WO2014152172A1 - Extrusion d'alliage par métallurgie des poudres - Google Patents

Extrusion d'alliage par métallurgie des poudres Download PDF

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Publication number
WO2014152172A1
WO2014152172A1 PCT/US2014/027033 US2014027033W WO2014152172A1 WO 2014152172 A1 WO2014152172 A1 WO 2014152172A1 US 2014027033 W US2014027033 W US 2014027033W WO 2014152172 A1 WO2014152172 A1 WO 2014152172A1
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WO
WIPO (PCT)
Prior art keywords
bag
precursor
article
airfoil
alloy
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2014/027033
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English (en)
Inventor
Thomas Demichael
Mark M. TIMKO
Thomas J. Watson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
RTX Corp
Original Assignee
United Technologies Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by United Technologies Corp filed Critical United Technologies Corp
Publication of WO2014152172A1 publication Critical patent/WO2014152172A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • This disclosure relates to alloys. More particularly, the disclosure relates to forging of aluminum aerospace alloys . [0003] Forging of powder-origin metal alloys including aluminum alloys is known.
  • Nonlimiting examples are of aluminum alloys include aluminum-based structural amorphous metals (SAM) and
  • SAM and I-phase aluminum have been proposed for aerospace uses including forged airfoil elements such as fan blades. These alloys are produced via rapid solidification using a variety of techniques; examples being comminution of melt-spun ribbon or gas-atomization of powder. Using
  • the powder is poured into a containment can which then contains both powder and the gas from atomization.
  • a containment can which then contains both powder and the gas from atomization.
  • An example of a can is one which is
  • the can is filled with powder, it is processed through a degassing cycle, where the can is heated (e.g., to 700°F (371°C)) while maintaining a vacuum to remove moisture and contaminants. Once an acceptable vacuum level is achieved (e.g., 5 X 10 ⁇ 6 Torr) , the can is sealed.
  • the degassing cycle can take an exemplary ten hours to two weeks to achieve the desired outgassing, depending on cleanliness and contaminants in the powder, can, and vacuum system.
  • the SAM/I-phase alloy-filled can is moved to a hydraulic compaction press, while still hot (e.g., 700°F (371°C)) and a load is applied to compact the alloy can.
  • exemplary compaction is to approximately ten inches in diameter by twenty-four inches tall by 0.250 inch wall thickness (25 cm diameter by 61 cm tall with a 6.4 mm wall thickness) . This compaction cycle does not fully compact the alloy powder into a solid billet, but is estimated to be approximately 60% compacted.
  • the billet cools to room temperature.
  • Solid metal pieces e.g., of 6061-T8 aluminum, ten inches (25.4 cm) in diameter
  • the pieces act as a leader/front (e.g., six inches (15 cm) thick) and follower/rear (e.g., four inches (10 cm) thick) to aid in the compaction/extrusion process.
  • the can and the welded leader and follower are then heated in an oven to achieve an elevated internal temperature (e.g., 675°F (357°C)), then placed into an extrusion press and pressed against a flat/blind die to fully compact the alloy powder into a solid state.
  • the blind die is removed from the press, and an extrusion die is loaded into the press.
  • an extrusion ratio of 10:1 is used for processing the SAM/I-phase alloy into an extruded log.
  • An issue with the extrusion process is the adiabatic heating caused by the friction of the alloy being pushed through a small diameter hole in comparison with the large (e.g., ten inch (25.4 cm)) starting diameter.
  • the adiabatic heating can reach as high as 850+°F (454+°C) . Any temperature exposure above a certain amount (e.g., 700°F (371°C)) has a detrimental effect on material properties of the SAM/I-phase alloys.
  • the extrudate is cooled to room temperature. [0010] Once the SAM/I-phase alloys are extruded, the leader and follower material is cut away and discarded.
  • the now fully dense alloy log is then cut into individual pieces, referred to as "mults" or “forging mults", and machined (removing the can) to be true in diameter and length (e.g., nine inches (22.9 cm) long by 3.5 inches (8.9 cm) in diameter in the example) .
  • the fully dense mults are now ready for forging.
