Apparatus and a method of manufacturing an article by consolidating powder material

Abstract

A method of manufacturing an article by consolidating powder material comprises forming a non-deformable tool ( 12 ) and a deformable tool ( 14 ). The non-deformable tool ( 12 ) comprises a plurality of tool parts ( 16,18 ). The non-deformable tool ( 12 ) defines a first cavity ( 20 ) having an open end ( 22 ) and the first cavity ( 20 ) corresponds in shape to that of the article. The non-deformable tool ( 12 ) is encapsulated in the deformable tool ( 14 ) and the non-deformable tool ( 12 ) and the deformable tool ( 14 ) define a second cavity ( 24 ) interconnected with the first cavity ( 20 ). The first and second cavities are filled with powder material ( 26 ). The deformable tool ( 14 ) is evacuated and sealed. Heat and pressure are applied to the deformable tool ( 14 ) and non-deformable tool ( 12 ) to consolidate the powder material ( 26 ) to form an article ( 30 ) in the first cavity ( 20 ) of the non-deformable tool ( 12 ). The method is used to make compressor blades, compressor vanes or compressor blisks for gas turbine engines.

1 . A method of manufacturing an article by consolidating powder material comprising the steps of:—
 (a) providing a non-deformable tool, the non-deformable tool comprising a plurality of tool parts, the non-deformable tool defining a first cavity having an open end, the first cavity corresponding in shape to that of the article,    (b) encapsulating the non-deformable tool in a deformable tool, the non-deformable tool and deformable tool defining a second cavity interconnected with the first cavity,    (c) filling the first cavity and second cavity with powder material,    (d) evacuating the deformable tool,    (e) sealing the deformable tool,    (f) applying heat and pressure to the deformable tool and non-deformable tool to consolidate the powder material to form an article in the first cavity of the non-deformable tool.    
     
     
         2 . A method as claimed in  claim 1  wherein step (f) comprises heating to a temperature of 925° C. and applying a pressure of 150 MPa and maintaining for 2 hours.  
     
     
         3 . A method as claimed in  claim 1  comprising removing the deformable tool from the non-deformable tool.  
     
     
         4 . A method as claimed in  claim 3  comprising dissolving the deformable tool from the non-deformable tool.  
     
     
         5 . A method as claimed in  claim 4  comprising dissolving the deformable tool using an acid.  
     
     
         6 . A method as claimed in  claim 1  wherein the deformable tool comprises a deformable vacuum bag.  
     
     
         7 . A method as claimed in  claim 6  wherein the vacuum bag comprises a metal.  
     
     
         8 . A method as claimed in  claim 7  wherein the metal comprises mild steel.  
     
     
         9 . A method as claimed in  claim 1  comprising removing the non-deformable tool from the article.  
     
     
         10 . A method as claimed in  claim 9  comprising removing the non-deformable tool by removing the tool parts.  
     
     
         11 . A method as claimed in  claim 10  wherein the non-deformable tool comprises at least two tool parts.  
     
     
         12 . A method as claimed in  claim 1  wherein the non-deformable tool comprises a non-deformable metal.  
     
     
         13 . A method as claimed in  claim 12  wherein the metal comprises high strength steel.  
     
     
         14 . A method as claimed in  claim 9  comprising removing the tool parts from the article and removing excess consolidated powder from the end of the article, which was adjacent the open end.  
     
     
         15 . A method as claimed in  claim 9  comprising removing excess consolidated powder from the end of the article and non-deformable tool, which was adjacent the open end and then removing the tool parts from the article.  
     
     
         16 . A method as claimed in  claim 1  wherein the powder material comprises metal powder, ceramic powder or metal powder and ceramic powder.  
     
     
         17 . A method as claimed in  claim 16  wherein the metal powder is an alloy powder or an elemental powder.  
     
     
         18 . A method as claimed in  claim 17  wherein the metal powder is nickel alloy powder, titanium alloy powder, aluminium alloy powder, cobalt alloy powder or iron alloy powder.  
     
     
         19 . A method as claimed in  claim 1  wherein the article is a compressor blade, a compressor vane, a turbine blade, a turbine vane, a compressor disc, a turbine disc, a compressor blisk or a turbine blisk.  
     
     
         20 . A method as claimed in  claim 1  wherein step (f) comprises hot isostatic pressing or isothermal pressing.  
     
     
         21 . An apparatus for manufacturing an article by consolidating powder material comprising a non-deformable tool and a deformable tool, the non-deformable tool comprising a plurality of tool parts, the non-deformable tool defining a first cavity having an open end, the first cavity corresponding in shape to that of the article, the non-deformable tool and deformable tool defining a second cavity interconnected with the first cavity.  
     
     
         22 . An apparatus as claimed in  claim 21  wherein the deformable tool comprises a deformable vacuum bag.  
     
     
         23 . An apparatus as claimed in  claim 22  wherein the vacuum bag comprises a metal.  
     
     
         24 . An apparatus as claimed in  claim 23  wherein the metal comprises mild steel.  
     
     
         25 . An apparatus as claimed in  claim 21  wherein the non-deformable tool comprises a non-deformable metal.  
     
     
         26 . An apparatus as claimed in  claim 25  wherein the metal comprises high strength steel.