Production of metal or alloy objects

Abstract

Disclosed is a method of producing an object, the object being made of metal or an alloy, having a desired shape and being non-porous, the method comprising: providing some metal or alloy having a first average solute level; using the provided metal or alloy, performing a net-shape or near-net shape manufacturing process to produce an intermediate object, the intermediate object having the desired shape, being non-porous, and having a second average solute level, the second average solute level being greater than or equal to the first average solute level; and performing a solute level changing process on the intermediate object to change the solute level of at least the bulk of the intermediate object such as to provide the intermediate object with a third average solute level, thereby providing the object, the third average solute level being different to the second.

1 . A method of producing an object, the object being made of titanium or titanium alloy, the object having a desired shape, the object being a non-porous object, the method comprising:
 providing some titanium or titanium alloy, the provided titanium or titanium alloy having a first average oxygen level;   using the provided titanium or titanium alloy, performing a net-shape or near-net shape manufacturing process to produce an intermediate object,
 the intermediate object having the desired shape, 
 the intermediate object being a non-porous object, 
 the intermediate object having a second average oxygen level, the second average oxygen level being greater than or equal to the first average oxygen level; 
   performing a deoxidation process to remove an amount of oxygen from a surface of the intermediate object such as to provide the intermediate object with a third average oxygen level, the third average oxygen level being less than the second average oxygen level; and   thereafter, performing a homogenisation process on the intermediate object to increase the uniformity of the oxygen level within the intermediate object, thereby providing the object.   
     
     
         2 . (canceled) 
     
     
         3 . A method according to  claim 1 , wherein the deoxidation and homogenisation processes are performed such that the intermediate object substantially retains its shape and solid density. 
     
     
         4 . (canceled) 
     
     
         5 . A method according to  claim 1 , wherein the object is made of Ti—6Al—4V. 
     
     
         6 - 8 . (canceled) 
     
     
         9 . A method according to  claim 1 , wherein the deoxidation process comprises exposing at least part of the intermediate object to a fluid, wherein the fluid comprises a chemical reactant, and the chemical reactant has a different level of reactivity to oxygen than the titanium or titanium alloy. 
     
     
         10 . (canceled) 
     
     
         11 . A method according to  claim 9 , wherein the chemical reactant is calcium. 
     
     
         12 . A method according to  claim 9 , wherein the fluid further comprises a flux material, the flux material being for facilitating the removal of a product of a reaction between the chemical reactant and the titanium or titanium alloy from a surface of the object. 
     
     
         13 . A method according to  claim 12 , wherein the flux material is calcium chloride. 
     
     
         14 . (canceled) 
     
     
         15 . A method according to  claims 9 , wherein the fluid is a vapour. 
     
     
         16 . A method according to  claim 1 , wherein the produced object and the intermediate object each have a solid density within the range 92% to 100%. 
     
     
         17 . A method according to  claim 1 , wherein the amount of titanium or titanium alloy is provided in powder form. 
     
     
         18 - 19 . (canceled) 
     
     
         20 . A method according to  claim 1 , wherein the net-shape or near-net shape manufacturing process is selected from the group consisting of casting, permanent mould casting, powder metallurgy, linear friction welding, metal injection moulding, rapid prototyping, spray forming, and superplastic forming. 
     
     
         21 . A method according to  claim 20 , wherein the net-shape or near-net shape manufacturing process is metal injection moulding. 
     
     
         22 . A method according to  claim 1 , wherein the deoxidation process comprises:
 removing an amount of oxygen from the intermediate object, thereby reducing the average oxygen level of the intermediate object; and adding an amount of oxygen to the intermediate object, thereby increasing the average oxygen level of the intermediate object; wherein an amount that the average oxygen level of the intermediate object is reduced by is greater than an amount that the average oxygen level of the intermediate object is increased by.   
     
     
         23 . A method according to  claim 22 , wherein the step of adding the amount of oxygen is performed after the step of removing the amount of oxygen. 
     
     
         24 . A method according to  claim 1 , wherein the first average oxygen level is a level within a range selected from the group of ranges consisting of: between 2300 and 10000 parts per million by weight, between 5000 and 10000 parts per million by weight, and greater than 10000 parts per million by weight. 
     
     
         25 . A method according to  claim 1 , wherein the third average oxygen level is a level within a range selected from the group of ranges consisting of: between 1000 and 2300 parts per million by weight, between 1300 and 1800 parts per million by weight, between 1700 and 1800 parts per million by weight, less than 2000 parts per million by weight, less than 1300 parts per million by weight, and less than or equal to 1000 parts per million by weight. 
     
     
         26 . A method according to  claim 1 , wherein the step of performing the deoxidation process comprises heating the intermediate object to between 1000° C. and 1200° C. 
     
     
         27 . (canceled) 
     
     
         28 . A method according to  claim 1 , wherein the homogenisation process is performed such that the oxygen level in the object is substantially uniform throughout the object. 
     
     
         29 . A method according to  claim 1 , wherein the step of performing the homogenisation process comprises heating the object to between 1000° C. and 1300° C. for between 0.5 and 100 hours. 
     
     
         30 . An object produced by performing a method according to  claim 1 . 
     
     
         31 - 32 . (canceled)