Forming a Composite Component

Abstract

A method of forming a composite component from a plurality of feed materials by the application of heat is disclosed. A negative mould ( 102 ) is obtained defining the geometry of the component to be formed. First feed material ( 104 ) and second feed material ( 104 ) are deployed into the mould. The temperature is increased during a heating stage to a first temperature above the melting point of a feed material, so as to cause the powdered feed material to melt within the mould. The temperature of the mould is decreased during a cooling stage to consolidate the feed materials forming a solid component.

1 - 17 . (canceled) 
     
     
         18 . A method of forming a composite component from a plurality of dissimilar powdered feed materials, comprising the steps of:
 obtaining a negative ceramic mould ( 102 ,  401 ,  601 ,  801 ,  901 ) of a component defining a first aperture ( 603 ,  804 ,  906 ) associated with a first region ( 602 ,  802 ,  902 ) of the mould and a second aperture ( 604 ,  805 ,  908 ) associated with a second region ( 605 ,  803 ,  904 ) of the mould;   deploying a first powdered feed material ( 104 ,  608 ,  806 ,  909 ) into said first region of the negative mould via the first aperture and a second powdered feed material ( 105 ,  609 ,  807 ,  910 ) into said second region of the negative mould via the second aperture;   preventing diffusion of said first feed material with said second feed material by means of a partition ( 808 ,  903 ) separating said first region and said second region;   increasing the temperature within said negative mould to a first temperature ( 1106 ) causing said first feed material to melt during a heating stage ( 106 ); and   melting said partition to allow diffusion of said first feed material with said second feed material.   
     
     
         19 . The method of  claim 18 , wherein said partition is melted when the temperature of said negative mould is increased to said first temperature during said heating stage. 
     
     
         20 . The method of  claim 18 , wherein said second feed material is melted during said heating stage. 
     
     
         21 . The method of  claim 18 , wherein said first powdered feed material diffuses with said second powdered feed material during said heating stage to join said first and second powdered feed materials. 
     
     
         22 . The method of  claim 18 , wherein said first feed material and said second feed material are metals. 
     
     
         23 . The method of  claim 22 , wherein said first feed metal is joined to said second feed metal by diffusion of the particles during said heating stage to alloy said first and second metals over an alloyed region ( 701 ) at the interface ( 610 ). 
     
     
         24 . The method of  claim 18 , further comprising the step of:
 decreasing the temperature within said negative mould to below said first temperature causing said first feed material to solidify during a cooling stage ( 108 ).   
     
     
         25 . The method of  claim 24 , further comprising the step of:
 feeding additional liquefied material into said negative mould during said cooling stage as the material contained within said negative mould contracts in volume.   
     
     
         26 . The method of  claim 18 , wherein said heating stage is performed under a pressure other than atmospheric pressure. 
     
     
         27 . The method of  claim 24 , wherein said cooling stage is performed under a pressure other than atmospheric pressure. 
     
     
         28 . The method of  claim 18 , wherein the temperature within said mould is increased to a second temperature ( 1203 ) during said heating stage. 
     
     
         29 . The method of  claim 28 , wherein said partition is melted when the temperature of said negative mould is increased to said second temperature during said heating stage. 
     
     
         30 . An apparatus for forming a composite component from a plurality of dissimilar powdered feed materials, comprising:
 a negative ceramic mould ( 102 ,  401 ,  601 ,  801 ,  901 ) defining a first aperture ( 603 ,  804 ,  906 ) associated with a first region ( 602 ,  802 ,  902 ) of the mould and a second aperture ( 604 ,  805 ,  908 ) associated with a second region ( 605 ,  803 ,  904 ) of the mould; wherein;   said first aperture is configured for insertion of a first powdered feed material ( 104 ,  608 ,  806 ,  909 ) into said first region of the mould and said second aperture is configured for insertion of a second powdered feed material ( 105 ,  609 ,  807 ,  910 ) into a second region of the mould; and   said negative ceramic mould is suitable for heating to a first temperature ( 1106 ) during a heating stage ( 106 ), characterised in that:   said negative ceramic mould further comprises a partition ( 808 ,  903 ) separating said first and said second regions, said partition configured to prevent diffusion of said first feed material with said second feed material when in a solid form and further configured to melt to allow diffusion of said first feed material with said second feed material.   
     
     
         31 . The apparatus of  claim 30 , wherein said negative ceramic mould is configured to be pervious to the atmosphere in use.