  • 675°F (357°C) for a short isothermal soak at temperature A single mult is then placed in a "blocker" die (which was previously heated in a die furnace) that has also been heated to 675°F (357°C), and forged in a hydraulic press producing a rectangular shape approximately eleven inches long by three inches wide by 1.75 inches thick.
  • the rectangular shape is removed from the blocker die and put back into the mult furnace at 675°F (357°C), soaked, then transferred to a hot (e.g., 675°F (357°C)) preform die (which was previously heated in the same die furnace as the blocker die) and forged into the preform shape.
  • a hot e.g., 675°F (357°C)
  • the preform shape is removed from the preform die, placed in the mult furnace, reheated and soaked at 675°F (357°C), then placed in the hot final form die (which was previously heated in the same die furnace as the blocker and preform dies) , and forged into the final shape, producing the desired near net-shape fan blade.
  • One aspect of the disclosure involves a method for forming an article.
  • One or more powders are introduced to a bag. Vacuum is applied to the bag and the bag is then sealed.
  • the one or more powders in the sealed bag are then forged to form a precursor of the article.
  • the precursor is extruded into a shaped die to form at least a second precursor of the article
  • the forging is the only forging.
  • the method further comprises a machining after the extrusion.
  • the article is a blade comprising an airfoil and an attachment root.
  • the second precursor comprises a precursor of the airfoil and a precursor of the root.
  • the precursor of the airfoil has a suction side and a pressure side, a leading edge, and a trailing edge.
  • the precursor of the root is protuberant relative to a rootward portion of the precursor of the airfoil.
  • the article comprises an aluminum alloy.
  • the aluminum alloy is a SAM alloy comprising Al with Y, Ni, Co, Zr.
  • the aluminum alloy is an I-phase alloy comprising Al with Cr, Mn, Co, and Zr.
  • a peak temperature is less than 500°C.
  • the bag comprises an aluminum alloy having a wall thickness less than 6.5 mm. [0027] In one or more embodiments of any of the foregoing embodiments, the bag comprises an aluminum alloy having a wall thickness less than 1.5 mm. [0028] In one or more embodiments of any of the foregoing embodiments, the bag comprises an inner surface which is separated from the outer surface by a thin-walled metal that, unlike a can, is collapsible or partially collapsible due to atmospheric pressure on the outer surface when the inner surface is subjected to a vacuum.
  • the bag comprises a polymer having a wall
  • the sealing comprises either liquid or solid state welding.
  • Another aspect is an article produced by the method.
  • FIG. 1 is a partially schematic longitudinal sectional view of a gas turbine engine.
  • FIG. 2 is a view of a fan blade of the engine of FIG. 1.
  • FIG. 3 is a plan view of an example pattern for forming a bag for forging a blade.
  • FIG. 4 is a simplified view of an example bag.
  • FIG. 5 is a longitudinal sectional view of a bag.
  • FIG. 6 is a schematic view of an apparatus for filling a bag .
  • FIG. 7 is a schematic view of an apparatus for final depressurization of the bag.
  • FIG. 8 is a schematic view of a first die in an open condition.
  • FIG. 9 is a schematic view of the first die in a closed condition .
  • FIG. 10 is a schematic view of the extrusion die in an open condition.
  • FIG. 11 is a schematic view of the extrusion die in a closed condition.
  • FIG. 1 is a schematic view of selected portions of an example gas turbine engine 10 suspended from an engine pylon 12 of an aircraft, as is typical of an aircraft designed for subsonic operation.
  • the gas turbine engine 10 is
  • the gas turbine engine 10 includes a fan 14, a compressor 16 having a low pressure compressor section 16a and a high pressure compressor section 16b, a combustion section 18, and a turbine 20 having a high pressure turbine section 20b and a low pressure turbine section 20a.
  • air compressed in the compressors 16a, 16b is mixed with fuel that is burned in the combustion section 18 and expanded in the turbines 20a and 20b.
  • the turbines 20a and 20b are coupled for rotation with, respectively, rotors 22a and 22b (e.g., spools) to rotationally drive the compressors 16a, 16b and the fan 14 in response to the expansion.
