Engine components and methods of forming engine components

Abstract

Engine components that include a compacted powder material comprising a nickel-based superalloy having less than five parts per million sulfur, by weight and methods of forming the components are provided. In an embodiment, by way of example only, a method includes flowing a gas into a can with a metal powder therein, the gas comprising hydrogen, the can configured to be used for a consolidation process, and the superalloy comprising sulfur. Gas is flowed into and then removed from the can. A sulfur content of the removed gas is determined during the process. The can and the metal powder therein are subjected to the consolidation process, if a determination is made that the sulfur content of the metal powder is below a threshold value, the threshold value being a value below about 1 part per million by weight.

1 . A method of forming a component, the method comprising the steps of:
 flowing a gas into a can with a metal powder therein, the gas comprising hydrogen, the can configured to be used for a consolidation process, and the metal powder comprising sulfur;   removing at least a portion of the gas from the can; and   subjecting the metal powder therein to the consolidation process, if a determination is made that a sulfur content of the metal powder is below a threshold value, the threshold value being a value below about 5 parts per million by weight.   
     
     
         2 . The method of  claim 1 , wherein the threshold value is a value less than about 1 part per million by weight. 
     
     
         3 . The method of  claim 1 , wherein the step of flowing the gas comprises flowing a gas mixture into the can, wherein the gas mixture comprises hydrogen and an inert gas. 
     
     
         4 . The method of  claim 1 , further comprising determining a sulfur content of the removed gas by sensing a hydrogen sulfide content thereof. 
     
     
         5 . The method of  claim 1 , wherein the step of subjecting comprises subjecting the metal powder to a consolidation process comprising a process selected from the group of hot isostatic pressing, extrusion, and forging. 
     
     
         6 . The method of  claim 1 , further comprising the step of repeating the steps of flowing and removing until the sulfur content of the metal powder is below the threshold value. 
     
     
         7 . The method of  claim 6 , wherein the step of repeating comprises performing the steps of flowing and removing over a time period of between about 1 hour and about 20 hours. 
     
     
         8 . The method of  claim 1 , wherein the steps of flowing and removing are performed within 300° C. of an incipient melting temperature of the metal powder. 
     
     
         9 . The method of  claim 1 , wherein the steps of flowing and removing comprises placing the can in a furnace and heating the can to a temperature that is between about 50° C. and about 100° C. lower than an incipient melting point of the metal powder. 
     
     
         10 . The method of  claim 1 , further comprising the step of transferring at least a portion of the desulfurized powder to another can, before the step of subjecting. 
     
     
         11 . A method of forming an engine component, the method comprising the steps of:
 flowing a gas into a can with a metal powder therein, the gas comprising hydrogen, the can configured to be used for a hot isostatic pressing process, and the metal powder comprising sulfur;   removing at least a portion of the gas from the can;   determining a sulfur content of the removed gas;   after a determination is made that the sulfur content of the metal powder is below a threshold value, the threshold value being below about 5 parts per million by weight, subjecting the metal powder therein to the hot isostatic pressing process to form compacted metal powder; and   machining the compacted metal powder to form the engine component.   
     
     
         12 . The method of  claim 11 , wherein the threshold value is a value that is less than about 1 part per million by weight. 
     
     
         13 . The method of  claim 11 , further comprising the step of repeating the steps of flowing and removing until the sulfur content of the metal powder is below the threshold value. 
     
     
         14 . The method of  claim 13 , wherein the step of repeating comprises performing the steps of flowing and removing over a time period of between about 1 hour and about 20 hours. 
     
     
         15 . The method of  claim 11 , wherein the steps of flowing and removing are performed within 300° C. of an incipient melting temperature of the metal powder. 
     
     
         16 . The method of  claim 11 , further comprising the step of heat treating the compacted metal powder before the step of machining. 
     
     
         17 . The method of  claim 11 , wherein the step of determining comprises sensing a hydrogen sulfide content of the removed gas. 
     
     
         18 . The method of  claim 11 , further comprising the step of transferring at least a portion of the desulfurized powder to another can, before the step of subjecting. 
     
     
         19 . An engine component comprising:
 a compacted powder material, the compacted powder material comprising a nickel-based superalloy having less than 5 parts per million sulfur, by weight.   
     
     
         20 . The engine component of  claim 19 , wherein the compacted powder material is shaped into a turbine disk.