tight enclosure for the assembly is likewise removed as by machining, acid pickling or a combination thereof.
- the ceramic mandrel may generally be removed by a mild grit-blasting operation. To facilitate removal it is preferred that the nondeformable ceramic mandrel by constructed from about percent alumina with the balance being a binding agent such as colloidal silica.
- any refractory oxide or a combination thereof, such as zirconia, alumina and silica may be used in combination with a suitable binding agent.
- the ceramic material of the mandrel be nondeformable under the existing pressure and temperature conditions during hot isostatic compacting so that the projections and grooves formed on the surface of the fully dense plate by welding and compacting of the powder relative to the plate will be of the desired configuration as governed by the configuration of the mandrels.
- refractory oxides are preferred materials for construction of the mandrels in that they will not deteriorate or lose significant strength at the high temperatures and pressures required for hot isostatic compacting and, consequently, the term refractory as used herein means that the material remains nondeformable under the high-temperature and pressure conditions incident to the hot isostatic compacting operation.
- alloy as used herein also includes metals in unalloyed or elemental form.
- the assembly To prevent contamination of the structure it is customary to subject the assembly to conventional outgassing" prior to compacting. In the wellknown manner the assembly would be heated to an intermediate temperature at which the gassification products would be withdrawn and the evacuated assembly would then be sealed against the atmosphere prior to hot isostatic compacting.
- the assembly 10 consists of a fully dense alloy plate 12 of generally rectangular configuration. Attached to the two major surfaces of the plate 12 in opposed relation are nondeformable ceramic mandrels 14a and 14b. There are, as shown in FIG. 2, three opposed pairs of mandrels with each pair secured to the plate 12 by pins 16. The periphery of the plate 12 is positioned and secured within a rectangular enclosure 18 which may be of mild steel. identical top and bottom covers 20, which are contoured to mate with the mandrels 14, are secured to the enclosure 18 and are in sealing engagement therewith, as by welding at 22.
- a stem 24 is provided for connection to a suitable vacuum pump forevacuating the interior of the assembly 10 during outgassing. Although only a single stem 24 is shown in the drawing, a plurality could in practice be employed for effective outgassing.
- the interior of the assembly as best shown in FIG. 2, is filled with alloy powder 26. The alloy powder 26 is in contact with the plate 12 and is confined.
- the assembly 10 as shown in FIG. 1, is placed in any suitable furnace (not shown) for heating to compacting temperature and is thereafter transferred to an autoclave for hot isostatic compacting. If desired, heating to compacting temperature may take place in the autoclave.
- the alloy powder 26 is compressed to substantially full density and simultaneously welded at the areas of contact to the plate 12. Since the mandrels 14 do not deform during the compacting operation the configuration of the final compacted structure will be substantially as defined by the configuration and orientation of the mandrels relative to the plate and alloy powder.
- pins 16, enclosure 18 and covers 20 With the assembly as best shown in FIG.) after compacting and removal of the mandrels 14, pins 16, enclosure 18 and covers 20, the deep surface grooved alloy structure as shown in FIG. 3 is produced.
- This structure identified generally as 30 in FIG. 3, has a web portion 32 constituting the plate 12 of assembly prior to the compacting operation, and ribs 34 defining grooves 36, which ribs are comprised of the alloy particles 26 of the assembly l0 compacted to full density and metallurgically bonded to the web.
- the grooves 36 therebetween are defined by the mandrels 14 of assembly 10.
- a fully dense alloy member or members may be substituted for a portion of the alloy particles 26 and positioned between the mandrels 14 of the assembly shown in FIG. 2; these fully dense members would be spaced apart from plate 12 with particles 26 being placed therebetween. With this embodiment, upon hot isostatic compacting these members would be bonded to the particles 26 as is the plate 12.
- Another embodiment would comprise substituting fully dense alloy members that are positioned between the mandrels 14 for the particles 26; accordingly, the plate 12 would be replaced by alloy particles.
- the structure of the type shown in FIG. 3 after compacting may be subjected to a further final sizing operation.
- This sizing operation may comprise hot-coining by the use of heated dies which are machined to the required tolerances.
- FIGS. 1 and 2 In accordance with the following which may be considered as a specific example of a typical practice of the invention, an assembly similar to that shown in FIGS. 1 and 2 would be constructed.
