Process for producing a near net shape component with consolidation of a metallic powder

Patent metadata

Field	Value
Publication number	US-11434766-B2
Application number	US-201514639464-A
Country	US
Kind code	B2
Filing date	Mar 5, 2015
Priority date	Mar 5, 2015
Publication date	Sep 6, 2022
Grant date	Sep 6, 2022

Abstract

A process of producing an article and an article made are provided. The process includes producing a near-net shape component. The process includes forming a consolidation shell by additive manufacturing. The consolidation shell defines an interior space having a geometry corresponding to a component. A metallic powder is provided to the interior space. Gas is removed from the interior space. The metallic powder is consolidated in the consolidation shell under sufficient heat and pressure to form the near-net shape component.

First claim

What is claimed is:

1. A process of producing a near-net shape component, the process comprising:
forming a consolidation shell by additive manufacturing, the consolidation shell defining an interior space having a geometry corresponding to a component;
providing a metallic powder to the interior space;
removing gas from the interior space; and
consolidating the metallic powder in the consolidation shell under sufficient heat and pressure to form the near-net shape component,
wherein the consolidation shell forms a coating material on the component, the coating material including a beneficial property relative to the consolidated metallic powder, the beneficial property being selected from the group consisting of corrosion resistance, oxidation resistance, erosion resistance, and combinations thereof.

2. The process of claim 1 , wherein the consolidating includes hot isostatic pressing.

3. The process of claim 1 , wherein the metallic powder includes metals selected from the group consisting of nickel, cobalt, titanium, iron, alloys thereof, and combinations thereof.

4. The process of claim 1 , wherein the geometry corresponding to the component includes a geometry that forms the near-net shape component after consolidation.

5. The process of claim 1 , wherein the near-net shape component is a gas turbine component selected from the group consisting of a compressor blade, a turbine bucket, a compressor vane, an airfoil segment, a nozzle, a shroud, and a combustion component.

6. The process of claim 5 , wherein the gas turbine component is a compressor blade.

7. A process of producing a near-net shape component, the process comprising:
forming a consolidation shell by additive manufacturing selected from the group consisting of direct metal laser sintering, direct metal laser melting, electron beam melting, and combinations thereof, the consolidation shell including a removable material, and defining an interior space having a geometry corresponding to a component;
providing a metallic powder to the interior space;
removing gas from the interior space;
then sealing the consolidation shell; and
then consolidating the metallic powder in the consolidation shell under sufficient heat and pressure to form the near-net shape component,
wherein the consolidation shell forms a coating material on the near-net shape component, the coating material including a beneficial property relative to the consolidated metallic powder, the beneficial property being selected from the group consisting of corrosion resistance, oxidation resistance, erosion resistance, and combinations thereof,
wherein the removable material is a metal or alloy including a material composition distinct from the metallic powder, and is removable to form channels in the component, and
wherein the near-net shape component is a gas turbine component.

8. The process of claim 7 , wherein the consolidating includes hot isostatic pressing.

9. The process of claim 7 , wherein the metallic powder includes metals selected from the group consisting of nickel, cobalt, titanium, iron, alloys thereof, and combinations thereof.

10. The process of claim 7 , wherein the gas turbine component is selected from the group consisting of a compressor blade, a turbine bucket, a compressor vane, an airfoil segment, a nozzle, a shroud, and a combustion component.

11. The process of claim 10 , wherein the gas turbine component is a compressor blade.

12. The process of claim 7 , wherein providing the metallic powder to the interior space includes providing a first metallic powder and a second metallic powder.

13. The process of claim 12 , wherein the first metallic powder and the second metallic powder have dissimilar compositions.

14. The process of claim 12 , wherein the first metallic powder and the second metallic powder have dissimilar properties.

15. The process of claim 7 , further including leaching or etching the removable material away.

16. The process of claim 7 , wherein the removable material has a greater activity with respect to at least one of leaching and etching than the metallic powder.

17. A process of producing a near-net shape component, the process comprising:
forming, by additive manufacturing, a consolidation shell comprising a first and a second material, the consolidation shell defining an interior space having a geometry corresponding to a component;
providing a metallic powder to the interior space;
removing gas from the interior space;
consolidating the metallic powder in the consolidation shell under sufficient heat and pressure to form the near-net shape component, wherein the near-net shape component is a compressor blade; and
removing said second material by a physical or chemical means to form channels in the component,
wherein the consolidation shell forms a coating material on the near-net shape component, the coating material including a beneficial property relative to the consolidated metallic powder, the beneficial property being selected from the group consisting of corrosion resistance, oxidation resistance, erosion resistance, and combinations thereof.

Assignees

• Gen Electric

Inventors

• Channel Timothy Eden
• Bouse Gregory Keith

Classifications

• B22F5/04 Primary

  of turbine blades · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• F01D5/18 Primary

  Hollow blades, {i.e. blades with cooling or heating channels or cavities (structure of hollow blades in general F01D5/147)}; Heating, heat-insulating or cooling means on blades · CPC title

• B22F2005/103

  Cavity made by removal of insert · CPC title

• F05D2220/32

  in gas turbines · CPC title