US2005281702A1PendingUtilityA1

Method of consolidating a powder

42
Assignee: ROLLS ROYCE PLCPriority: Jun 16, 2004Filed: May 20, 2005Published: Dec 22, 2005
Est. expiryJun 16, 2024(expired)· nominal 20-yr term from priority
Inventors:Daniel ClarkJustin Burrows
B22F 2999/00B22F 3/105B22F 2998/10B22F 3/14
42
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Claims

Abstract

A method of consolidating a powder ( 10 ) comprises the steps of filling an electrically conductive container ( 12 ) with the powder ( 10 ). Any air is evacuated out of the filled container ( 12 ), which is then sealed. The sealed container ( 12 ) is placed in a die ( 20 ) and a force is applied to consolidate the powder ( 10 ). Simultaneously an electric pulse and an ultrasonic pulse are applied to the container ( 12 ) as the powder ( 10 ) is consolidated. The electric and ultrasound pulses are applied during consolidation to disrupt the grain boundaries and assist in the fragmentation of any oxides. The container ( 12 ) is then removed from the die ( 20 ) and from the consolidated powder ( 10 ).

Claims

exact text as granted — not AI-modified
1 . A method of consolidating a powder comprising the steps of filling an electrically conductive container with powder, evacuating any air out of the filled container and sealing the filled container after evacuation, placing the sealed container in a die and applying a force sufficient to consolidate the powder whilst simultaneously applying an electric pulse and an ultrasonic pulse to the container, removing the container from the die and removing the container from the consolidated powder.  
   
   
       2 . A method as claimed in  claim 1  in which electrical energy in the range of 1-20 KJ is applied to the container.  
   
   
       3 . A method as claimed in  claim 1  in which the frequency of the electrical energy is of the order of 20 KHz.  
   
   
       4 . A method claimed in  claim 1  in which the force used to compress the powder is a mechanically induced shock wave.  
   
   
       5 . A method as claimed in  claim 1  in which the shock wave applies a force in the range of 5-20 GPa.  
   
   
       6 . A method as claimed in  claim 1  in which the ultrasound pulse has a frequency of 20 KHz.  
   
   
       7 . A method as claimed in  claim 1  in which the container is vibrated as it is filled with powder.  
   
   
       8 . A method as claimed in  claim 1  in which the powder is a nickel alloy.  
   
   
       9 . A method as claimed in  claim 1  in which the container is made from nickel.  
   
   
       10 . A method as claimed in  claim 1  in which the consolidated powder is sintered after removal of the container.  
   
   
       11 . A method as claimed in  claim 1  in which the consolidated powder is hot isostatically pressed after removal of the container.  
   
   
       12 . A method of consolidating a powder to join preforms comprising the steps of placing at least two preforms in abutting relationship in an electrically conductive container, coating the abutting surfaces of the preforms with powder, evacuating any air out of the container and sealing the container after evacuation, placing the sealed container in a die and applying a force sufficient to consolidate the powder and join the preforms whilst simultaneously applying an electric pulse and an ultrasonic pulse to the container, removing the container from the die and removing the container from the joined preforms.  
   
   
       13 . A method as claimed in  claim 12  in which the composition of each of the preforms is different.  
   
   
       14 . A method as claimed in  claim 12  in which the powder coating has a different composition to the preforms.  
   
   
       15 . A method as claimed in  claim 12  in which electrical energy in the range of 1-20 KJ is applied to the container.  
   
   
       16 . A method as claimed in  claim 12  in which the frequency of the electrical energy is of the order of 20 KHz.  
   
   
       17 . A method claimed in  claim 12  in which the force used to compress the powder is a mechanically induced shock wave.  
   
   
       18 . A method as claimed in  claim 12  in which the shock wave applies a force in the range of 5-20 GPa.  
   
   
       19 . A method as claimed in any of  claim 12  in which the ultrasound pulse has a frequency of 20 KHz.  
   
   
       20 . A method of consolidating a powder to coat a perform comprising the steps of placing at least one perform in an electrically conductive container, coating the surfaces of the perform with powder, evacuating any air out of the container and sealing the container after evacuation, placing the sealed container in a die and applying a force sufficient to consolidate the powder into a coating on the preform whilst simultaneously applying an electric pulse and an ultrasonic pulse to the container, removing the container from the die and removing the container from the coated preform.  
   
   
       21 . A method as claimed in  claim 20  in which the powder coating has a different composition to the preforms.  
   
   
       22 . A method as claimed in  claim 20  in which electrical energy in the range of 1-20 KJ is applied to the container.  
   
   
       23 . A method as claimed in  claim 20  in which the frequency of the electrical energy is of the order of 20KHz.  
   
   
       24 . A method claimed in  claim 20  in which the force used to compress the powder is a mechanically induced shock wave.  
   
   
       25 . A method as claimed in  claim 20  in which the shock wave applies a force in the range of 5-20 GPa.  
   
   
       26 . A method as claimed in  claim 20  in which the ultrasound pulse has a frequency of 20 KHz.

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