- the assembly would include a fully dense plate or web member of a titanium-base alloy of the approximate alloy composition of 6 percent by weight aluminum, 4 percent by weight vanadium and the balance titanium.
- the plate dimensions are 24 X 12 X Va in.
- the alloy particles are 60 mesh US. Standard and of substantially identical alloy composition as that of the plate.
- the mandrels are constructed from zirconia.
- the assembly is heated to a temperature of about l,650 F and then hot isostatically compacted while being maintained at substantially this temperature at a pressure of approximately 15,000 psi. by the use of nitrogen gas. After compacting, cooling and disassembly the resulting alloy structure, which is similar to that of FIG. 3, would have a density of substantially 100 percent of theoretical and an integral bond formed between the ribs, which are of the compacted alloy particles, and the plate.
- a method for producing an alloy structure having a deep surface groove formed by the bonding of alloy powder to at least one fully dense alloy member comprising placing adjacent said fully dense member at least one nondeformable mandrel having a configuration and orientation conforming to said deep surface groove desired on said structure, placing said alloy powder adjacent said mandrel and adjacent said fully dense member, sealing said fully dense member, said mandrel and said alloy powder in a deformable envelope to form an assembly that is sealed against the atmosphere, heating said assembly to an elevated temperature, hot isostatically compacting said assembly by the application of fluid pressure sufficient to deform said envelope and compress said alloy powder against said nondeformable mandrel and said fully dense member to compact said alloy powder to substantially full density and produce a metallurgical bond between said fully dense powder and said fully dense member without deforming said mandrel and upon completion of said compacting removing said nondeformable mandrel from said assembly to expose said surface groove on the resulting alloy structure.
- said fully dense alloy member has two substantially parallel, coextensive surfaces each of which has adjacent thereto at least one said nondeformable mandrel and said alloy powder.
- said assembly comprises a fully dense alloy plate having two substantially parallel, coextensive major surfaces, at least one nondeformable ceramic mandrel on each of said major surfaces, with said mandrels being removably secured to said surfaces within said deformable envelope.
- a method for producing an alloy structure having deep surface grooves formed by the bonding of alloy powder to opposite surfaces of a fully dense alloy plate of substantially the same alloy composition as said alloy powder comprising removably securing on each of said opposite plate surfaces at least one nondeformable ceramic mandrel having a configuration and orientation conforming to the deep surface grooves desired on said alloy structure, placing said plate and mandrels in a deformable envelope substantially filled with said alloy powder to form an assembly, evacuating said assembly, sealing said assembly against the atmosphere, heating said assembly to an elevated temperature, hot isostatically compacting said assembly by the application of fluid pressure sufficient to deform said envelope and compress said alloy powder against said nondeformable mandrel and said plate to compact said alloy powder to substantially full density and produce a metallurgical bond between said fully dense powder and said fully dense plate without deforming said mandrel and upon completion of said compacting removing said nondeformable mandrel from said assembly to expose said surface groove on the resulting alloy structure.
- nondeformable ceramic mandrels are constructed from an admixture comprising refractory oxide particles from at least one of the group of refractory oxides consisting of zircon, alumina and silica, and a binding agent.
- binding agent is colloidal silica.
