Low porosity powder metallurgy produced components

Abstract

Components produced by powder metallurgy techniques are described herein. Embodiments of these components have little or no porosity therein after processing. Embodiments of these components are created by creating a preform from a powder; creating a component from the preform; heat treating the component to create a predetermined microstructure therein; and then hot isostatic pressing the heat treated component to reduce any porosity therein. The components can then be machined to their final dimensions, if necessary.

1 . A method for forming a component comprising: 
 providing a powder;    creating a preform from the powder;    creating a component from the preform;    heat treating the component to create a predetermined microstructure therein; and    hot isostatic pressing the heat treated component to reduce any porosity therein.    
   
   
       2 . The method of  claim 1 , wherein the powder comprises at least one of: a gamma-TiAl powder, a nickel aluminide powder, an iron aluminide powder, a titanium alloy powder, and a superalloy powder.  
   
   
       3 . The method of  claim 1 , wherein the powder comprises about 44-48 atomic percent aluminum, about 1-2 atomic percent niobium, about 1-2 atomic percent chromium, about 1-2 atomic percent molybdenum, about 0.1-0.2 atomic percent boron, and about 0.1-0.2 atomic percent carbon, the balance substantially titanium.  
   
   
       4 . The method of  claim 1 , wherein the powder has an average particle size of about 70 μm.  
   
   
       5 . The method of  claim 1 , wherein creating the preform from the powder comprises hot isostatic pressing the powder at a temperature sufficient to densify the preform and consolidate the powder through bonding thereof.  
   
   
       6 . The method of  claim 5 , wherein hot isostatic pressing the powder occurs at about 925-1320° C. and about 15-45 ksi for about 2-10 hours.  
   
   
       7 . The method of  claim 5 , wherein hot isostatic pressing the powder occurs in an argon atmosphere.  
   
   
       8 . The method of  claim 1 , wherein the component is created from the preform via at least one of: extrusion and isothermal forging.  
   
   
       9 . The method of  claim 8 , wherein the component is created from the preform at a temperature below the alpha transus temperature of the powder.  
   
   
       10 . The method of  claim 1 , wherein after the component is created, and prior to heat treating the component, the component comprises a near gamma microstructure.  
   
   
       11 . The method of  claim 1 , wherein heat treating the component occurs at a temperature above the alpha transus temperature of the powder.  
   
   
       12 . The method of  claim 1 , wherein heat treating the component occurs at about 925-1370° C. for about 2-10 hours.  
   
   
       13 . The method of  claim 1 , wherein the predetermined microstructure is a lamellar microstructure.  
   
   
       14 . The method of  claim 1 , wherein hot isostatic pressing the heat treated component occurs at a temperature low enough to prevent significant grain growth from occurring in the component.  
   
   
       15 . The method of  claim 1 , wherein hot isostatic pressing the heat treated component occurs at a temperature sufficient to preserve a lamellar microstructure in the component.  
   
   
       16 . The method of  claim 1 , wherein hot isostatic pressing the heat treated component occurs at about 925-1320° C. and about 15-45 ksi for about 2-10 hours.  
   
   
       17 . The method of  claim 1 , wherein any porosity in the heat treated and hot isostatic pressed component is less than about 0.005 inches in size.  
   
   
       18 . The method of  claim 1 , further comprising: 
 machining the heat treated and hot isostatic pressed component to its final dimensions.    
   
   
       19 . The method of  claim 1 , wherein the component comprises a gas turbine engine component.  
   
   
       20 . The method of  claim 19 , wherein the gas turbine engine component comprises at least one of: a compressor disk, a compressor blade, a low pressure turbine blade, and a tangential on board injector.  
   
   
       21 . A method for forming a component comprising: 
 providing a gamma-TiAl powder;    consolidating the gamma-TiAl powder into a preform;    creating a component from the preform;    heat treating the component to create a predetermined microstructure therein; and    hot isostatic pressing the heat treated component to reduce any porosity therein.    
   
   
       22 . The method of  claim 21 , wherein the gamma-TiAl powder comprises about 44-48 atomic percent aluminum, about 1-2 atomic percent niobium, about 1-2 atomic percent chromium, about 1-2 atomic percent molybdenum, about 0.1-0.2 atomic percent boron, and about 0.1-0.2 atomic percent carbon, the balance substantially titanium.  
   
   
       23 . The method of  claim 22 , wherein the gamma-TiAl powder has an average particle size of about 70 μm.  
   
   
       24 . The method of  claim 21 , wherein consolidating the gamma-TiAl powder into a preform comprises hot isostatic pressing the gamma-TiAl powder at about 1260° C. and about 25 ksi for about 4 hours in an argon atmosphere.  
   
   
       25 . The method of  claim 21 , wherein the component is created from the preform via at least one of: extrusion and isothermal forging.  
   
   
       26 . The method of  claim 21 , wherein after the component is created, and prior to heat treating the component, the component comprises a near gamma microstructure.  
   
   
       27 . The method of  claim 21 , wherein heat treating the component to create a predetermined microstructure therein comprises heat treating the component at about 1354° C. for about 4 hours.  
   
   
       28 . The method of  claim 27 , wherein the predetermined microstructure is a lamellar microstructure.  
   
   
       29 . The method of  claim 21 , wherein hot isostatic pressing the heat treated component occurs at about 1232° C. and about 25 ksi for about 10 hours.  
   
   
       30 . The method of  claim 21 , wherein the microstructure of the heat treated and hot isostatic pressed component comprises a lamellar microstructure substantially similar to the lamellar microstructure that existed in the heat treated component prior to being hot isostatic pressed.  
   
   
       31 . The method of  claim 21 , wherein the heat treated and hot isostatic pressed component has less porosity than the heat treated component prior to being hot isostatic pressed.  
   
   
       32 . The method of  claim 21 , wherein any porosity in the heat treated and hot isostatic pressed component is less than about 0.005 inches.  
   
   
       33 . The method of  claim 21 , further comprising: 
 machining the heat treated and hot isostatic pressed component to its final dimensions.    
   
   
       34 . The method of  claim 21 , wherein the component comprises a gas turbine engine component.  
   
   
       35 . The method of  claim 34 , wherein the gas turbine engine component comprises at least one of: a compressor disk, a compressor blade, a low pressure turbine blade, and a tangential on board injector.  
   
   
       36 . A component formed by the method of  claim 1.