Integrated method for manufacturing high-temperature resistant thin-walled component by preforming by laying metal foil strip

Patent metadata

Field	Value
Publication number	US-11207732-B2
Application number	US-202016938648-A
Country	US
Kind code	B2
Filing date	Jul 24, 2020
Priority date	Jan 13, 2020
Publication date	Dec 28, 2021
Grant date	Dec 28, 2021

Abstract

An integrated method for manufacturing a high-temperature resistant thin-walled component by preforming by laying a metal foil strip. The integrated manufacturing method includes: designing a preform, preparing a support die, determining a thickness of a foil strip, determining a width of the foil strip, developing a laying process, laying an A foil strip and a B foil strip, obtaining an AB laminated preform, bulging the preform, performing a reactive synthesis and a densification process of a bulged component, and performing a subsequent treatment of the thin-walled component. Various embodiments obtain an integral thin-walled preform with a complex structure, a uniform wall thickness and a shape close to the final part by continuously laying a metal foil strip with an appropriate width.

First claim

What is claimed is:

1. An integrated method for manufacturing a high-temperature resistant thin-walled component by preforming by laying a metal foil strip, comprising steps of:
defining a dimensional size and a shape for a thin-walled preform;
forming a support die by using an inner wall of the preform as a characteristic surface;
defining a thickness of a plurality of A single-layer foil strips and a plurality of B single-layer foil strips: calculating a total thickness ratio of the A single-layer foil strips composed of a metal A to the B single-layer foil strips composed of a metal B, and then calculating theft thickness of the A single-layer foil strips and the B single-layer foil strips, according to a ratio of the number of atoms A to the number of atoms B in an intermetallic compound (IMC) composed of the metal A and the metal B;
defining a width of each foil strip: defining a width for each of the A single-layer foil strips and each of the B single-layer foil strips applicable in each characteristic zone to produce the plurality of the A single-layer foil strips and the B single-layer foil strips, and pretreating each of the A single-layer foil strips and each of the B single-layer foil strips;
developing a laying process: determining a sequence and a path for laying each layer of foil, according to the thickness of the A single-layer foil strips and the B single-layer foil strips and the width of the A single-layer foil strips and the B single-layer foil strips in each characteristic zone;
laying the A single-layer foil strips and the B single-layer foil strips: alternately laying the plurality of A single-layer foil strips and B single-layer foil strips on a surface of the support die according to the sequence and the path for laying each layer of foil;
filling a first gap between the A single-layer foil strips vertically adjacent to each other with one of an A liquid or an A powder made of the metal A, and filling a second gap between the B single-layer foil strips vertically adjacent to each other with one of a B liquid or B powder made of the metal B to define an AB laminated preform on the support die;
obtaining the AB laminated preform: separating the AB laminated preform from the support die to obtain the AB laminated preform;
bulging the AB laminated preform: placing the AB laminated preform into a bulging die to bulge to fully fit with the bulging die to produce a bulged component with a desired shape;
performing a reactive synthesis and a densification process of the bulged component: subjecting the bulged component to a diffusion synthesis and a densification process under a high temperature and a high pressure in the bulging die to produce a complex thin-walled alloy component;
performing a subsequent treatment of the complex thin-walled alloy component: cutting or polishing an end and a surface of the complex thin-walled alloy component;
wherein the support die is formed from a foam plastic by using an inner wall of the thin-walled shaped component as the characteristic surface by three-dimensional (3D) printing.

2. The integrated method for manufacturing a high-temperature resistant thin-walled component by preforming by laying a metal foil strip according to claim 1 , wherein during the step of laying the foil strips, two foil strip nozzles are used to lay the A single-layer foil strips and the B single-layer foil strips alternately layer by layer; a first powder nozzle is used to spray one of the A liquid or the A powder to fill the first gap between the vertically adjacent A single-layer foil strips on a layer of A foil; a second powder nozzle is used to spray one of the B liquid or the B powder to fill the second gap between the vertically adjacent B single-layer foil strips on a layer of B foil; the support die is rotated by a rotary platform; a foil strip nozzle and the first and second powder nozzles are driven by a multi-degree-of-freedom robotic arm to realize space movement and swing.

3. The integrated method for manufacturing a high-temperature resistant thin-walled component by preforming by laying a metal foil strip according to claim 1 , wherein in the bulging step, the AB laminated preform is placed into the bulging die heated in advance to 500-800° C. to bulge to fit the bulging die.

Assignees

• Univ Dalian Tech

Inventors

• He Zhubin
• Liang Jiangkai
• Xu Yi
• Du Wei
• Lin Yanli
• Zheng Kailun
• Lin Peng
• Liu Gang
• Yuan Shijian

Classifications

• B21D26/033

  Deforming tubular bodies (corrugating tubes by applying fluid pressure B21D15/03, B21D15/10) · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B21D26/053

  characterised by the material of the blanks · CPC title

• B22F2007/042

  characterised by the layer forming method · CPC title

• B21D37/16

  Heating or cooling · CPC title