- a method for producing an alloy structure having deep surface grooves formed by the bonding of alloy powder to a surface of a fully dense alloy plate comprising removably securing to said plate surface at least one nondeformable ceramic mandrel having a configuration and orientation conforming to a deep surface groove desired on said alloy structure, placing a fully dense alloy member contiguous to said mandrel and in spaced apart relation to said plate surface, placing said plate, alloy member and mandrel in a deformable envelope substantially filled with said alloy powder to form an assembly, evacuating said assembly, sealing said assembly against the atmosphere, heating said assembly to elevated temperature, hot isostatically compacting said assembly by the application of fluid pressure sufficient to deform said envelope and compress said alloy powder against said nondeformable mandrel, said alloy member and said plate to compact said alloy powder to substantially full density and produce a metallurgical bond between said fully dense powder, said alloy member and said plate without deforming said mandrel and upon completion of said compacting removing said nondeformable mandre
Abstract
Description
Claims (13)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US00350423A US3844778A (en) | 1973-04-12 | 1973-04-12 | Method for producing grooved alloy structures |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US00350423A US3844778A (en) | 1973-04-12 | 1973-04-12 | Method for producing grooved alloy structures |
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US3844778A true US3844778A (en) | 1974-10-29 |
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US00350423A Expired - Lifetime US3844778A (en) | 1973-04-12 | 1973-04-12 | Method for producing grooved alloy structures |
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Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3992202A (en) * | 1974-10-11 | 1976-11-16 | Crucible Inc. | Method for producing aperture-containing powder-metallurgy article |
US3996048A (en) * | 1975-10-16 | 1976-12-07 | Avco Corporation | Method of producing holes in powder metallurgy parts |
US4063939A (en) * | 1975-06-27 | 1977-12-20 | Special Metals Corporation | Composite turbine wheel and process for making same |
US4097276A (en) * | 1975-07-17 | 1978-06-27 | The Garrett Corporation | Low cost, high temperature turbine wheel and method of making the same |
US4368074A (en) * | 1977-12-09 | 1983-01-11 | Aluminum Company Of America | Method of producing a high temperature metal powder component |
FR2541152A1 (en) * | 1983-02-17 | 1984-08-24 | Mitsubishi Heavy Ind Ltd | Method for producing composite metallic bodies |
US4526748A (en) * | 1980-05-22 | 1985-07-02 | Kelsey-Hayes Company | Hot consolidation of powder metal-floating shaping inserts |
US8392016B2 (en) | 2010-06-25 | 2013-03-05 | LNT PM Inc. | Adaptive method for manufacturing of complicated shape parts by hot isostatic pressing of powder materials with using irreversibly deformable capsules and inserts |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2783504A (en) * | 1953-05-06 | 1957-03-05 | Utica Drop Forge & Tool Corp | Method of forming articles from comminuted material |
US2847708A (en) * | 1953-08-20 | 1958-08-19 | Kelsey Hayes Co | Means for making die inserts |
US3166836A (en) * | 1962-05-24 | 1965-01-26 | Rca Corp | Manufacture of electron tube cathodes |
US3361562A (en) * | 1964-12-18 | 1968-01-02 | Siemens Ag | Method for providing metal coatings |
US3394446A (en) * | 1965-08-30 | 1968-07-30 | Olin Mathieson | Method of making composite metal structure |
-
1973
- 1973-04-12 US US00350423A patent/US3844778A/en not_active Expired - Lifetime
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2783504A (en) * | 1953-05-06 | 1957-03-05 | Utica Drop Forge & Tool Corp | Method of forming articles from comminuted material |
US2847708A (en) * | 1953-08-20 | 1958-08-19 | Kelsey Hayes Co | Means for making die inserts |
US3166836A (en) * | 1962-05-24 | 1965-01-26 | Rca Corp | Manufacture of electron tube cathodes |
US3361562A (en) * | 1964-12-18 | 1968-01-02 | Siemens Ag | Method for providing metal coatings |
US3394446A (en) * | 1965-08-30 | 1968-07-30 | Olin Mathieson | Method of making composite metal structure |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3992202A (en) * | 1974-10-11 | 1976-11-16 | Crucible Inc. | Method for producing aperture-containing powder-metallurgy article |
US4063939A (en) * | 1975-06-27 | 1977-12-20 | Special Metals Corporation | Composite turbine wheel and process for making same |
US4097276A (en) * | 1975-07-17 | 1978-06-27 | The Garrett Corporation | Low cost, high temperature turbine wheel and method of making the same |
US3996048A (en) * | 1975-10-16 | 1976-12-07 | Avco Corporation | Method of producing holes in powder metallurgy parts |
US4368074A (en) * | 1977-12-09 | 1983-01-11 | Aluminum Company Of America | Method of producing a high temperature metal powder component |
US4526748A (en) * | 1980-05-22 | 1985-07-02 | Kelsey-Hayes Company | Hot consolidation of powder metal-floating shaping inserts |
FR2541152A1 (en) * | 1983-02-17 | 1984-08-24 | Mitsubishi Heavy Ind Ltd | Method for producing composite metallic bodies |
US8392016B2 (en) | 2010-06-25 | 2013-03-05 | LNT PM Inc. | Adaptive method for manufacturing of complicated shape parts by hot isostatic pressing of powder materials with using irreversibly deformable capsules and inserts |
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