  • the rotor 22a drives the fan 14 through a gear train 24.
  • the gas turbine engine 10 is a high bypass geared turbofan arrangement.
  • the bypass ratio is greater than 10:1
  • the fan 14 diameter is substantially larger than the diameter of the low pressure compressor 16a and the low pressure turbine 20a has a pressure ratio that is greater than 5:1.
  • the gear train 24 can be any known suitable gear system, such as a planetary gear system with orbiting planet gears, planetary system with non-orbiting planet gears, or other type of gear system.
  • the gear train 24 has a constant gear ratio.
  • An outer housing, nacelle 28, (also commonly referred to as a fan nacelle) extends circumferentially about the fan 14.
  • a generally annular fan bypass passage 30 extends between the nacelle 28 and an inner housing, inner cowl 34, which generally surrounds the compressors 16a, 16b and turbines 20a, 20b.
  • the gas turbine engine 10 also includes guide vanes 29 (shown schematically) .
  • the fan 14 draws air into the gas turbine engine 10 as a core flow, C, and into the bypass passage 30 as a bypass air flow, D. In one example, approximately 80 percent of the airflow entering the nacelle 28 becomes bypass airflow D.
  • a rear exhaust 36 discharges the bypass air flow D from the gas turbine engine 10.
  • the gas turbine engine 10 may include airfoil components in one or more of the sections of the engine.
  • An example is an aluminum alloy fan blade 60 (FIG. 2) having an airfoil portion 62 and a root portion 64 for mounting the airfoil component in the gas turbine engine 10 (e.g., to a fan hub) .
  • the airfoil portion extends from an inboard end 66 at the root (or an intervening platform) to an outboard end 68 (e.g., a tip shown as a free (unshrouded) tip) .
  • the airfoil extends streamwise from a leading edge 70 to a trailing edge 72 and has a pressure side (e.g., generally concave) 74 and a suction side (e.g., generally convex) 76.
  • the bag may be made of aluminum foil (e.g., an aluminum alloy having a characteristic thickness 1.5 mm or less, more particularly 1.0 mm or less or an exemplary 0.4-1.0 mm) .
  • the exemplary bag for making a particular blade is, eleven inches long by three inches wide by three inches tall by 0.030 inch wall thickness (28 cm by 7.6 cm by 7.6 cm by 0.8 mm wall thickness) .
  • the exemplary bag is constructed by picking a shape, cutting a flat pattern 300 (FIG. 3) for the three-dimensional shape out via laser, or something as simple as scissors, depending on the gage.
  • a tube 320 (FIG. 4) is then welded onto the bag and the other end has a quick disconnect valve 322 (FIG. 6) on it which can be opened to allow for evacuation of either gas or air from the bag, or allow for filling of the bag with an inert gas.
  • the seams will be where the bag is joined together after being cut from the sheet.
  • seams might be as simple as those to make a right circular cylinder, or they may occur in such a way as to define a preform shape that can be used to start extrusion operations of an airfoil shape.
  • the only fitting is envisioned to be on an end for evacuation/pressurization purposes. The end would be chosen such that minimal deformation of the fitting would occur, thus precluding the possibility that the powder becomes exposed to air prior to the establishment of a high relative density (which then provides for closing off any remaining porosity from the outside environment) .
  • the powder enters the bag through the tube.
  • the exemplary bag has an internal volume of 300 in 3 (4.9 liters) .
  • the bag may be made of a high temperature polymer (e.g., KAPTON polyimide foil).
  • Exemplary SAM alloys are found in US Patent 6,248,453 Bl, US Patent 6,974,510 B2 and US Patent 7,413,621 B2 and generally comprise Al with Y, Ni, Co, and Zr.
  • Exemplary SAM alloys are found in US Patent 6,248,453 Bl, US Patent 6,974,510 B2 and US Patent 7,413,621 B2 and generally comprise Al with Y, Ni, Co, and Zr.
  • I-phase powders generally comprise Al with Cr, Mn, Co, and Zr.
  • the exemplary bag is filled with about 30 kg of such alloys.
