Net-shape or near net-shape powder isostatic pressing process

Abstract

A method of producing a net or near net-shape component from metal powder comprises producing an insert of accurate dimensions corresponding to the dimensions of a bore to be created in the finished component, the bore having a length of at least 750 mm, supporting the insert within a mould cavity, filling the mould cavity with metal powder, subjecting the powder to isostatic pressing, and subsequently removing the material of the insert. The mould can be an independent mould that is removed after an initial step to bind the powder together into a pre-form, and the pre-form is then encapsulated in a suitable containment, such as a canister or a sprayed coating. The insert can be a metallic insert of a material, such as copper, that is subsequently removable by chemical etching. The insert can be coated with a material that is amenable to removal by etching, and to enable the insert to be extracted. A metallic insert can be coated with a material that provides a diffusion barrier to prevent the material of the insert from diffusing by atomic diffusion into the powder being consolidated during HIPing.

1 . A method of producing a net or near net-shape component from metal powder comprising producing an insert of accurate dimensions corresponding to the dimensions of a bore to be created in the finished component, the bore having a length of at least 750 mm, supporting the insert within a mould cavity, filling the mould cavity with metal powder, subjecting the powder to isostatic pressing, and subsequently removing the material of the insert. 
     
     
         2 . The method of  claim 1  in which the mould is an independent mould that is removed after an initial step to bind the powder together into a pre-form, and the pre-form is then encapsulated in a suitable containment. 
     
     
         3 . The method of  claim 2  in which the containment is a canister. 
     
     
         4 . The method of  claim 2  in which the containment is a sprayed coating. 
     
     
         5 . The method of  claim 1  in which the insert is supported in position in the mould cavity by a plurality of formers of a material that is compatible with the finally consolidated powder. 
     
     
         6 . The method of  claim 1  in which the insert is a metallic insert of a material that is subsequently removable by chemical etching. 
     
     
         7 . The method of  claim 6  in which the insert comprises copper. 
     
     
         8 . The method of  claim 7  in which the chemical etching is assisted by electrolytic reaction. 
     
     
         9 . The method of  claim 1  in which the insert is coated with a material that is amenable to removal by etching, and comprising the steps of releasing the insert by etching the coating, and then extracting the insert. 
     
     
         10 . The method of  claim 6  in which the metallic insert is coated with a material that provides a diffusion barrier to prevent the material of the insert from diffusing by atomic diffusion into the powder being consolidated during HIPing. 
     
     
         11 . The method of  claim 10  in which the diffusion barrier comprises Al 2 O 3  applied by vapour phase deposition. 
     
     
         12 . The method of  claim 10  in which the diffusion barrier comprises Al 2 O 3  applied by high velocity spraying. 
     
     
         13 . The method of  claim 10  in which the diffusion barrier is created by applying boron nitride as an aqueous solution by spraying. 
     
     
         14 . The method of  claim 1  in which the insert is produced by taking a copper rod, of a diameter in the range of 6 to 10 mm and of length greater than 2 m, bending the copper rod into a helix of the required dimensions, and then holding the helical rod in position in a powder containment prior to filling the containment with powder, the containment enclosing the powder, rod and former, and then consolidating the powder by solid state diffusion using a HIPing method. 
     
     
         15 . The method of  claim 1  in which the insert is produced by taking a preformed metal tube, of 6 mm to 10 mm diameter, filling the tube with ceramic particles, and bending the filled tube to a helical shape, placing the helical filled tube within the powder containment prior to filling the containment with powder, holding the tube in position with formers compatible with the finally consolidated powder, providing a containment encompassing the metallic and/or cermet/MMC powder, and then consolidating the contained material by solid state diffusion using a HIPing method. 
     
     
         16 . The method of  claim 15  comprising removing the ceramic particles mechanically by a vibration technique to leave a clean hole through the finished component. 
     
     
         17 . A net or near net-shape component produced by the method of  claim 1 .