  • a broader weight range for blades of a generally similar type for different engine sizes is 10-80 kg, but for a broader part range 1-500 kg.
  • the exemplary bag replaces a much larger baseline containment can and also allows for omitting steps in the baseline process.
  • time at temperature during thermal processing in general, reduces the strength characteristics of the SAM/I-phase alloy, and is additive. Thus, this process may eliminate significant time at
  • a powder source 330 (FIG. 6) containing metal powder 331 may be in a form such as a static or dynamic degassing unit (or any closed container with a valve opening) containing the powder.
  • FIG. 6 further shows a vacuum source 332 and an inert gas source 400.
  • the vacuum source 332, the powder source 330, and the gas source 400 are coupled to a port for connection to the valve 322.
  • One or more valves 334, 335, and 336 selectively control flow amongst the powder source 330, the vacuum source 332, the gas source 400, and the bag 310.
  • valves 334, 335, and 336 are closed.
  • the valve 335 may then be opened and the vacuum source 332 (e.g., a pump) evacuates the cross joint 340.
  • the pump mechanical or other evacuates the cross to a pressure on the order 10 ⁇ 3 to 10 ⁇ 4 Torr.
  • the valve 322 is opened. This evacuates air from the bag. If the bag is a pump.
  • valve 335 can be closed and valve 336 can be opened to fill the bag 310 with inert gas from gas source 400, thereby returning it to its original shape. Repeating this procedure two to three times will assure that the bag is free of contaminants.
  • the bag may be heated. The heating helps further drive off any moisture on the inner wall surface of the bag. If heated, the bag may then be cooled to room temperature, and in this case, is still under pressure from the inert gas.
  • the valve 322 is then closed to close off communication with the bag.
  • the valve 336 is then closed to close off communication with the gas source. [0056] Thereafter, the valve 334 may be opened. This opening causes powder to flow from the source 330 into the cross 340.
  • valve 322 may be opened causing the powder to fall into the bag 310, filling the bag, while simultaneously displacing the inert gas in the bag. With the bag full, the valves 322 and 334 may be closed and the bag disengaged. If the bag is not crushed by atmospheric pressure, it can be seen that appropriate opening and closing of valves 322, 335, and 336 could create a vacuum in the bag 310. Keeping valves 335 and 336 closed and valve 322 open, the vacuum in bag 310, once valve 334 is opened, would further encourage, rather than depending on gravity alone as was the situation in the prior case, the filling of bag 310 due to the pressure differential between bag 310 and powder source 330.
  • the bags may then be evacuated (for the case of a collapsible bag) /further evacuated (for the case of a rigid bag) to reduce/further reduce their pressure (e.g., with a stronger vacuum pump (e.g., diffusion, cryo-pumps) 350 (FIG. 7)) .
  • the vacuum pump may be connected to a manifold 352 for simultaneously evacuating multiple bags.
  • the trunk and branch of the manifold may each have a valve for flow control.
  • the filled bag is then connected to an associated branch of the vacuum manifold 352 (e.g., to which many such bags (typically ten to sixteen bags) are connected via respective branches 354)) .
  • all bags would be attached to this system simultaneously.
  • the system valves would then be opened to remove the air between the system valves and the bag valves.
  • the bag valves would then be opened and the residual gas in the bags removed.
  • the system and bag valves would be closed to the existing bags, and then opened for the new bags. Once the pressure for the new bags reached the pressure of the existing bags, then all valves could be opened to all bags. While this would not be as efficient as the method for placing all bags on the manifold
  • the pump 350 may optionally pre-evacuate the manifold. Then the valves are opened to evacuate the bags. For yet further evacuation of water or other undesirable
  • the bags may further be heated during this process.
  • the vacuum tube 320 on the bag is crimped and welded.
  • the bag is then disconnected from the vacuum source 350. Due to the reduced powder volume in a bag (e.g., about 300 in 3 (4.9 liters) in one example) versus a can (e.g., 4500 in 3 (74 liters) , the outgassing cycle time and time at
  • temperature may be reduced to less than two hours, saving fourteen or more hours to days of heat exposure.
  • the filled bag is ready for forging.
  • Filled bags are placed in a mult furnace at an
  • the filled bags 310 are each (e.g., consecutively or using separate die sets) placed in a "blocker" die 600 (FIGS. 8 & 9) that has been heated in a die furnace to 675°F (357°C), and forged in a hydraulic press producing a rectangular shape 604 (a first precursor of the blade) approximately eleven inches long by three inches wide by 1.75 inches thick (28 cm long by 7.6 cm wide by 4.4 cm thick) .
  • This step combines the compaction, compaction/extrusion, and blocking process in one step, eliminating thermal cycles, containment can materials, leaders, followers, machining, and thermal processing.
  • the rectangular shape 604 is then placed into the mult furnace at an exemplary 675°F (357°C), soaked, then
  • the exemplary die 610 has a holder 620 having a
  • the remaining portion of the die is formed by multiple split sections (e.g., two sections shown as 630 and 632 split along a parting boundary approximately along airfoil leading edge and trailing edge) .
  • the sections 630 and 632 when assembled, define a compartment or cavity 640 shaped to define the blade precursor (e.g., having respective airfoil and root regions 642 and 644) .
  • the sections further include a gating boss 650 which forms a piston having surfaces defining a passageway leading to the cavity 640 upon a compacting shift 660 (FIG. 11) .
  • the boss is driven into the compartment 622 and extrudes the material of the shape 604 into the cavity.
  • the extrusion extrudes the material into a shaped die (e.g., as distinguished from extruding into a cylindrical form for subsequent shaping) .
  • the exemplary second precursor is
  • machining may create the final blade shape.
  • the bag may become a part of the extruded structure.
  • the bag could be aluminum based and the powder could be conventional aluminum alloys including 6000, 2000, 7000, or more recently, Al-Li alloys.
  • the bag could be composed of a SAM/I-phase alloy that has the same composition as the powder. Or maybe the bag is an I-phase alloy with better corrosion resistance, but reduced mechanical properties relative to the powder alloy.
  • the surface, whether composed of the bag or not, would be machined, peened, and coated as appropriate.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé de formation d'un article (60) par l'introduction d'au moins une poudre (331) dans un sac (310). On applique du vide au sac. Le sac est scellé. La ou les poudres du sac scellé sont forgées pour former un premier précurseur (604) de l'article. Le précurseur est extrudé en une matrice profilée afin de former au moins un deuxième précurseur (606) de l'article.
PCT/US2014/027033 2013-03-15 2014-03-14 Extrusion d'alliage par métallurgie des poudres Ceased WO2014152172A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201361789353P 2013-03-15 2013-03-15
US61/789,353 2013-03-15
US201361908390P 2013-11-25 2013-11-25
US61/908,390 2013-11-25

Publications (1)

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WO2014152172A1 true WO2014152172A1 (fr) 2014-09-25

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4066449A (en) * 1974-09-26 1978-01-03 Havel Charles J Method for processing and densifying metal powder
US6274082B1 (en) * 1998-09-03 2001-08-14 Ykk Corporation Process for producing shaped article
US6974510B2 (en) * 2003-02-28 2005-12-13 United Technologies Corporation Aluminum base alloys
US20080237403A1 (en) * 2007-03-26 2008-10-02 General Electric Company Metal injection molding process for bimetallic applications and airfoil
US20110044844A1 (en) * 2009-08-19 2011-02-24 United Technologies Corporation Hot compaction and extrusion of l12 aluminum alloys

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4066449A (en) * 1974-09-26 1978-01-03 Havel Charles J Method for processing and densifying metal powder
US6274082B1 (en) * 1998-09-03 2001-08-14 Ykk Corporation Process for producing shaped article
US6974510B2 (en) * 2003-02-28 2005-12-13 United Technologies Corporation Aluminum base alloys
US20080237403A1 (en) * 2007-03-26 2008-10-02 General Electric Company Metal injection molding process for bimetallic applications and airfoil
US20110044844A1 (en) * 2009-08-19 2011-02-24 United Technologies Corporation Hot compaction and extrusion of l12 aluminum alloys

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